A method for testing power batteries

Abstract

This invention discloses a power battery testing method. The method involves installing an external impact detection mechanism on the outer wall of the battery box, enabling real-time monitoring of whether the battery box has been impacted from different angles. It also involves installing a first deformation detection mechanism inside the battery box, with a leakage detection mechanism mounted on top of this first deformation detection mechanism. This allows for real-time monitoring of both the deformation and leakage of the power battery from different angles, achieving comprehensive monitoring of battery compression and leakage, thus improving the accuracy of power battery testing. Furthermore, by cooperating with the second deformation detection mechanism and the leakage detection mechanism, and installing the second deformation detection mechanism between adjacent power batteries, it enables real-time monitoring of whether deformation or leakage exists between any two adjacent power batteries within the battery box, further enhancing the comprehensiveness of power battery testing.

Description

Technical Field

[0001] This invention belongs to the field of power battery testing technology, and specifically relates to a power battery testing method. Background Technology

[0002] Power batteries are batteries that provide power to vehicles, primarily used in new energy vehicles, electric bicycles, and other transportation vehicles. To avoid unnecessary traffic accidents, such as minor collisions or crushing of new energy vehicles, or slight bottoming out, the vehicle's collision sensors often fail to detect the collision signal. Simultaneously, because the battery pack is only slightly crushed, the battery system monitoring signals will not show obvious abnormalities, making these collisions or crushing events difficult to detect in a timely manner. This can easily lead to overlooking battery system conditions, resulting in safety hazards in the vehicle and, in some cases, accidents. Therefore, the timely detection of battery pack collisions or crushing is a very urgent need.

[0003] Current methods for testing power batteries involve placing a detection unit inside the battery casing and using changes in the resistance of this unit to detect whether the battery has been impacted or compressed. For example, patent application number 201910701913.9 discloses a power battery testing system, a power battery testing method, and a power battery. This application provides a power battery including a detection unit disposed within the battery casing; and a sensor coupled to the detection unit to sense the conductivity of the detection unit; wherein the conductivity of the detection unit changes with its deformation. This power battery can be detected when it is compressed.

[0004] However, due to the uncertainty of the location of external impact or leakage in the power battery, the above-mentioned detection methods are not convenient for omnidirectional detection of the power battery, which limits the detection accuracy. To address this issue, we propose a power battery detection method to solve the above problems, enabling comprehensive monitoring of power battery compression or leakage and improving the accuracy of power battery detection. Summary of the Invention

[0005] The purpose of this invention is to provide a power battery testing method that can comprehensively monitor the power battery under pressure or leakage, improve the accuracy of power battery testing, and solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A method for testing power batteries includes the following steps:

[0008] S1. An external impact detection mechanism is installed on the outer wall of the battery box, and a first deformation detection mechanism is installed on the inner wall of the battery box. The external impact detection mechanism includes multiple first airbags, which are respectively installed on the outer periphery of the battery box. The first deformation detection mechanism includes multiple second airbags, which are respectively installed on the inner wall of the battery box. Pressure sensors are installed inside the inflation ports of the first and second airbags.

[0009] S2. Connect the air pressure sensors on the multiple first airbags and the air pressure sensors on the multiple second airbags to the controller via wires.

[0010] S3. Install a leakage detection mechanism on the first deformation detection mechanism and connect the leakage detection mechanism to the controller;

[0011] S4. Multiple air pressure sensors monitor whether the battery box is deformed or impacted. When the air pressure sensor on the first airbag detects fluctuations in the air pressure value inside the airbag, it is determined that an impact has occurred outside the battery box and proceeds to S6. When the air pressure sensor on the second airbag detects fluctuations in the air pressure value inside the airbag, it is determined that the battery box is deformed inside and proceeds to S6. When the air pressure sensor on the first or second airbag detects no fluctuations in the air pressure value inside the airbag, it indicates that the power battery is not abnormal.

