A kind of anti-feed control method of aerial work machinery power battery

Abstract

The application belongs to the technical field of engineering machinery vehicle application, and particularly relates to a power battery anti-feedback control method for high-altitude operation machinery, which comprises a power battery system, a battery management system, a DC / DC module, a remote data platform and an audible and visual alarm device, the DC / DC module is connected with the power battery system and a storage battery, the battery management system is connected with the audible and visual alarm device, the storage battery and linked with the remote monitoring platform, early warning, control and processing functions of the power battery anti-feedback control of the high-altitude operation machinery vehicle are realized, and the battery stability, safety and long service life of the vehicle are improved. The application can avoid the feedback problem by judging improper power-off, solve the charging problem that the battery management system cannot be woken up due to the extreme feedback of the whole machine, effectively control the risk and prevent the battery from being continuously over-discharged, help to improve the service life of the power battery, and effectively avoid potential dangerous results caused by the misoperation of non-professionals.

Description

Technical Field

[0001] This invention belongs to the field of engineering machinery and vehicle application technology, and in particular relates to a method for preventing power depletion of the power battery of aerial work machinery. Background Technology

[0002] In the application of lithium-ion battery systems for aerial work machinery, users habitually turn on the emergency stop switch to power off the machine after operation. At this time, the lithium-ion battery system is still powered on. Prolonged storage can lead to over-discharge of the lithium-ion battery, making it difficult to recharge the battery at the construction site. Once an over-discharge problem occurs, it will cause great difficulties for users to solve the charging problem. If the extreme over-discharge fault is triggered, after-sales personnel will need to restore it on-site.

[0003] Construction machinery, especially aerial work platforms, is currently mainly leased. During the winter off-season, the entire machine may be stored for three months or more. If the battery is left to stand for a long time with low charge, it may cause irreversible over-discharge of the battery, affecting its service life and even the safety of the entire vehicle. Summary of the Invention

[0004] This invention addresses the problem of over-discharge of lithium-ion power batteries or lead-acid batteries caused by improper power-off operation or prolonged storage. It provides a reasonable, simple, and theoretically sound method for preventing power failure and providing early warning control for aerial work machinery, which can achieve automatic charging and hibernation.

[0005] To achieve the above objectives, the technical solution adopted by this invention is as follows: a power battery anti-power-out control method for aerial work machinery, comprising a power battery system, a DC / DC module, a battery management system, a remote monitoring module, a timed wake-up unit, a storage battery, and an audible and visual alarm device. The DC / DC module connects the power battery system and the storage battery. The battery management system connects the audible and visual alarm device and the storage battery, and is linked to a remote monitoring platform. The battery management system is responsible for collecting the individual cell voltages of the power battery pack and estimating the system's state of charge (SOC), timed wake-up of the individual lithium battery cell voltages and temperatures, and monitoring discharge current and usage time. The method includes sending a shutdown command to the power battery system after the aerial work machinery is powered off to initiate the power-off process. Upon receiving the instruction, the system determines whether a critical fault has been triggered. If so, it exits the wake-up state and powers down. Otherwise, it checks for high-voltage power-down faults, SOC values ​​below the set value, or minimum cell voltage values ​​below the set value. If any of these conditions are met, the battery management system delays for 5 minutes and enters sleep mode. It then normally reports the current cell voltage, temperature, SOC, and fault information to the remote monitoring platform. Afterward, it enters a short-term wake-up state and then sleep mode. Otherwise, it checks whether the lead-acid battery voltage is below the set protection value. If so, it enters the pre-charge high-voltage process, enabling the DC / DC converter to charge the lead-acid battery. Once the lead-acid battery voltage exceeds the safety set value, the charging stops, and the battery management system enters the power-down process and then sleep mode. Otherwise, it enters a long-term wake-up state and then sleep mode. If the KEY ON signal is valid, the aerial work platform opening the emergency stop switch to perform a power-down operation is invalid. The battery management system checks whether the output current is below the set value and remains below the set time. If not, it maintains the previous state; otherwise, it enters the power-down process and then sleep mode.

[0006] Preferably, the "no explicit shutdown command or triggering of a fault to enter the power-down process" refers to...

[0007] As a preferred option, if a Level 3 low-voltage fault occurs during the charging process of the power battery system to the lead-acid battery, the battery management system will enter a sleep state after a set delay. During this period, it will normally report the current cell voltage, temperature, SOC and fault to the remote monitoring platform, and then enter a short-term timed wake-up state before entering sleep state.

