Battery pack dynamic management and self-cleaning switching system and battery pack dynamic management method

Abstract

The invention relates to the technical field of electric vehicle power supply systems, and discloses a battery pack dynamic management and self-cleaning switching system and a battery pack dynamic management method.The system comprises a vehicle frame, a battery pack power supply system and a battery pack self-cleaning system, and the vehicle frame comprises a main supporting pipe and a plurality of side support sets; the mounting box body is arranged in a mounting position formed by the side bracket group; the plurality of battery packs are mounted in the mounting box body and are arranged in a shape like a Chinese character'tian '; and the multi-power-supply selective connecting device is mounted in the frame. The multi-power-supply selective connecting device comprises a plurality of sets of communicating contact heads, a mode adjusting mechanism, a scale deposition layer cleaning structure, an operation mounting disc and a transmission mechanism. The system further comprises a monitoring system and a power supply control system. The control method comprises a real-time monitoring step, an abnormity judging step, a mode switching step and a scale cleaning step. According to the system, the functions of real-time monitoring, dynamic switching and fault isolation of the battery pack are realized, and the problem of contact reliability in a traditional multi-battery switching system is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle power management, and in particular to a battery pack dynamic management and self-cleaning switching system and a control method thereof, which are particularly suitable for two-wheeled electric vehicles powered by multiple battery packs. Background Art

[0002] Lead-acid batteries are currently the most commonly used power source in two-wheeled electric vehicles. Generally, four or five 12V batteries are connected in series to power the vehicle. In actual use, if a battery in the battery pack has a serious abnormality or poor contact, it will affect the working state of the entire series circuit. What is more dangerous is that users often cannot detect this abnormality in time, and continued use will cause other batteries to work in an abnormal state for a long time, which not only accelerates the performance degradation of the battery pack, but may also cause the vehicle to suddenly lose power during driving, causing great trouble to the user, and even causing safety hazards in serious cases.

[0003] To solve the above problems, a system is needed that can detect the status of single cells and flexibly adjust the battery connection method. Such a system can not only detect battery abnormalities in a timely manner and take countermeasures, but also charge batteries with large performance differences individually or in groups, thereby balancing the performance differences of each battery, effectively extending the service life of the battery pack and reducing the failure rate.

[0004] However, implementing this detection and flexible charging solution requires the layout of numerous electronic components, complex circuits, and multiple switches. These switches and contacts are prone to oxidation and spark corrosion during frequent switching, resulting in uneven contact surfaces, affecting effective contact on the contact surfaces, and increasing resistance, which not only causes heating problems but also affects charging effects. In addition, complex circuit systems also increase failure points, increasing maintenance difficulty and costs.

[0005] In view of the above problems, the present invention proposes a solution to complete line switching by replacing electronic components with mechanical structures. This solution can not only realize battery status detection and flexible charging methods through special mechanical structure design, but also promptly notify the user to switch to temporary voltage reduction riding mode when battery abnormality is detected, so that the vehicle can safely reach the maintenance point and avoid the trouble of road breakdown. At the same time, the contact design of this solution is easy to clean and maintain, which significantly improves the reliability and service life of the system. Summary of the invention

[0006] The object of the present invention is to solve the deficiencies of the prior art. The present invention provides a battery pack dynamic management and self-cleaning switching system for two-wheeled electric vehicles, which adopts a "field" - shaped battery layout and a self-cleaning design for the fouling layer. Through the integrated multi-power selective connection device, the real-time monitoring, dynamic switching, and fault isolation functions of the battery pack are realized, effectively solving the contact reliability problem in the traditional multi-battery switching system. At the same time, the heat dissipation efficiency of the system is improved, realizing the intelligent management and long-term stable operation of the battery pack.

