Battery pack intelligent sensing controller and application

Abstract

The application provides a battery pack intelligent sensing controller and application, comprising: a data acquisition unit for acquiring a plurality of parameters of the battery pack; a communication and processing unit for processing and operating the plurality of parameters, sending to a communication network, and providing for an external battery management system main controller or a power domain controller; the communication and processing unit receives an instruction from the battery management system main controller or the power domain controller; a high-voltage relay driving unit controls the closing and opening of an external high-voltage relay, enables or terminates the charging and discharging of the battery pack, and performs fault diagnosis and safety protection; a power supply unit supplies low-voltage power for the data acquisition unit, the communication and processing unit, and the high-voltage relay driving unit; and a communication and power supply isolation unit isolates external low-voltage power supply and communication. The application is used for controlling a relay, integrating the functions of current, voltage and other parameter acquisition, monitoring, and relay control, and when the intelligent sensing controller fails, the whole vehicle system is not affected.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy, in particular, to a battery pack intelligent sensing controller, application and a new energy vehicle. BACKGROUND

[0002] At present, the application range and attention degree of lithium ion battery pack are higher and higher, such as energy storage application and new energy vehicle application. Due to high energy density, wide popularization range and close range to users, the safety requirement is higher and higher.

[0003] In order to ensure the safety of new energy vehicles, there is a vehicle safety integrity level standard, that is, when the new energy vehicle encounters a fault, each component or system needs to reach the corresponding functional safety level to avoid the occurrence of serious accidents. In the prior art, the functional safety target of the battery pack in the electric vehicle includes: collecting the current in the battery pack and determining whether the current in the battery pack exceeds the specified range, judging whether the current in the battery pack is overcurrent, whether the battery pack is faulty; collecting the high voltage in the battery pack and determining whether the voltage is in the normal range; collecting the insulation resistance value of the battery pack and determining whether the value is in the normal range; controlling the high voltage relay of the battery pack to determine whether the battery pack can output power to the outside.

[0004] However, the current HALL current sensor collects the current in the battery pack, the HALL current sensor has zero drift phenomenon and is easy to be interfered by electromagnetic interference; the collection of high voltage and the control of high voltage relay are often completed by the battery management system master controller or the power domain controller outside the battery pack, so that the design of the battery management system master controller or the power domain controller is complex, the high voltage collection line, the relay driving line and the isolation requirement are very high, once a problem occurs, the battery management system master controller or the power domain controller is easy to be burned out, causing a safety fault. SUMMARY

[0005] In view of the defects in the prior art, the purpose of the present application is to provide a battery pack intelligent sensing controller, application and a new energy vehicle.

[0006] According to one aspect of the present application, a battery pack intelligent sensing controller is provided, comprising:

[0007] A data acquisition unit acquires a plurality of parameters of the battery pack and converts them into digital signals, and the plurality of parameters include current, voltage, power, power, energy change value, insulation resistance value, temperature and gas concentration;

[0008] A communication and processing unit, which aggregates digital signals of a plurality of the parameters, performs processing operations, and transmits to a communication network for use by an external battery management system main controller or power domain controller; the communication and processing unit receives instructions from the battery management system main controller or power domain controller;

[0009] A high-voltage relay driving unit, which controls the closing and opening of an external high-voltage relay according to the instructions received by the communication and processing unit, enables or terminates the charging and discharging of the battery pack, and performs fault diagnosis and safety protection;

[0010] A power supply unit, which supplies low-voltage power to the acquisition unit, communication and processing unit, and high-voltage relay driving unit;

[0011] A communication and power supply isolation unit, which isolates the low-voltage power supply and communication of the external battery management system main controller or power domain controller.

[0012] Preferably, the data acquisition unit comprises:

[0013] A shunt, which acquires an analog current signal passing through a busbar of the battery pack and converts it into an analog voltage signal;

[0014] A current acquisition chip, which converts the analog voltage signal across the shunt into a digital signal;

[0015] A voltage acquisition circuit, which acquires a plurality of voltages of the battery pack, converts analog voltage signals of the plurality of voltages into digital signals; based on the current and voltage parameter information obtained by the shunt, current acquisition chip, and voltage acquisition circuit, the amount of charge and discharge is obtained by integrating the charge and discharge current with respect to time; the real-time input and output power is obtained by multiplying the current and voltage; the energy change value of the battery pack is calculated by integrating the input and output power;

[0016] A gas sensor, which senses a dangerous gas concentration signal in the battery pack and converts it into a digital signal;

[0017] A temperature sensor, which senses a temperature signal in the battery pack and converts it into a digital signal;

[0018] An insulation resistance detection switch, which is periodically closed and opened to obtain the voltage change of the measurement loop and obtain the insulation resistance value of the positive and negative ground of the battery pack.