[0012] S5. Monitor whether there is leakage in the power battery inside the battery box through the leakage detection mechanism. When the leakage detection mechanism is conductive, it indicates that the power battery is leaking and proceeds to S6; when the leakage detection mechanism is not conductive, it indicates that the power battery is not leaking.

[0013] S6. The controller controls the alarm to sound an alarm and displays the abnormal location on the display.

[0014] Preferably, the external impact detection mechanism further includes a second support plate for supporting the first airbag, the second support plate forming a first mounting cavity with the outer wall of the battery box, and the first airbag located in the first mounting cavity.

[0015] Preferably, the first deformation detection mechanism further includes a first support piece corresponding to the number of second airbags, and multiple first support pieces are respectively fixed to the inner wall of the battery box, forming a second mounting cavity between the first support piece and the inner wall of the battery box, and the second airbags are located in the second mounting cavity.

[0016] Preferably, both the first and second airbags are rectangular in shape, and each airbag has an inflation tube. The sensing end of the air pressure sensor is sealed inside the inflation tube, and a sealing cap is detachably installed at one end of the inflation tube.

[0017] Preferably, the leakage detection mechanism includes a rubber mesh, a detection circuit board, and an insulating protective sheet. The detection circuit board is located between the insulating protective sheet and the rubber mesh. The rubber mesh abuts against the outer wall of the power battery. The insulating protective sheet is attached to the first support sheet by a film.

[0018] Preferably, the detection circuit board includes a substrate layer, a first circuit layer and a second circuit layer, the substrate layer is located between the first circuit layer and the second circuit layer, the first circuit layer is bonded to an insulating protective sheet, the second circuit layer is bonded to a rubber mesh, and the first circuit layer and the second circuit layer are connected by copper-plated holes.

[0019] Preferably, the second circuit layer consists of a plurality of first conductive sheets with successively decreasing aperture shapes and sizes, and a plurality of second conductive sheets with successively decreasing aperture shapes and sizes. The first and second conductive sheets are arranged in a cross-shaped and equidistant manner. The plurality of first conductive sheets are connected through the first circuit layer, and the plurality of second conductive sheets are connected through the first circuit layer.

[0020] Preferably, a second deformation detection mechanism is installed between steps S3 and S4. The second deformation detection mechanism is movably placed inside the battery box between two adjacent power batteries. Leakage detection mechanisms are installed on opposite sides of the second deformation detection mechanism. The second deformation detection mechanism and the leakage detection mechanism are connected to the controller. The second deformation detection mechanism includes a third airbag. A pressure sensor is installed inside the inflation port of the third airbag. The pressure sensor monitors whether the pressure value inside the third airbag fluctuates. When fluctuation occurs, it is determined that there is a deformation phenomenon between two adjacent power batteries, and then proceed to step S6.

[0021] Preferably, the second deformation detection mechanism further includes a support base, on which an installation groove for installing the third airbag is provided, and a leakage detection mechanism is attached to the side of the support base that contacts the power battery.

[0022] Preferably, the third airbag is rectangular in shape, and the length of the third airbag is the same as the length of the power battery. The thickness of the first airbag, the second airbag, and the third airbag are all the same.

[0023] The power battery testing method proposed in this invention has the following advantages compared with the prior art:

[0024] 1. This invention, by installing an external impact detection mechanism on the outer wall of the battery box, can monitor whether the battery box has been impacted in real time from different directions. By installing a first deformation detection mechanism inside the battery box, and installing a leakage detection mechanism on the first deformation detection mechanism, it can not only monitor the deformation of the power battery inside the battery box in real time from different directions, but also monitor whether the power battery is leaking in real time. This achieves comprehensive monitoring of the power battery under pressure or leakage, and improves the accuracy of power battery detection.

