Gas sensor, battery high-temperature detection equipment and detection method
By designing a gas sensor and battery high-temperature detection device that can detect battery electrolyte leakage in a high temperature environment, the problem that existing equipment cannot detect battery leakage in a real-time manner at high temperatures is solved, and efficient and accurate battery leakage detection and alarm are achieved.
Patent Information
- Application Number
- CN202411785644.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-06
- Publication Date
- 2025-03-11
AI Technical Summary
Existing battery leakage detection equipment cannot measure the leakage status of battery electrolyte in real time under high temperature environments, and cannot effectively detect volatile toxic and harmful gases.
A gas sensor and battery high-temperature detection device are designed. The sensor consists of a metal cap, a chip, a gas varistor and a heater. It can detect gas concentration in real time in a high-temperature environment, and realize real-time data updates and alarms through the connection between the host and the probe.
Real-time detection of battery electrolyte leakage in a high temperature environment of 200℃ is achieved, which improves detection speed and accuracy, promptly alarms and reduces later maintenance costs.
Smart Images
Figure CN119595716A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of battery online detection, and in particular to a gas sensor, a battery high temperature detection device and a detection method. Background Art
[0002] As a core component of electric vehicles, lithium batteries are directly related to the vehicle's endurance and driving safety. Their quality level has become a decisive factor in the quality and experience of electric vehicles.
[0003] In order to ensure the long-term performance and safe operation of battery components, leakage detection is an essential step in quality control. The electrolyte leakage detection equipment currently on the market has an integrated design of sensors and equipment host, which cannot measure the battery electrolyte leakage in a high temperature environment in real time.
[0004] When a battery leaks, some toxic and harmful gases will evaporate. These gases are liquid at room temperature and cannot be effectively detected by existing all-in-one devices at room temperature. Summary of the invention
[0005] The purpose of the present invention is to solve the above problems and to provide a gas sensor, a battery high temperature detection device and a detection method, which can place the sensor in a high-temperature battery detection environment far away from the host for detection, with a fast detection speed, real-time data update and timely alarm.
[0006] The technical solution adopted by the present invention is: A gas sensor, characterized in that it includes a metal cap and a chip arranged in the metal cap, a base is arranged below the metal cap, the chip includes a gas-sensitive resistor arranged on the front side of the substrate and a heater arranged on the back side of the substrate, four pins are arranged on the base, two pins are electrically connected to the gas-sensitive resistor, and two pins are connected to the heater, and an opening is arranged at the front end of the metal cap.
[0007] Furthermore, the gas-sensitive resistor is a metal oxide coated on the front side of the substrate, and the heater is a RuO2 material covered on the back side of the substrate.
[0008] Furthermore, the metal cap is made of stainless steel, and a stainless steel mesh is arranged at the opening.
[0009] Furthermore, all components in the gas sensor are high temperature resistant components, and the high temperature resistance temperature is not less than 200°C.
[0010] A high-temperature detection device for detecting battery electrolyte leakage, characterized in that it includes a host, a wiring harness and a probe, the probe is connected to the host through the wiring harness, the wiring harness is a high-temperature resistant shielded wire, the probe includes a shell, the gas sensor and a PCBA, the gas sensor is arranged at the head of the shell, the four pins of the gas sensor are connected to the PCBA, the PCBA is connected to the host through the wiring harness, the host applies voltage to two pins of a gas-sensitive resistor and a heater respectively, the gas-sensitive resistor is connected in series with a load resistor, and the host indirectly measures the resistance value of the gas-sensitive resistor by measuring the resistance value of the load resistor.
[0011] Furthermore, a high-temperature thermistor is provided on the PCBA, and the thermistor is connected to the host through a wiring harness and is used to measure the temperature of the probe.
[0012] Furthermore, the operating temperature of the electronic components on the PCBA is -50-200°C, the PCBA is an FR-4 substrate, and the housing of the probe is a high-temperature resistant aluminum-magnesium alloy material, requiring a high temperature value greater than 200°C.
[0013] Furthermore, the host has a built-in voltage-controlled constant current source, which is composed of an operational amplifier connected to a triode, and provides a constant heating current for the heater.
[0014] A method for detecting battery electrolyte leakage, characterized in that it comprises the following steps: (1) Place the probe in the test environment to be tested; (2) The host measures the resistance of the high-temperature thermistor set on the PCBA to determine the ambient temperature; (3) According to the ambient temperature, the heating voltage of the heater is controlled to heat the sensor to a stable state, and the working voltage is applied to the gas sensor; (4) The host monitors the resistance value of the gas sensor at any time to determine the gas concentration within the monitoring range; (5) When the host detects that the gas concentration exceeds the set threshold, the alarm device on the host will sound an alarm.
[0015] Further, the method further comprises the steps of: (6) The host saves real-time gas concentration information through a storage device.