[0008] Preferably, the power battery system and monitoring platform complete the transmission of data on cell voltage, temperature, SOC and faults through a remote monitoring module.

[0009] Preferably, the battery management system is woken up by a timed wake-up unit. The battery management system directly detects the battery voltage status and wakes up the DC / DC module and performs enable control through electrical signals or message commands. The DC / DC module then charges the battery through power conversion.

[0010] Preferably, the battery management system detects a high-voltage power failure or a critical fault and provides an audible and visual alarm.

[0011] As a preferred option, the short-term wake-up state accumulates and cycles. If the short-term wake-up triggers a limit fault, the limit undervoltage fault characteristics will be uploaded to the monitoring platform after a set delay time. The system will then power down and go into hibernation mode. The fault can only be resolved and restored by on-site after-sales service. Otherwise, the KEY ON signal will not be able to start the power battery system normally.

[0012] Preferably, the power battery system is connected to the external power source via an emergency stop switch. Disconnecting the emergency stop switch can cut off the high-voltage input to the drive end, but at this time the DC / DC converter is still in operation and the power battery system is in a high-voltage state. Opening the emergency stop switch is an ineffective power cut-off.

[0013] Preferably, when the power battery system is powered on at high voltage, the main circuit relay is closed, and the battery management system is in a wake-up state. At this time, the battery management system starts the insulation detection function, voltage acquisition, current acquisition, temperature acquisition, drive the relay to close, processor calculation, remote monitoring data transmission and fault diagnosis functions.

[0014] As a preferred option, during the battery charging process after wake-up, although high voltage has been applied, the system does not respond to walking, lifting, or lowering control commands.

[0015] As a preferred option, the battery management system enters sleep mode when it is determined that there is no power-off characteristic. At this time, the KEY ON signal is valid, but it does not respond to lifting and walking commands. It needs to be restarted to operate normally.

[0016] As a preferred option, the electrical design of the power battery system and battery management system conforms to the power-off and hibernation modes. After the battery management system enters the hibernation state, the static power consumption of the system reaches the mA level, which supports long-term storage without power depletion when the battery is in a healthy state.

[0017] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0018] This invention comprises a power battery system, a DC / DC module, a battery management system, a remote monitoring module, a timed wake-up unit, a storage battery, and an audible and visual alarm device. It achieves early warning, control, and handling functions for the onboard power battery of aerial work machinery to prevent power depletion, thereby improving the vehicle's battery stability, safety, and lifespan. By determining when to stop powering down and avoiding power depletion, this invention solves the problem of the battery management system being unable to be woken up due to extreme power depletion, effectively controlling risks and preventing continuous over-discharge of the battery, thus contributing to improved power battery lifespan. It also effectively avoids potential dangers caused by misoperation by non-professionals. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a block diagram of the anti-power-outage control system according to an embodiment of the present invention;

[0021] Figure 2 This is a flowchart illustrating the abnormal power-down process of the anti-power-out control method according to an embodiment of the present invention.

[0022] Figure 3 This is a flowchart illustrating the power-on or wake-up process of the anti-power-out control method according to an embodiment of the present invention.

[0023] Figure 4 This is a power-down flowchart of the anti-power-out control method according to an embodiment of the present invention. Detailed Implementation

[0024] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0025] Numerous specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways than those described herein, and therefore the invention is not limited to the specific embodiments disclosed in the following specification.

[0026] As lithium-ion power batteries gradually penetrate road vehicles, energy storage, and off-road construction machinery, problems such as over-discharge, battery life degradation, and even irreversible damage have emerged, particularly in construction machinery, especially aerial work platforms. Traditional aerial work platforms are widely used in construction, power, and civil engineering fields. Operational methods typically involve activating an emergency switch to shut down the power. Furthermore, aerial work platform management is generally based on leasing, with equipment management operators providing unified operation and maintenance management through a backend system. Aerial work platform rentals are concentrated on construction sites, leading to prolonged storage of vehicles during the off-season from October to January. If the lithium battery or lead-acid battery is low before storage or improper shutdown operations cause it to remain in an ON state, it exacerbates the losses caused by over-discharge, battery life degradation, and even irreversible damage. Therefore, how to achieve early warning, control, and handling of battery depletion prevention for aerial work platform vehicles to improve battery stability, safety, and lifespan is a pressing issue that needs to be addressed.