[0025] 2. By combining the second deformation detection mechanism with the leakage detection mechanism, the second deformation detection mechanism is installed between two adjacent power batteries, which can monitor in real time whether there is deformation or leakage between each pair of adjacent power batteries in the battery box, thus improving the comprehensiveness of power battery detection. Attached Figure Description

[0026] Figure 1 This is a flowchart of the present invention;

[0027] Figure 2 This is a schematic diagram of the battery box structure of the present invention;

[0028] Figure 3 This is a schematic diagram of the exploded structure of the battery box of the present invention;

[0029] Figure 4 This is a cross-sectional structural diagram of the present invention;

[0030] Figure 5 For the present invention Figure 4 Enlarged structural diagram at point A in the middle;

[0031] Figure 6 This is a schematic diagram of the stacked structure of the leakage detection mechanism of the present invention;

[0032] Figure 7 This is a schematic diagram of the detection circuit board structure of the present invention.

[0033] In the diagram: 1. Battery box; 2. External impact detection mechanism; 21. Second support plate; 22. First airbag; 221. Inflation tube; 23. First mounting cavity; 3. First deformation detection mechanism; 31. First support plate; 311. Leakage detection mechanism; 32. Second airbag; 33. Second mounting cavity; 4. Second deformation detection mechanism; 41. Support base; 42. Third airbag; 5. Rubber mesh; 6. Detection circuit board; 61. First conductive sheet; 62. Second conductive sheet; 7. Insulating protection sheet. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] This invention provides, for example Figure 1-6 The power battery testing method shown includes the following steps:

[0036] S1. An external impact detection mechanism 2 is installed on the outer wall of the battery box 1, and a first deformation detection mechanism 3 is installed on the inner wall of the battery box 1. The external impact detection mechanism 2 includes multiple first airbags 22, which are respectively installed on the outer periphery of the battery box 1. The first deformation detection mechanism 3 includes multiple second airbags 32, which are respectively installed on the inner wall of the battery box 1. Pressure sensors are installed inside the inflation ports of the first airbags 22 and the second airbags 32. The pressure sensors are used to monitor the pressure value inside the airbags in real time.

[0037] S2. Connect the air pressure sensors on the multiple first airbags 22 and the multiple second airbags 32 to the controller via wires; the controller is set to a 51 microcontroller controller, which processes the air pressure values ​​sensed by the air pressure sensors in real time, determines whether there are fluctuations in the air pressure values, and controls the alarm to sound an alarm based on the air pressure fluctuation signal. At the same time, the abnormal location and alarm are displayed on the display.

[0038] S3. Install the leakage detection mechanism 311 on the first deformation detection mechanism 3, and connect the leakage detection mechanism 311 to the controller;

[0039] S4. Multiple air pressure sensors monitor whether there is deformation or impact in the battery box 1. When the air pressure sensor on the first airbag 22 detects fluctuations in the air pressure value inside the airbag, it is determined that an impact has occurred outside the battery box 1 and the process proceeds to S6. When the air pressure sensor on the second airbag 32 detects fluctuations in the air pressure value inside the airbag, it is determined that the battery box 1 has deformed inside and the process proceeds to S6. When the air pressure sensor on the first airbag 22 or the second airbag 32 detects no fluctuations in the air pressure value inside the airbag, it indicates that the power battery is not abnormal.

[0040] S5. Monitor whether there is leakage in the power battery inside the battery box 1 through the leakage detection mechanism 311. When the leakage detection mechanism 311 is conductive, it indicates that the power battery is leaking and proceeds to S6; when the leakage detection mechanism 311 is not conductive, it indicates that the power battery is not leaking.

[0041] S6. The controller controls the alarm to sound an alarm and displays the abnormal location on the display.

[0042] By installing an external impact detection mechanism 2 on the outer wall of the battery box 1, it is possible to monitor whether the battery box 1 has been impacted in real time from different positions. By installing a first deformation detection mechanism 3 inside the battery box 1 and installing a leakage detection mechanism 311 on the first deformation detection mechanism 3, it is possible not only to monitor the deformation of the power battery inside the battery box 1 in real time from different positions, but also to monitor whether the power battery is leaking in real time. This achieves comprehensive monitoring of the power battery being squeezed or leaking, and improves the accuracy of power battery detection.