[0016] The beneficial effects of the present invention are: (1) Ability to detect battery electrolyte leakage in real time at a high temperature of 200°C; (2) The gas-sensitive components inside the gas sensor are kept at a constant temperature through software and hardware solutions, making the measurement results more accurate; (3) The parts are highly interchangeable, the structural components are easy to replace and can be reused, which reduces the subsequent maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Attached Figure 1 It is a structural schematic diagram of a battery high temperature detection device; Attached Figure 2 It is a schematic diagram of the structure of the detection probe; Attached Figure 3 It is a schematic diagram of the structure of the gas sensor; Attached Figure 4 This is a schematic diagram of the front of the gas sensor chip; Attached Figure 5 This is a schematic diagram of the reverse side of the gas sensor chip; Attached Figure 6 This is the power supply diagram of the gas sensor; Attached Figure 7 This is the constant current source control circuit diagram of the heater; Attached Figure 8 This is a graph of gas sensor detection data of this patent.
[0018] The reference numerals in the accompanying drawings are: 1. Host; 2. Wiring harness; 3. Probe; 4. Housing; 5. Gas sensor; 6. PCBA; 7.Metal cap; 8.Chip; 9. Base; 10. Stainless steel mesh; 11. Gas sensor; 12. Heater; 13. Pins. DETAILED DESCRIPTION
[0019] The specific implementation methods of the gas sensor, battery high temperature detection equipment and detection method of the present invention are described in detail below with reference to the accompanying drawings.
[0020] Lithium batteries are prone to thermal runaway or electrolyte leakage in high temperature environments. This patent can detect battery thermal runaway or battery electrolyte leakage in a high temperature environment of 200°C in the laboratory, and can detect battery failure or experimental failure in a timely manner.
[0021] See attached Figure 1 The battery high temperature detection equipment of this patent includes a host 1, a wiring harness 2 and a sensor probe 3. The host 1 works at room temperature, and the probe 3 works at a high temperature in the test environment, which can withstand temperatures exceeding 200°C. The wiring harness 2 is also made of high temperature resistant materials, which can withstand temperatures above 200°C. It uses high temperature shielded wires, which are composed of tinned copper wire, high temperature resistant glass fiber wire and an outer stainless steel shielding mesh, and has an operating temperature of 0-500°C.
[0022] See attached Figure 2The probe 3 is composed of a housing 4, a gas sensor 5, a PCBA 6 and other components. The gas sensor 5 is arranged at the head of the probe 3 and communicates with the test environment. The gas sensor 5 is connected to the PCBA 6, and the signal is connected to the PCBA 6. The PCBA 6 is connected to the host 1 through a wiring harness.
[0023] The probe is made of aluminum-magnesium alloy, which can work for a long time in a 250℃ environment and maintain working strength, and the maximum working temperature can reach 350℃; the working temperature of all electrical components on the PCBA is -50-200℃, and the PCBA uses TG-200's FR-4 substrate, which has good high temperature resistance.
[0024] See attached Figure 3-5 The gas sensor 5 includes a metal cap 7 and a chip 8 disposed in the metal cap 7. A base 9 is disposed below the metal cap 7. An opening is disposed at the front end of the metal cap 7. The metal cap 7 is made of stainless steel, and a stainless steel mesh 10 is disposed at the opening. The chip 8 includes a gas-sensitive resistor 11 disposed on the front of the substrate and a heater 12 disposed on the back of the substrate. Four pins 13 are disposed on the base, two of which are electrically connected to the gas-sensitive resistor 11, and two of which are connected to the heater 12.
[0025] The gas sensor is a metal oxide coated on the front of the substrate, and the heater is a RuO2 material covered on the back of the substrate. All components in the gas sensor are high temperature resistant components, and the high temperature resistance temperature is not less than 200℃.
[0026] The four pins of the gas sensor are connected to the PCBA, and the PCBA is connected to the host through a wiring harness.
[0027] See attached Figure 6 ,The host applies voltages Vc and VH to the two pins of the gas-sensitive resistor Rs and the heater RH respectively. The gas-sensitive resistor Rs is connected in series with a load resistor RL. The host indirectly measures the resistance of the gas-sensitive resistor by measuring the resistance of the load resistor RL. That is, through the series resistor voltage division principle, the resistance change of the gas-sensitive resistor Rs is determined by measuring the voltage VRL across the load resistor RL. According to the resistance change of the gas-sensitive resistor Rs, the concentration of the released gas in the test environment is determined.
[0028] See attached Figure 7 , a voltage-controlled constant current source is set in the host, which is composed of an op amp U1 connected to a transistor Q1, and the voltage-controlled constant current source is applied to the two pins of the heater. The voltage at the input end is sent to the op amp U1, and the input and output ends of the op amp U1 are compared to realize the function of a constant current follower, stabilize the output current, and realize constant current output control.
[0029] The voltage-controlled constant current source can accurately control the heating current of the gas sensor through a control program. The host MCU detects the ambient temperature through the built-in thermistor of the probe, and the control program adjusts the heating current according to the ambient temperature to ensure that the sensitivity of the gas sensor is consistent under different ambient temperatures.