[0019] Preferably, the communication and processing unit comprises a main chip which receives and sends signals according to a communication protocol, receives parameter information of the data acquisition unit and performs data processing and control; the high-voltage relay driving unit comprises a high-voltage relay driving circuit which comprises a high-side or low-side driving, receives control signals from the main chip, controls closing and opening of the relay, enables or terminates charging and discharging of the battery pack, and performs fault diagnosis and safety protection.

[0020] Preferably, when the high-voltage relay is closed, 12V or 24V is output to the high-voltage relay control coil through the high-voltage relay driving circuit, so that the high-voltage relay contact is closed; when the high-voltage relay is opened, the 12V or 24V output to the high-voltage relay control coil is disconnected, so that the high-voltage relay contact is opened.

[0021] The fault diagnosis comprises: judging whether the high-voltage relay performs closing or opening according to the instruction according to the voltage of the battery pack measured by the data acquisition unit, and whether there is a sticking phenomenon.

[0022] Preferably, the communication protocol comprises protocols CAN, RS485, LIN, FlexRay and / or Ethernet.

[0023] Preferably, the main chip can determine whether to disconnect the high-voltage relay according to the collected current, voltage, temperature, gas concentration and fault diagnosis information.

[0024] Preferably, when a fault occurs inside the battery pack and the sensing controller is burned out, the communication and power supply isolation unit protects the whole vehicle and the battery management system main controller from being affected.

[0025] According to a second aspect of the present application, an application of the battery pack intelligent sensing controller is provided, the battery pack intelligent sensing controller and the battery pack are integrated in a battery pack connection box, and the intelligent sensing controller communicates with an external battery management system main controller or a power domain controller.

[0026] Preferably, when the battery management system or the power domain controller is adapted to different vehicle models, the battery pack intelligent sensing controller does not need to be redesigned.

[0027] According to a third aspect of the present application, a new energy vehicle is provided, characterized in that the new energy vehicle comprises the battery pack intelligent sensing controller or the application of the battery pack intelligent sensing controller.

[0028] Compared with the prior art, the present application has the following beneficial effects:

[0029] The battery pack intelligent sensing controller in the embodiment of the application integrates the current, voltage and other parameter collection and monitoring functions, is located in an independent battery pack intelligent sensing controller, and will not affect the whole vehicle system when the intelligent sensing controller fails.

[0030] The battery pack intelligent sensing controller in the embodiment of the application reduces the introduction of errors and is more accurate because the current and voltage detection is collected, calculated and converted into a communication signal in real time on site.

[0031] The battery pack intelligent sensing controller in the embodiment of the application has low-voltage power supply and communication between the battery management system main controller or the power domain controller and the battery pack intelligent sensing controller, does not have high-voltage measurement, and once the battery pack fails, the high-voltage part is isolated, and the battery management system main controller or the power domain controller is not affected, so that the battery management system main controller or the power domain controller has more time and opportunity to process faults and ensure safety.

[0032] The application of the battery pack intelligent sensing controller in the embodiment of the application separates the current sampling, high-voltage sampling and high-voltage relay driving from the main controller, and the main controller and the battery pack are only connected through low-voltage communication and low-voltage power supply to the battery pack intelligent sensing controller, so that the main controller and the battery pack are completely isolated from high voltage, and the problem that the system architecture is not clear in the prior art is overcome, and the hidden danger that the main controller is directly burned once a problem occurs in the battery pack is avoided.