[0007] To solve the above problems, the present invention adopts the following scheme: A battery pack dynamic management and self-cleaning switching system, comprising: A frame, the frame includes a main support pipe and multiple groups of side support groups connected to the main support pipe. The side support groups are arranged in a three-sided surrounding shape and form an installation position for placing batteries; An installation box body disposed in the installation position, the installation box body has a drain hole and a ventilation structure; Multiple battery packs installed in the installation box body, the multiple battery packs are designed in a "field" - shaped layout, and there is a heat dissipation space between the multiple battery packs; A multi-power selective connection device installed in the frame, the multi-power selective connection device includes: Multiple groups of connecting contacts for electrically connecting with the multiple battery packs, and the surface of the connecting contacts is coated with a conductive elastic layer; A mode adjustment mechanism, the mode adjustment mechanism includes an adjustment disk. At both ends of the adjustment disk, a plurality of contact points are evenly distributed along the circumferential direction, and the plurality of contact points form several groups of gear position contact point combinations; a plurality of connection areas are provided on the outer peripheral wall of the adjustment disk, and power-off friction areas are provided between the connection areas; A fouling layer cleaning structure, the fouling layer cleaning structure is disposed between the adjustment disk and the connecting contacts for cleaning the fouling on the surfaces of the connecting contacts and the contact points; An operation installation disk for installing the adjustment disk and the fouling layer cleaning structure; and A transmission mechanism, the transmission mechanism includes an adjustment gear disposed at the edge of the end face of the adjustment disk, and a gear transmission rod meshing with the adjustment gear; Monitoring system, the monitoring system includes: a voltage monitoring unit for monitoring the battery pack voltage; a current monitoring unit for monitoring the charging and discharging current of the battery pack; a temperature monitoring unit for monitoring the battery pack temperature; an internal resistance monitoring unit for monitoring the internal resistance of the battery pack; and a control unit for controlling the mode adjustment mechanism to perform mode switching according to the monitoring data; a power supply control system, the power supply control system includes: two sets of electrical connection devices arranged on the outer peripheral wall of the adjustment disc, each set of electrical connection devices includes an electrical connection wire and an electrical contact block; a gold-plated compression spring arranged between the electrical contact block and the electrical connection wire; and an installation housing for accommodating the electrical connection wire, the installation housing forms a sealed fit with the operation mounting disc.

[0008] Beneficial effects: Through the "field"-shaped battery pack layout design and the provided heat dissipation space, the heat dissipation efficiency of the system can be effectively improved, and the battery service life can be extended; The frame with a three-sided surrounding design and the installation box body with drainage and ventilation structures improve the structural stability, while protecting the battery pack from the environment; The integrated design of the multi-power selective connection device, combined with a comprehensive monitoring system and a power supply control system, realizes the real-time monitoring and dynamic switching functions of the battery pack; Through the setting of the scale deposit cleaning structure, the contact reliability problem in the traditional system is solved, ensuring the long-term stable operation of the system.

[0009] Preferably, the side support group is made of hollow steel pipes, the diameter of the main support pipe is 30 - 40 mm, and the diameter of the secondary support pipe is 20 - 25 mm; The distance between the battery packs is 30 - 50 mm.

[0010] Beneficial effects: The design of the hollow steel pipe reduces the overall weight while ensuring strength. The optimized diameter parameters of the main support pipe and the secondary support pipe provide the best support strength. At the same time, the reasonable setting of the battery pack distance ensures sufficient heat dissipation space, improving the heat dissipation efficiency and structural stability of the system.

[0011] Preferably, the thickness of the conductive elastic layer is 0.2 - 0.3 mm and it is made of graphene composite material.

[0012] Beneficial effects: Through the precise control of the thickness of the conductive elastic layer and the application of graphene composite material, not only good electrical conductivity is ensured, but also the durability of the system is improved. The setting of the elastic layer provides a stable contact pressure, thus improving the reliability and service life of the overall connection.

[0013] Preferably, the scale deposit cleaning structure includes: A contact friction arc section for cleaning the scale deposit on the communicating contact head; and A contact friction arc section for cleaning the scale deposit on the contact point; Wherein, the contact friction arc segment and the contact point friction arc segment are symmetrically installed on two side surfaces of the operation installation plate.

[0014] Beneficial effects: The double-sided cleaning structure and symmetrical installation design not only improve the cleaning efficiency and ensure the uniformity and stability of the cleaning, but also the realization of the automatic cleaning function extends the maintenance cycle of the system and reduces the maintenance cost.

[0015] Preferably, the contact friction arc segment comprises: a first friction surface for contacting the connecting contact head, the surface roughness Ra value of the first friction surface is 0.8-1.2 μm; wherein the contact friction arc segment is provided with a plurality of connecting holes, and the connecting holes correspond one-to-one to the connecting contact heads.

[0016] Beneficial effects: Through the precise control of surface roughness and the one-to-one correspondence design of the connection holes, combined with the design characteristics of the arc structure, the reliability of the cleaning effect and the stability of the electrical connection are ensured, while the uniformity of cleaning and the overall work efficiency are improved.

[0017] Preferably, the connecting area of ​​the regulating disc is made of gold-plated copper alloy, the power-off friction area is made of tungsten carbide matrix material, and the surface of the power-off friction area is processed with fine grooves with a depth of 0.1 mm and a spacing of 0.5 mm.

[0018] Beneficial effects: Through the application of gold-plated copper alloy and the use of tungsten carbide matrix materials, combined with the special design of micro-grooves, the conductivity and wear resistance of the system are significantly improved, the cleaning effect is improved, and the service life of the overall system is effectively extended.