[0043] The external impact detection mechanism 2 further includes a second support plate 21 for supporting the first airbag 22. The second support plate 21 forms a first mounting cavity 23 with the outer wall of the battery box 1. The first airbag 22 is located in the first mounting cavity 23. The second support plate 21 is made of a plate with a thickness of 0.2-0.5mm. The support force provided by the second support plate 21 and the outer wall of the battery box 1 allows the first airbag 22 to maintain a constant shape when not subjected to external force. When subjected to external force, the second support plate 21 is relatively thin and will promptly compress the first airbag 22 through external force, thereby improving the accuracy of the airbag in force monitoring.

[0044] The first deformation detection mechanism 3 also includes a first support plate 31 corresponding to the number of second airbags 32. Multiple first support plates 31 are respectively fixed to the inner wall of the battery box 1. A second mounting cavity 33 is formed between the first support plate 31 and the inner wall of the battery box 1. The second airbags 32 are located in the second mounting cavity 33. The first support plate 31 is made of a plate with a thickness of 0.2-0.5mm. Through the support force provided by the first support plate 31 and the inner wall of the battery box 1, the second airbags 32 maintain a constant shape when no external force is applied. When deformation occurs, the deformed position of the power battery squeezes the second airbag 32 through the first support plate 31, so that the air pressure sensor can detect the change of the airbag in time, thereby improving the accuracy of deformation monitoring by the airbag.

[0045] The first airbag 22 and the second airbag 32 are both rectangular in shape. The first airbag 22 and the second airbag 32 are provided with an inflation tube 221. The sensing end of the air pressure sensor is sealed and installed inside the inflation tube 221. One end of the inflation tube 221 is detachably fitted with a sealing cap. The inflation tube 221 is used to facilitate the inflation of the first airbag 22 and the second airbag 32 with sufficient gas. After inflation, the sealing cap is installed to seal the airbag and prevent gas leakage from the airbag.

[0046] The leakage detection mechanism 311 includes a rubber mesh 5, a detection circuit board 6, and an insulating protective sheet 7. The detection circuit board 6 is located between the insulating protective sheet 7 and the rubber mesh 5. The rubber mesh 5 abuts against the outer wall of the power battery. The insulating protective sheet 7 is attached to the first support sheet 31 by an adhesive film. The rubber mesh 5 allows the leaking liquid to flow through the rubber mesh 5 to the detection circuit board 6 when leakage occurs in the power battery. Since the leaking liquid is conductive, when the first conductive sheet 61 and the second conductive sheet 62 are connected, it indicates that the power battery is leaking. The insulating protective sheet 7 is used to protect the detection circuit board 6 and increase the safety of the detection circuit board 6. The adhesive film attaches the detection circuit board 6 to the first support sheet 31, making the detection circuit board 6 detachable and facilitating its replacement and installation.

[0047] The detection circuit board 6 includes a substrate layer, a first circuit layer, and a second circuit layer. The substrate layer is located between the first circuit layer and the second circuit layer. The first circuit layer is bonded to an insulating protective sheet 7, and the second circuit layer is bonded to a rubber mesh 5. The first circuit layer and the second circuit layer are connected by copper-plated holes. The first circuit layer is used to lead out wires to facilitate the detection of whether there is a continuity between the first conductive sheet and the second conductive sheet.

[0048] The second circuit layer consists of multiple first conductive sheets 61 with successively decreasing orifice shapes and sizes, and multiple second conductive sheets 62 with successively decreasing orifice shapes and sizes. The first conductive sheets 61 and the second conductive sheets 62 are arranged in a cross-shaped and equidistant manner. The multiple first conductive sheets 61 are connected through the first circuit layer, and the multiple second conductive sheets 62 are connected through the first circuit layer. The cooperation of the first conductive sheets 61 and the second conductive sheets 62 increases the range of leakage detection, so that no matter where the liquid leaks into the detection circuit board 6, it can be detected in time.