[0033] The application of the battery pack intelligent sensing controller in the embodiment of the application does not need to change the high-voltage and current sampling part when the battery management system or the power domain controller is adapted to different vehicle models, reduces the complexity of the whole machine design, and facilitates the rapid design and delivery of the battery management system BMS whole system. BRIEF DESCRIPTION OF DRAWINGS

[0034] Other features, objects and advantages of the application will become more apparent from the following detailed description of non-limiting embodiments with reference to the following drawings:

[0035] Figure 1 FIG. 1 is a structural diagram of a battery pack intelligent sensing controller in an embodiment of the application;

[0036] Figure 2 FIG. 2 is an application structure schematic diagram of a battery pack intelligent sensing controller in another embodiment of the application;

[0037] In the figure, 1 - shunt, 2 - current acquisition chip, 3 - voltage acquisition circuit, 4 - gas sensor, 5 - temperature sensor, 6 - insulation resistance detection switch, 7 - communication and processing unit, 8 - high voltage relay, 9 - high voltage relay drive circuit, 10 - power supply circuit, 11 - communication and power supply isolation circuit, 12 - battery pack, 13 - battery management system main controller or power domain controller, 14 - battery pack intelligent sensor controller. DETAILED DESCRIPTION

[0038] The application will be described in detail below with specific examples. The following examples will help those skilled in the art to further understand the application, but do not limit the application in any form. It should be pointed out that for those skilled in the art, without departing from the concept of the application, a number of modifications and improvements can be made. These are within the scope of the application.

[0039] In the prior art conventional architecture, HALL sensor or battery management system main controller is used to collect the voltage across the shunt 1 to obtain the current. This method will result in inaccurate current sampling, low anti-interference performance, and single function. There is no voltage acquisition, no high voltage relay control, no temperature and gas detection, and no fault diagnosis function in the battery pack and its connection box. These functions often have to be integrated into the battery management system main controller or power domain controller, resulting in complex battery management system main controller or power domain controller and difficult development. Moreover, the system architecture is not clear, and once there is a problem in the battery pack, the main controller may be directly burned out, causing a safety accident. Based on this, the application provides several embodiments to provide new technologies to overcome the above-mentioned defects.

[0040] Reference Figure 1The application provides an embodiment of a battery pack intelligent sensing controller, which comprises a data acquisition unit, a communication and processing unit 7, a high-voltage relay driving unit, a power supply unit and a communication and power supply isolation unit. The data acquisition unit acquires a plurality of parameters of the battery pack 12 and converts them into digital signals, the plurality of parameters including current, voltage, power, electric quantity, energy change value, insulation resistance value, temperature and gas concentration; the communication and processing unit 7 collects the digital signals of the plurality of parameters, performs operation and processing, and sends them to a communication network for use by an external battery management system main controller or power domain controller 13; the communication and processing unit 7 receives instructions from the battery management system main controller or power domain controller 13; the high-voltage relay driving unit controls the closing and opening of an external high-voltage relay 8 according to the instructions received by the communication and processing unit 7, enables or terminates the charging and discharging of the battery pack 12, and performs fault diagnosis and safety protection (including warning the user through a fault light, speed limiting, disconnecting the high-voltage relay and the like); the power supply unit supplies low-voltage power for the acquisition unit, the communication and processing unit 7 and the high-voltage relay driving unit; and the communication and power supply isolation unit isolates the low-voltage power supply and communication of the external battery management system main controller or power domain controller 13.

[0041] The intelligent sensing controller in the embodiment can improve current acquisition accuracy, realize voltage acquisition, high-voltage relay control, fault diagnosis, gas information acquisition, temperature acquisition and the like, and meet the use requirements of new energy vehicles and energy storage.

[0042] In a preferred embodiment of the application, a preferred structure of the data acquisition unit is provided. Specifically, the current acquisition is realized by a shunt 1 and a current acquisition chip 2. The shunt 1 acquires an analog current signal flowing through a bus in the battery pack 12 and converts it into an analog voltage signal, and the current acquisition chip 2 converts the analog voltage signal between the two ends of the shunt 1 into a digital signal. The current acquisition chip 2 has an acquisition accuracy of 16 bits or more, so the acquired signal also has an acquisition accuracy of 16 bits or more. The embodiment realizes current detection function, has a high accuracy of 1%, has a wide measurement range of -1500A-1500A, has no zero drift and is resistant to electromagnetic interference, and the shunt 1 is directly integrated into the intelligent sensing controller, the current detection is acquired, calculated and converted into a communication signal in real time on site, the introduction of errors is reduced, and the current detection is more accurate.