[0030] When the sensor is working, the heater needs to maintain the metal oxide at a temperature of several hundred degrees to maintain the sensitivity of the metal oxide. Since both the metal oxide and the heating component can work at a temperature of several hundred degrees, the current of the heater can be adjusted by the host controller to make the gas sensor work in different high temperature environments to avoid zero drift or range offset. Constant current power supply ensures that the temperature is heated to a constant high temperature each time it works, so that the concentration detected by the gas sensor has a fixed standard.
[0031] Using this patent to detect battery electrolyte leakage includes the following steps: (1) Place the probe in the test environment to be tested; (2) The host measures the resistance of the high-temperature thermistor set on the PCBA to determine the ambient temperature; (3) According to the ambient temperature, the heating current of the heater is controlled to heat the sensor to a stable state, and a working voltage is applied to the gas sensor; (4) The host monitors the resistance value of the gas sensor at any time to determine the gas concentration of the monitored test environment; (5) When the host detects that the gas concentration in the test environment exceeds the set threshold, the alarm device on the host will sound an alarm; (6) The host saves real-time gas concentration information through a storage device.
[0032] See attached Figure 8 After the above steps, a practical test was conducted, and the test results are as follows Figure 8 As shown, the horizontal axis is the measurement time, the left vertical axis is the ambient temperature (Temperature), and the right vertical axis is the gas concentration (PPM). First, the test environment is raised to 200°C (dashed line in the figure). The gas concentration fluctuates during the temperature increase (solid line in the figure), and the error is eliminated through software calibration. In the high temperature environment of 200°C, the gas concentration remains unchanged at first, and then the concentration increases sharply, indicating that the battery electrolyte leakage is detected at this time. When the gas concentration exceeds the set threshold, the device will alarm.
[0033] The above are only preferred embodiments of the present invention. It should be pointed out that ordinary technicians in this technical field can make several improvements and modifications without departing from the principles of the present invention. These improvements and modifications should also be regarded as the protection scope of the present invention.
Claims
1. A gas sensor, characterized in that: It includes a metal cap and a chip arranged in the metal cap, a base is arranged under the metal cap, the chip includes a gas-sensitive resistor arranged on the front side of the substrate and a heater arranged on the back side of the substrate, four pins are arranged on the base, two pins are electrically connected to the gas-sensitive resistor, and two pins are connected to the heater, and an opening is arranged at the front end of the metal cap.
2. The gas sensor according to claim 1, characterized in that: The gas-sensitive resistor is a metal oxide coated on the front side of the substrate, and the heater is a RuO2 material covered on the back side of the substrate.
3. The gas sensor according to claim 1, characterized in that: The metal cap is made of stainless steel, and a stainless steel mesh is arranged at the opening.
4. The gas sensor according to claim 1, characterized in that: The components in the gas sensor are all high temperature resistant components, and the high temperature resistance temperature is not less than 200°C.
5. A high temperature detection device for detecting battery electrolyte leakage, using the gas sensor as claimed in claim 4, characterized in that: It includes a host, a wiring harness and a probe, wherein the probe is connected to the host through the wiring harness, and the wiring harness is a high temperature resistant shielded wire. The probe includes a shell, the gas sensor and a PCBA, the gas sensor is arranged at the head of the shell, four pins of the gas sensor are connected to the PCBA, the PCBA is connected to the host through the wiring harness, the host applies voltage to two pins of the gas-sensitive resistor and the heater respectively, the gas-sensitive resistor is connected in series with a load resistor, and the host indirectly measures the resistance value of the gas-sensitive resistor by measuring the resistance value of the load resistor.
6. The high temperature detection device for detecting battery electrolyte leakage according to claim 5, characterized in that: A high-temperature thermistor is disposed on the PCBA and connected to the host through a wiring harness for measuring the temperature of the probe.
7. The high temperature detection device for detecting battery electrolyte leakage according to claim 5, characterized in that: The operating temperature of the electronic components on the PCBA is -50-200°C. The PCBA is an FR-4 substrate. The housing of the probe is made of a high-temperature resistant aluminum-magnesium alloy material, and the required high temperature value is greater than 200°C.
8. The high temperature detection device for detecting battery electrolyte leakage according to any one of claims 5 to 7, characterized in that: The host has a built-in voltage-controlled constant current source, which is composed of an operational amplifier connected to a triode, and provides a constant heating current for the heater.
9. A method for detecting battery electrolyte leakage, using the high temperature detection device as described in any one of claims 5 to 8, characterized in that: The steps include: (1) Place the probe in the test environment to be tested; (2) The host measures the resistance of the high-temperature thermistor set on the PCBA to determine the ambient temperature; (3) According to the ambient temperature, the heating voltage of the heater is controlled to heat the sensor to a stable state, and the working voltage is applied to the gas sensor; (4) The host monitors the resistance value of the gas sensor at any time to determine the gas concentration within the monitoring range; (5) When the host detects that the gas concentration exceeds the set threshold, the alarm device on the host will sound an alarm.
10. The method for detecting battery electrolyte leakage according to claim 9, characterized in that: Also includes the steps: (6) The host saves real-time gas concentration information through a storage device.