[0049] For cases where multiple power batteries are installed in a battery box, this invention also provides a power battery detection method. Between steps S3 and S4, a second deformation detection mechanism 4 is installed. This second deformation detection mechanism 4 is movably placed between two adjacent power batteries inside the battery box 1. Leakage detection mechanisms 311 are installed on opposite sides of the second deformation detection mechanism 4. The second deformation detection mechanism 4 and the leakage detection mechanism 311 are connected to a controller. The second deformation detection mechanism 4 includes a third airbag 42. A pressure sensor is installed inside the inflation port of the third airbag 42. The pressure sensor monitors whether the pressure value inside the third airbag 42 fluctuates. When fluctuation occurs, it is determined that there is deformation between two adjacent power batteries. If the pressure sensor inside the third airbag does not detect any fluctuation in the pressure value, it indicates that there is no deformation between the two adjacent power batteries. Through the cooperation of the second deformation detection mechanism 4 and the leakage detection mechanism 311, and by installing the second deformation detection mechanism 4 between two adjacent power batteries, it is possible to monitor in real time whether there is deformation or leakage between each pair of adjacent power batteries in the battery box 1, improving the comprehensiveness of power battery detection.

[0050] The second deformation detection mechanism 4 also includes a support base 41, on which an installation groove for the third airbag 42 is provided. A leakage detection mechanism 311 is attached to the side of the support base 41 that contacts the power battery. The thickness of the side walls of the support base 41 that contact the power battery is between 0.1-0.5 mm. The support base 41 provides support for the third airbag 42, so that the third airbag 42 can maintain a constant state when it is not squeezed by external force. When it is subjected to external force, the side walls of the support base 41 can squeeze the third airbag 42, causing the air pressure value inside the third airbag 42 to fluctuate.

[0051] The third airbag 42 is rectangular in shape and has the same length as the power battery. The first airbag 22, the second airbag 32, and the third airbag 42 all have the same thickness, so that the first airbag 22 can be evenly distributed on different surfaces of the battery box 1, the second airbag 32 can be evenly distributed inside the battery box 1, and the third airbag 42 can be stably attached to the power battery, thereby improving the comprehensiveness of monitoring the battery box 1 from different positions.

[0052] Based on the above-described power battery testing method, the present invention also provides a power battery, including a battery box 1. An external impact detection mechanism 2 is installed on the outer wall of the battery box 1, and a first deformation detection mechanism 3 is installed on the inner wall of the battery box 1. A leakage detection mechanism 311 is installed on the first deformation detection mechanism 3. The external impact detection mechanism 2 monitors the battery box 1 in real time from different positions to see if an impact has occurred. The first deformation detection mechanism 3 monitors the deformation of the power battery inside the battery box 1 in real time from different positions. The leakage detection mechanism 311 monitors the power battery in real time from different positions to see if there is leakage. This achieves comprehensive monitoring of the power battery under pressure or leakage, improving the accuracy of power battery testing.