[0043] The voltage acquisition is realized by a voltage acquisition circuit 3. Specifically, the voltage acquisition circuit 3 acquires a plurality of voltages and converts analog voltage signals into digital signals, so that the embodiment realizes a plurality of high-voltage detection functions and can support 1-5 high-voltage (0-1200V) detection.

[0044] The communication and processing unit 7 is based on the collected data of the current and voltage, and the charge and discharge electric quantity is counted by integrating the charge and discharge current with respect to time (ampere-hour integration); the real-time input and output power is obtained by multiplying the current with the high voltage; and the energy change of the battery pack 12 is counted by integrating the power.

[0045] The gas concentration and temperature are collected by the gas sensor 4 and the temperature sensor 5, respectively. Specifically, the gas sensor 4 converts the concentration of the index dangerous gas in the battery pack 12 into a digital signal; and the temperature sensor 5 converts the temperature signal in the battery pack 12 into a digital signal. The embodiment realizes the temperature detection function, which can detect multiple temperature, such as the temperature of the current shunt 1, for improving the current detection accuracy, the ambient temperature, for over-temperature alarm, etc. Similarly, the gas detection function is also realized, which can detect the gas substance in the battery pack environment, for battery pack fault alarm. Generally, the index dangerous gas refers to H2, CO, CH4, etc.

[0046] The insulation resistance value is obtained by the insulation resistance detection switch 6. Specifically, according to the high and low level digital signals of the main chip in the communication and processing unit 7, the insulation resistance detection switch 6 is controlled to be opened and closed, and the insulation resistance value between the positive and negative ground of the battery pack is measured according to the voltage change of the measurement loop, that is, the insulation resistance detection function is realized.

[0047] In a preferred embodiment of the present application, the preferred structure of the communication and processing unit is provided, specifically the main chip. The preferred structure of the high-voltage relay driving unit is also provided, specifically the high-voltage relay driving circuit 9. The main chip contains an operating system and application layer software, which is used for data processing and receiving and sending signals according to the communication protocol, controlling the action of the high-voltage relay 8, supporting multiple working modes, including sleep mode (to reduce power consumption), normal working mode (for data processing and conversion and control), diagnostic mode (for fault diagnosis and software upgrade), etc. The data processing refers to calculating the power, electric quantity change and energy change through the collected current, voltage and other signals.

[0048] The high-voltage relay 8 outside the battery pack intelligent sensing controller is connected with the main chip, and the high-voltage relay driving circuit 9 includes high-side or low-side driving, receives the control signal from the main chip, and outputs or disconnects the 12V / 24V relay driving voltage. That is, the embodiment realizes the closing and opening control function of multiple high-voltage relays 8.

[0049] In a preferred embodiment, the main chip is connected to the vehicle communication network through CAN communication, and also supports RS485, LIN, FlexRay and / or Ethernet communication, so as to send the collected battery pack information and fault diagnosis results to the battery management system main controller or power domain controller 13, and receive control instructions therefrom.

[0050] In another preferred embodiment of the present application, a preferred structure of the power supply unit is provided, i.e., the power supply circuit 10, which converts the low-voltage power supply of the vehicle network into the levels required by the main chip and other components inside the battery pack intelligent sensor controller. Further, the passenger car is generally of 12V nominal level (the actual power supply voltage can be 9-16V), and the commercial vehicle is generally of 24V level (the actual power supply voltage can be 12V-36V), which can be converted by the power supply circuit 10 into the 5V and 3.3V levels required by the main chip and other components. That is, the power supply circuit 10 enables the battery pack intelligent sensor controller to normally work in the power supply range of 9-36V, meeting the application of passenger cars (nominal 12V) and commercial vehicles (nominal 24V).

[0051] In another preferred embodiment of the present application, a preferred structure of communication and power supply isolation is provided, i.e., the communication and power supply isolation circuit 11, which isolates the intelligent sensor controller end from the low-voltage (12 / 24V) power supply and communication of the vehicle / battery management system network. When the intelligent sensor controller is burned due to the internal failure of the battery pack, the vehicle and battery management system main controller are protected from being affected, and there is sufficient time for safety protection measures.