[0027] like Figure 1 As shown, to address the aforementioned deficiencies, this invention proposes a power battery anti-power-out control method for high-altitude work machinery. The method includes a power battery system, a DC / DC module, a battery management system, a remote monitoring module, a timed wake-up unit, a storage battery, and an audible and visual alarm device. The DC / DC module connects to the power battery system and the storage battery. The battery management system connects to the audible and visual alarm device, the storage battery, and is linked to a remote monitoring platform. The battery management system is responsible for collecting the individual cell voltages of the power battery pack and estimating the system's state of charge (SOC), timed wake-up of the individual lithium battery cell voltages and temperatures, and monitoring discharge current and usage time.

[0028] like Figure 2 , 3As shown in Figure 4, the method includes sending a shutdown command or triggering a fault to the power battery system after the high-altitude work machinery is powered down, thus entering the power-down process. Upon receiving the command, the battery management system determines whether a limit fault has been triggered. If so, it exits the wake-up state and powers down. The battery management system detects a high-voltage power-down fault or a limit fault and provides a warning via an audible and visual alarm. Otherwise, it determines whether a high-voltage power-down fault, a state of charge (SOC) less than a set value, or a minimum single-cell voltage less than a set value exists. If any one of these conditions is met, the battery management system delays for 5 minutes and enters sleep mode, normally reporting the current single-cell voltage, temperature, SOC, and fault to the remote monitoring platform. Afterward, it enters a short-term wake-up state and then sleep mode. Otherwise, it determines whether the lead-acid battery voltage is lower than a set protection value. If so, it enters a pre-charge high-voltage process, enabling the DC / DC converter to recharge the lead-acid battery. Recharging stops when the lead-acid battery voltage exceeds a safety set value, and the battery management system enters the power-down process and then sleep mode. Otherwise, it enters a long-term wake-up state and then sleep mode. Without a clear shutdown command or a triggered fault, the system enters a power-down process (a valid KEY ON signal but an invalid power-down operation is achieved by activating the emergency stop switch on the aerial work platform). The battery management system determines whether the output current is lower than the set value and remains so for a set time. If not, it maintains the previous state; otherwise, it enters the power-down process or hibernation mode. If the system fails to meet power-down requirements, it enters hibernation mode. In this state, the KEY ON signal is valid, but it does not respond to lifting and walking commands from the control panel. A restart is required for normal operation, thus standardizing user operation behavior. The electrical design of the power battery system and battery management system conforms to power-down and hibernation modes. After entering hibernation, the system's static power consumption reaches the mA level, supporting long-term storage without battery depletion in a healthy state.

[0029] To ensure safety, if a high-voltage fault (level 3) occurs during the charging process of the lead-acid battery, the battery management system (BMS) will enter a sleep state after a set delay. During this period, it will normally report the current cell voltage, temperature, SOC, and fault information to the remote monitoring platform. Afterward, it will enter a short-term timed wake-up state and then enter sleep mode. The BMS is woken up by a timed wake-up unit. The BMS directly detects the battery voltage status and wakes up the DC / DC module via electrical signals or message commands, enabling and controlling the DC / DC module to charge the battery.

[0030] To effectively control risks and prevent continuous over-discharge of the battery, a short-term wake-up state is accumulated and cycled. If a short-term wake-up triggers a critical fault, a delay is set to upload the critical undervoltage fault characteristics to the monitoring platform, followed by power-down and hibernation. This requires on-site fault clearing by after-sales personnel to resolve and restore the system; otherwise, the KEY ON signal cannot properly start the power battery system. The power battery system is connected to the external power source via an emergency stop switch. Disconnecting the emergency stop switch cuts off the high-voltage input to the drive end, but the DC / DC converter remains operational, and the power battery system is under high voltage. Opening the emergency stop switch is therefore an ineffective power-off. Currently, operators of aerial work platforms are accustomed to pressing the emergency stop switch to cut off power. The control method mentioned in this technical solution can effectively identify and eliminate power-down characteristics, preventing battery depletion and ensuring personnel safety against electric shock.

[0031] When the power battery system is powered on at high voltage, the main circuit relay is closed, and the battery management system is in a wake-up state. At this time, the battery system starts insulation detection, voltage acquisition, current acquisition, temperature acquisition, drive relay closure, processor calculation, remote monitoring data transmission, and fault diagnosis functions. The static current of the board reaches the ampere level. At this time, the static current consumption is high, and prolonged storage without electrodes can easily lead to power depletion. First, the lithium battery depletes, then the lead-acid battery depletes, resulting in the entire machine failing to start. This invention avoids the power depletion problem by judging whether to power off, thus solving the charging problem of the battery management system failing to wake up due to extreme power depletion. During the battery charging process after wake-up, although high voltage is applied, it does not respond to walking, lifting, or lowering control commands, which can effectively avoid potential dangerous consequences caused by misoperation by non-professionals.