[0019] The present invention also provides a method for dynamic management of battery packs using the above-mentioned multi-power selective connection device, comprising the following steps: a real-time monitoring step, comprising: monitoring voltage parameters of multiple battery packs, wherein the monitoring range of the voltage parameters is 10.5-14.4V; monitoring current parameters of multiple battery packs, wherein the monitoring range of the current parameters is -50A to +50A; monitoring temperature parameters of multiple battery packs, wherein the monitoring range of the temperature parameters is -20°C to 60°C; monitoring internal resistance parameters of multiple battery packs, wherein the monitoring range of the internal resistance parameters is 5-15mΩ; The abnormality judgment steps include: judging whether the voltage is lower than 10.5V; judging whether the temperature exceeds 55°C; judging whether the discharge current exceeds 45A; judging whether the internal resistance mutation exceeds 30%; The mode switching step includes: when an abnormal parameter is detected, controlling the adjustment disk to rotate to switch the connection mode of the battery pack; controlling the rotation speed of the adjustment disk to be within the range of 60-120rpm; ensuring the positioning accuracy of the adjustment disk to be within the range of ±1°; The scale cleaning steps include: automatically performing scale cleaning when switching the battery pack connection mode; performing scale cleaning according to a preset maintenance plan; and performing cleaning at a pressure of 0.6-0.8MPa.

[0020] Beneficial effects: Through comprehensive parameter monitoring range settings and specific abnormal judgment standards, combined with precise control parameters and cleaning pressure requirements, the safety, reliability and stability of system operation are comprehensively improved, effectively ensuring the efficient management and long-term stable operation of the battery pack; at the same time, through the integration of automatic fouling cleaning functions, the system maintenance cost is reduced and the operating efficiency is improved.

[0021] Preferably, the mode switching step comprises: Manual control mode: operate the starting operating parts on the front part of the vehicle; drive the installation disc to rotate by pulling the pull rope, and the stroke of the pull rope is 15-20mm; drive the adjustment disc to rotate by the adjustment operating part with an operating torque not exceeding 2N•m; or automatic control mode: drive the installation disc to rotate by a servo motor; drive the adjustment disc to rotate by a stepper motor or servo motor; the system response time does not exceed 200ms.

[0022] Beneficial effects: The design of manual and automatic control modes, combined with precise stroke control and fast response characteristics, not only ensures the flexibility and reliability of system operation, but also improves the efficiency of the switching process; at the same time, through the limitation of operating torque and the requirement of fast response time, the safety of operation and the real-time performance of the system are ensured.

[0023] Preferably, the connection modes in the mode switching step include: Standard working mode: 48V mode: four batteries are connected in series for standard working conditions; Emergency working mode: 36V mode: three batteries are connected in series, automatically skipping the faulty battery; 24V mode: two batteries are connected in series for emergency conditions; Diagnostic working mode: Single battery mode: used for single battery performance evaluation.

[0024] Beneficial effects: Through the design of multiple voltage level working modes and the function of automatically skipping faulty batteries, the system can be flexibly applied under different working conditions, improving the reliability and adaptability of the system. At the same time, through the setting of diagnostic mode, it is easy to detect and deal with battery failures in a timely manner, effectively ensuring the continuity and stability of power supply.

[0025] Compared with the prior art, the technical solution of the present invention has the following advantages: Through innovative structural design and intelligent control methods, the present invention achieves the following overall beneficial effects: (1) By adopting a "field"-shaped battery layout and a frame design surrounded by three sides, combined with an installation box body for drainage and ventilation, it not only improves the structural stability and heat dissipation efficiency but also facilitates installation and maintenance; (2) The multi-power selective connection device provided, in cooperation with a comprehensive monitoring system and a power supply control system, realizes the real-time monitoring and dynamic switching functions of the battery pack, ensuring the safe and reliable operation of the system; (3) The unique scale layer cleaning structure and precise parameter control solve the contact reliability problem in the traditional system, extend the service life of the system, and improve the power transmission efficiency; (4) The design of multiple working modes and fault protection mechanisms enhances the adaptability and stability of the system, realizing the intelligent management and long-term stable operation of the battery pack. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings described below are only some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0027] Figure 1 It is a general flow block diagram of the system of the present invention; Figure 2 It is a flow block diagram of the cleaning part of the system of the present invention; Figure 3 It is a flow block diagram of the mode switching part of the system of the present invention; Figure 4 It is a flow block diagram of the monitoring part of the system of the present invention; Figure 5 It is a schematic structural diagram of the present invention when applied to an electric vehicle frame; Figure 6 It is a schematic internal structure diagram of the switching device of the present invention cooperating with the battery pack; Figure 7 is Figure 6 a partial enlarged view of part Ⅰ in Figure 8 It is a schematic structural diagram of the mode adjustment mechanism of the present invention; Fig. 9 It is a schematic structural diagram of the scale layer cleaning structure of the present invention installed on the operation installation part; Fig.10 It is a schematic structural diagram of the scale layer cleaning structure of the present invention; Fig.11 It is a schematic structural diagram of the adjustment disc of the present invention connected to the electrical contact block.