[0052] Referring to Figure 2 Based on the same inventive concept, in another embodiment of the present application, an application of the battery pack intelligent sensor controller is provided, which integrates the above-mentioned battery pack intelligent sensor controller 14 and high-voltage relay 8 in a battery pack connection box, and the intelligent sensor controller 14 communicates with the external battery management system main controller or power domain controller 13. When the battery management system or power domain controller is adapted to different vehicle models, the battery pack intelligent sensor controller does not need to be redesigned, which reduces the complexity of the overall design and facilitates the rapid design and delivery of the BMS system.

[0053] In this embodiment, the current sampling, high-voltage sampling and high-voltage relay driving are separated from the main controller, and are completed by the battery pack intelligent sensor controller located in the battery pack. The main controller and the battery pack are only connected through low-voltage communication and low-voltage power supply to the battery pack intelligent sensor controller, so that the main controller and the battery pack high-voltage are completely isolated, overcoming the unclear system architecture division in the prior art and avoiding the risk of burning the main controller due to the internal problem of the battery pack.

[0054] Based on the same inventive concept, in other embodiments of the application, a new energy vehicle is provided, comprising the above-mentioned battery pack intelligent sensing controller, or an application of the above-mentioned battery pack intelligent sensing controller.

[0055] In order to facilitate further clear and detailed understanding of the technical solutions of the application, in other embodiments of the application, a complete typical working scene of the battery pack intelligent sensing controller is provided as follows:

[0056] The power supply circuit 10 converts the low-voltage power supply of the vehicle network into 5V and 3.3V levels required by the intelligent sensing controller, so that the intelligent sensing controller can work normally.

[0057] The shunt 1 collects the analog current signal of the busbar flowing through the battery pack 12, converts it into an analog voltage signal, and the current collection chip 2 converts the analog voltage signal into a digital signal and sends it to the main chip.

[0058] The voltage collection circuit 3 converts the multiple analog voltage signals into digital signals and sends them to the main chip.

[0059] The gas sensor 4 converts the concentration of the index hazardous gas in the battery pack 12 and other signals into digital signals and provides them to the main chip.

[0060] The temperature sensor 5 converts the temperature signal in the battery pack 12 into a digital signal and provides it to the main chip.

[0061] The main chip collects the above-mentioned collected digital signals and adds a check code, encodes them into CAN, RS485, LIN, FlexRay and / or Ethernet messages according to the communication protocol, and periodically sends them to the communication network for the battery management system main controller or power domain controller 13 to use, process and / or protect.

[0062] At the same time, the main chip periodically receives the high-voltage relay control signal on the communication network (the sender is the battery management system main controller or power domain controller 13), and according to the communication instruction, controls the corresponding high-voltage relay 8 to be opened or closed through the high-voltage relay drive circuit 9.

[0063] According to the voltage value collected by the voltage collection circuit 3, the main chip calculates the voltage change before and after the high-voltage relay 8 is opened or closed, judges whether the high-voltage relay 8 has a fault, such as sticking, and if a fault exists, sends the fault information to the communication network for the battery management system main controller or power domain controller 13 to use, process and / or protect.

[0064] The main chip controls the periodic closing and opening of the insulation resistance detection switch 6, and combines the voltage value collected by the voltage collection circuit 3 to calculate the insulation resistance value of the positive ground of the battery pack 12 and the negative ground of the battery pack 12 at the closing and opening time, and periodically reports to the communication network for the battery management system main controller or the power domain controller 13 to use, process and / or protect.

[0065] In addition, the main chip can determine whether to disconnect the high-voltage relay 8 according to the collected current, voltage, temperature, gas and diagnostic information, and in the case of a dangerous fault, disconnect the electrical connection between the battery pack 12 and the vehicle to protect safety. Generally, the vehicle is divided into multiple safety levels, and according to the degree of danger, the measures for low-level faults are to turn on the fault light, and only in the case of high-risk faults, the vehicle controller or the power domain controller instructs the battery pack intelligent sensing controller to disconnect the relay through the high-voltage relay driving circuit 9 to disconnect the high-voltage output of the battery pack from the electrical connection of the vehicle.

[0066] The specific embodiments of the application are described above. It should be understood that the application is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or changes within the scope of the claims, which does not affect the essential content of the application. The above preferred features can be used in combination in the case of not conflicting with each other.