[0032] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A method for preventing power drain of a power battery in high-altitude work machinery, characterized in that, The system includes a power battery system, a DC / DC module, a battery management system, a remote monitoring module, a timed wake-up unit, a storage battery, and an audible and visual alarm device. The DC / DC module connects to the power battery system and the storage battery. The battery management system connects to the audible and visual alarm device, the storage battery, and is linked to a remote monitoring platform. The battery management system is responsible for collecting the individual cell voltages of the power battery pack and estimating the system's state of charge (SOC). It also time-wise wakes up the individual lithium battery cell voltages and temperatures, monitors the discharge current, and trackes usage time. The method includes sending a shutdown command to the power battery system after the aerial work platform is powered down, initiating the power-down process. Upon receiving the command, the battery management system determines whether a critical fault has been triggered. If so,... Exit wake-up state and power down; otherwise, determine if there is a high-voltage power-down fault, SOC less than the set value, or minimum cell voltage less than the set value. If any of these conditions are met, the battery management system delays for 5 minutes and goes into sleep mode. Normally, it reports the current cell voltage, temperature, SOC, and fault to the remote monitoring platform. After that, it enters short wake-up state and sleep mode. Otherwise, determine if there is a problem with the lead-acid battery voltage being lower than the set protection value. If so, it enters the pre-charge high-voltage process, enables DC / DC to charge the lead-acid battery. When the lead-acid battery voltage is greater than the safety set value, it stops charging and the battery management system enters the power-down process and sleep mode. Otherwise, it enters long wake-up state and sleep mode. When the KEY ON signal is valid, the aerial work platform will activate the emergency stop switch to perform a power-off operation, which is an invalid power-off operation. The battery management system will determine whether the output current is lower than the set value and remains so for a set time. If not, it will maintain the previous state; otherwise, it will enter the power-off process or hibernation.

2. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, If a third-level low-voltage fault occurs during the charging process of the power battery system to the lead-acid battery, the battery management system will go into hibernation after a set delay. During this period, it will normally report the current cell voltage, temperature, SOC and fault to the remote monitoring platform. After that, it will enter a short-term timed wake-up state and go into hibernation.

3. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, The power battery system and monitoring platform complete the transmission of data on individual cell voltage, temperature, SOC, and faults through a remote monitoring module.

4. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, The battery management system is woken up by a timed wake-up unit. The battery management system directly detects the battery voltage status and wakes up the DC / DC module and enables it through electrical signals or message commands. The DC / DC module then charges the battery through power conversion.

5. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, The battery management system detects a high-voltage power failure or a critical fault and alerts the user via an audible and visual alarm.

6. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, The short-term wake-up state accumulates and cycles. If the short-term wake-up triggers a limit fault, the limit undervoltage fault characteristics will be uploaded to the monitoring platform after a set delay. The system will then power down and go into hibernation. The fault can only be cleared and restored on-site by after-sales service. Otherwise, the KEY ON signal will not be able to start the power battery system normally.

7. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, The power battery system is connected to the external power source via an emergency stop switch. Disconnecting the emergency stop switch can cut off the high-voltage input to the drive end, but at this time the DC / DC converter is still in operation and the power battery system is in a high-voltage state. Opening the emergency stop switch is an ineffective power cut-off.

8. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, When the power battery system is powered on at high voltage, the main circuit relay is closed, and the battery management system is in a wake-up state. At this time, the battery management system starts the insulation detection function, voltage acquisition, current acquisition, temperature acquisition, drive relay closure, processor calculation, remote monitoring data transmission and fault diagnosis functions.

9. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, During the battery charging process after being woken up, although high voltage has been applied, it does not respond to walking, lifting or lowering control commands.

10. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, If the battery management system detects that the battery is not powered off, it enters a sleep state. At this time, the KEY ON signal is valid, but it does not respond to lifting and walking commands. It needs to be restarted to operate normally.

11. The method for preventing power outage of a power battery for high-altitude work machinery according to claim 1, characterized in that, The electrical design of the power battery system and battery management system conforms to the power-off and hibernation modes. After the battery management system enters the hibernation state, the static power consumption of the system reaches the mA level, which supports long-term storage without power depletion when the battery is in a healthy state.

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