[0028] Reference numerals: vehicle frame 10, main support tube 11, side support assembly 12, mounting position 121, mounting box 13, steering support frame 18, battery pack 21, external connection line 22, connection frame 30, multi-power selective connection device 40, connection contact head 41, mode adjustment mechanism 42, fouling layer cleaning structure 43, operation installation plate 44, adjustment disc 421, gear contact assembly 422, contact 4221, contact friction arc segment 431, first friction surface 4311, connection hole 431 2. Contact friction arc segment 432, second friction surface 4321, mounting disc 441, connecting through hole 4411, arc groove 4412, mounting space 442, protruding connecting block 443, pulling rope 444, protective baffle 45, adjusting gear 51, gear transmission rod 52, making way gap 53, electrical connecting line 61, electrical contact block 62, elastic member 63, connecting area 71, power-off friction area 72, third friction surface 721, placement shell 80, arc gap 81, electrical conductive line 90. DETAILED DESCRIPTION

[0029] The following will be combined Figure 1-Figure 7 The preferred embodiments of the present invention are described in detail. It should be noted that the following description is only a preferred embodiment of the present invention, rather than a limitation of the present invention. Those skilled in the art should understand that various modifications and variations can be made to the present invention without departing from the spirit and scope of the present invention. The scope of protection of the present invention shall be subject to the attached claims.

[0030] Embodiment 1: refer to Figure 1-Figure 5 This embodiment provides a battery pack dynamic management and self-cleaning switching system, which is mainly used in the field of electric vehicles, and is particularly suitable for two-wheeled electric vehicles powered by multiple battery packs. The system realizes the real-time monitoring, dynamic switching and fault isolation functions of the battery pack through an innovative multi-power selective connection device 40, and integrates a unique contact self-cleaning mechanism, which effectively solves the contact reliability problem in the traditional multi-battery switching system. The system adopts a modular design and can be flexibly installed under the main support tube of the frame, which not only ensures the compactness of the vehicle structure, but also facilitates maintenance and operation.

[0031] The multi-power selective connection device 40 is installed in the frame 10 of the two-wheeled electric vehicle. The frame 10 is connected to the steering support frame 18. The frame 10 includes a main support pipe 11 connected to the steering support frame 18. On both sides of the main support pipe 11 along the width direction of the electric vehicle, a plurality of groups of symmetric side bracket groups 12 are connected. Among them, the side bracket group 12 is made of hollow steel pipes. The diameter of the main support pipe is 30 - 40 mm, and the diameter of the secondary support pipe is 20 - 25 mm. Each bracket group is fixedly connected by welding, and reinforcing rib plates are added at key nodes. The plurality of groups of side bracket groups 12 are arranged in a three-sided surrounding shape, and an installation position 121 for placing the battery is formed. An installation box body 13 with a waterproof design is arranged in the installation position 121. The installation box body 13 has drainage holes and a ventilation structure, and a shock pad is arranged inside. The battery is installed in the installation box body 13.

[0032] The power supply architecture of this system adopts a "field" - shaped layout design, configuring four 12V battery units, and dividing them into left and right two groups of battery packs 21 with the symmetry axis of the electric vehicle's traveling direction. The distance between the two groups of battery packs is, for example, 30 - 50 mm. The space formed realizes the dynamic control of the battery temperature through a forced convection heat dissipation system, and at the same time accommodates the multi-power selective connection device 40. The system adopts a standardized interface design, and the external connection wires 22 equipped for each battery unit use waterproof type quick - plug electrical connectors.

[0033] Reference Figure 2-Figure 7 , the core structure of the multi-power selective connection device 40 includes four groups of connected contacts 41, a mode adjustment mechanism 42, a scale deposit layer cleaning structure 43, and an integrated operation and installation disk 44. The technical features of each component are as follows: Connected contacts 41: Adopt a symmetric layout. Each group of connected contacts 41 is equipped with a corresponding scale deposit layer cleaning structure 43, located on both sides of the mode adjustment mechanism 42; The contact head material is selected as a highly conductive gold - plated copper alloy, and two pairs of positive and negative contact heads are arranged on each side; Connect to the battery pole through a waterproof electrical connector to ensure that the contact resistance ≤ 0.5 mΩ; Adopt a coaxial self - rotation design, and the rotation torque is controlled within 0.8 N•m; The four connected contacts 41 are distributed in an equally divided circular arc shape to ensure uniform force.