Claims

1. A smart sensor controller for a battery pack, characterized in that, include: The data acquisition unit acquires multiple parameters of the battery pack and converts them into digital signals. The multiple parameters include current, voltage, power, charge, energy change value, insulation resistance value, temperature, and gas concentration. The communication and processing unit aggregates the digital signals of multiple parameters acquired by the data acquisition unit, performs processing operations, and sends them to the communication network for use by the external battery management system main controller or power domain controller; the communication and processing unit receives instructions from the battery management system main controller or power domain controller. The high-voltage relay drive unit, according to the received instructions, controls the opening and closing of the external high-voltage relay through the high-voltage relay drive unit, enables or terminates the charging and discharging of the battery pack, and performs fault diagnosis and safety protection. The power supply unit converts the voltage of the external battery management system main controller or power domain controller to provide low-voltage power to the data acquisition unit, communication and processing unit and high-voltage relay drive unit. A communication and power supply isolation unit is provided, which isolates the low-voltage power supply and communication of the external battery management system main controller or power domain controller. The data acquisition unit includes: The shunt acquires the analog current signal flowing through the bus of the battery pack and converts it into an analog voltage signal; A current acquisition chip that converts the analog voltage signal across the shunt into a digital signal; A voltage acquisition circuit acquires multiple voltage signals from the battery pack and converts the analog voltage signals of the multiple voltage signals into digital signals. The communication and processing unit obtains the current and voltage parameter information obtained by the shunt, current acquisition chip and voltage acquisition circuit, and obtains the charge and discharge capacity by integrating the charge and discharge current over time; it obtains the real-time input and output power by multiplying the current and voltage; and it calculates the energy change value of the battery pack by integrating the input and output power. A gas sensor that senses the concentration signal of hazardous gas in the battery pack and converts it into a digital signal; A temperature sensor that senses temperature signals in the battery pack and converts them into digital signals; An insulation resistance detection switch is used to periodically close and open to obtain the voltage change of the measurement circuit and thus the insulation resistance values ​​of the battery pack to ground and to ground. The communication and processing unit includes a main chip, which receives and sends signals according to a communication protocol, receives parameter information from the data acquisition unit, and performs data processing and control. The high-voltage relay drive unit includes a high-voltage relay drive circuit, which includes high-side or low-side drive, receives control signals from the main chip, controls the closing and opening of external relays, enables or terminates the charging and discharging of the battery pack, and performs fault diagnosis and safety protection.

2. The intelligent sensor controller for a battery pack according to claim 1, characterized in that, When the high-voltage relay is closed, 12V or 24V is output to the high-voltage relay control coil through the high-voltage relay drive circuit, causing the high-voltage relay contacts to close; when the high-voltage relay is opened, the 12V or 24V output to the high-voltage relay control coil is disconnected, causing the high-voltage relay contacts to open. The fault diagnosis includes: determining whether the high-voltage relay closes or opens according to the command based on the battery pack voltage measured by the data acquisition unit, and whether there is any sticking.

3. The intelligent sensing controller for a battery pack according to claim 1, characterized in that, The communication protocols include CAN, RS485, LIN, FlexRay, and / or Ethernet.

4. The intelligent sensor controller for a battery pack according to claim 1, characterized in that, The main chip can automatically decide whether to disconnect the high-voltage relay based on the collected current, voltage, temperature, gas concentration, and fault diagnosis information.

5. A battery pack intelligent sensing controller according to claim 1, characterized in that, When a fault occurs inside the battery pack and burns out the sensor controller, the communication and power supply isolation unit protects the vehicle and the main controller of the battery management system from being affected.

6. An application of a smart sensor controller for a battery pack, characterized in that, The battery pack intelligent sensor controller according to any one of claims 1-5 and the battery pack are integrated in a battery pack connection box, wherein the intelligent sensor controller communicates with the external battery management system main controller or power domain controller.

7. The application of the intelligent sensing controller for a battery pack according to claim 6, characterized in that, When the battery management system or power domain controller is adapted to different vehicle models, the battery pack intelligent sensing controller does not need to be redesigned.

8. A new energy vehicle, characterized in that, This includes the application of the battery pack intelligent sensor controller according to any one of claims 1-5, or the application of the battery pack intelligent sensor controller according to any one of claims 6-7.

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