[0053] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for testing power batteries, characterized in that: Includes the following steps: S1. The external impact detection mechanism (2) is installed on the outer wall of the battery box (1), and the first deformation detection mechanism (3) is installed on the inner wall of the battery box (1). The external impact detection mechanism (2) includes multiple first airbags (22), which are respectively installed on the outer periphery of the battery box (1). The first deformation detection mechanism (3) includes multiple second airbags (32), which are respectively installed on the inner wall of the battery box (1). Pressure sensors are installed inside the inflation ports of the first airbags (22) and the second airbags (32). The external impact detection mechanism (2) further includes a second support plate (21) for supporting the first airbag (22), and a first mounting cavity (23) is formed between the second support plate (21) and the outer wall of the battery box (1), and the first airbag (22) is located in the first mounting cavity (23); The first deformation detection mechanism (3) further includes a first support piece (31) corresponding to the number of second airbags (32). Multiple first support pieces (31) are fixed to the inner wall of the battery box (1). A second mounting cavity (33) is formed between the first support piece (31) and the inner wall of the battery box (1). The second airbags (32) are located in the second mounting cavity (33). S2. Connect the pressure sensors on the multiple first airbags (22) and the multiple second airbags (32) to the controller via wires; S3. Install a leakage detection mechanism (311) on the first deformation detection mechanism (3) and connect the leakage detection mechanism (311) to the controller; The leakage detection mechanism (311) includes a rubber mesh (5), a detection circuit board (6) and an insulating protective sheet (7). The detection circuit board (6) is located between the insulating protective sheet (7) and the rubber mesh (5). The rubber mesh (5) is in contact with the outer wall of the power battery. The insulating protective sheet (7) is attached to the first support sheet (31) by a film. The detection circuit board (6) includes a substrate layer, a first circuit layer and a second circuit layer. The substrate layer is located between the first circuit layer and the second circuit layer. The first circuit layer is bonded to an insulating protective sheet (7), and the second circuit layer is bonded to a rubber mesh (5). The first circuit layer and the second circuit layer are connected by copper-plated holes. The second circuit layer consists of multiple first conductive sheets (61) with decreasing sizes and multiple second conductive sheets (62) with decreasing sizes. The first conductive sheets (61) and the second conductive sheets (62) are arranged in a cross-shaped and equidistant manner. The multiple first conductive sheets (61) are connected through the first circuit layer, and the multiple second conductive sheets (62) are connected through the first circuit layer. S4. Monitor the battery box (1) for deformation or impact by multiple air pressure sensors. When the air pressure sensor on the first airbag (22) detects fluctuations in the air pressure inside the airbag, it is determined that an impact has occurred outside the battery box (1) and enters S6. When the air pressure sensor on the second airbag (32) detects fluctuations in the air pressure inside the airbag, it is determined that the battery box (1) has deformed inside and enters S6. When the air pressure sensor on the first airbag (22) or the second airbag (32) detects no fluctuations in the air pressure inside the airbag, it indicates that the power battery is not abnormal. S5. Monitor whether there is leakage in the power battery in the battery box (1) through the leakage detection mechanism (311). When the leakage detection mechanism (311) is connected, it indicates that the power battery is leaking and proceeds to S6; when the leakage detection mechanism (311) is not connected, it indicates that the power battery is not leaking. S6. The controller controls the alarm to sound an alarm and displays the abnormal location on the display.

2. The power battery testing method according to claim 1, characterized in that: The first airbag (22) and the second airbag (32) are both rectangular in shape. The first airbag (22) and the second airbag (32) are provided with an inflation tube (221). The sensing end of the air pressure sensor is sealed inside the inflation tube (221). One end of the inflation tube (221) is detachably fitted with a sealing cap.

3. A method for testing a power battery according to any one of claims 1-2, characterized in that: Between steps S3 and S4, a second deformation detection mechanism (4) needs to be installed. The second deformation detection mechanism (4) is placed movably inside the battery box (1) between two adjacent power batteries. A leakage detection mechanism (311) is installed on the opposite sides of the second deformation detection mechanism (4). The second deformation detection mechanism (4) and the leakage detection mechanism (311) are connected to the controller. The second deformation detection mechanism (4) includes a third airbag (42). A pressure sensor is installed inside the inflation port of the third airbag (42). The pressure sensor monitors whether the pressure value inside the third airbag (42) fluctuates. When fluctuation occurs, it is determined that there is a deformation phenomenon between two adjacent power batteries, and then proceed to S6.

4. The power battery testing method according to claim 3, characterized in that: The second deformation detection mechanism (4) also includes a support base (41), on which an installation groove for the third airbag (42) is provided, and a leakage detection mechanism (311) is attached to the side of the support base (41) that is in contact with the power battery.

5. The power battery testing method according to claim 4, characterized in that: The third airbag (42) is rectangular in shape, and the length of the third airbag (42) is the same as the length of the power battery. The thickness of the first airbag (22), the second airbag (32) and the third airbag (42) are all the same.

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