[0034] The modular design of the system supports flexibly configuring the number of connected contacts 41 according to actual application requirements, maintaining a symmetric distribution on both sides of the mode adjustment mechanism 42.

[0035] Key component design of the mode adjustment mechanism 42: Adjustment disk 421: Made of wear - resistant engineering plastic, with a diameter of 80 - 100 mm and a thickness of 15 - 20 mm; Contact distribution: Multiple contacts 4221 are evenly distributed along the circumferential direction at both ends of the adjustment disk 421 (only the contacts at one end of the adjustment disk are shown in the figure), and the contacts are made of silver-plated copper alloy, with a contact resistance of ≤0.3mΩ; Shift combination: Multiple contacts 4221 form several shift contact combinations 422. The contacts 4221 of each shift contact combination 422 are symmetrically distributed at both ends of the adjustment disk 421. The number of contacts matches the number of connected contacts 41. Circuit design: Each gear contact combination 422 realizes line connection of different modes by adjusting the wire (cross-sectional area ≥ 2.5mm²) inside the disc 421. The contact 4221 can be reused in different gear contact combinations 422 to improve space utilization; When a battery in the battery pack is in an abnormal state (voltage <10.5V or current fluctuation exceeds the rated value ±20%), the system can drive the adjustment disc 421 to rotate (angle 0-360°, step angle 15°) through the stepper motor to achieve the reconnection of the battery pack. The stepper motor drive ensures that the positioning accuracy is within ±0.5° and the contact pressure of the contact point is maintained within the range of 0.6-0.8MPa.

[0036] refer to Figure 7 , Figure 8-Figure 9 The fouling layer cleaning structure 43 is mainly composed of the following components: two contact friction arc segments 431 for cleaning the fouling of the connecting contact head 41, and two contact friction arc segments 432 for cleaning the fouling of the contact 4221; these friction components are symmetrically installed on the two sides of the operation installation plate 44, and are respectively located between the adjustment disk 421 and the corresponding connecting contact head 41. The contact friction arc segment 431 is made of tungsten carbide material with a hardness not less than HRA90, and is designed with four connection holes 4312, which correspond to the connecting contact head 41 one by one. Its key technical parameters are as follows: First friction surface 4311: in contact with the connecting contact head 41, with a surface roughness Ra value of 0.8-1.2 μm; Second friction surface 4321: in contact with contact point 4221, using the same surface treatment process; All friction contact surfaces have been treated for anti-oxidation, and their service life is ≥ 10,000 reciprocating movements; by rotating the operating mounting disk 44, the first friction surface 4311 of the contact friction arc segment 431 and the connecting contact head 41 are subjected to relative movement cleaning; by rotating the adjusting disk 421, the second friction surface 4321 of the contact friction arc segment 432 rubs and cleans the contact 4221.

[0037] This innovative self-cleaning design effectively solves the fouling problem caused by environmental oxidation, spark corrosion and other factors in traditional systems. Through regular or automatic cleaning during switching, the contact surface roughness can be maintained below Ra 1.6μm and the contact resistance can be controlled within 0.5mΩ. The design is expected to extend the battery life by 30-50% and ensure that the supply voltage fluctuation is ≤±2%.

[0038] The design of the contact friction arc section 431 not only has a cleaning function, but also integrates an electrical isolation function. A complete dwelling space is designed in the area outside the connection hole 4312, which can accommodate a connection contact head 41, and the dirt is removed through the surface friction of 3-5N. The system uses step rotation to achieve precise positioning, and the ratchet structure can achieve a positioning accuracy of ±0.5° and has a self-locking function, ensuring that the connection contact head 41 can be completely located in the dwelling space to achieve reliable electrical isolation. In terms of contact interface optimization, the inner wall of the connection hole 4312 adopts a 15° chamfer design (depth 0.5-0.8mm) and is anodized. The end of the connection contact head 41 close to the contact 4221 adopts a spherical design and is plated with a 3-5μm gold layer, which controls the friction coefficient between 0.1-0.15 and the operating force is controlled below 5N to ensure a smooth and reliable conversion process. In order to improve the conductivity, the surface of the connection contact head 41 is coated with a conductive elastic layer of 0.2-0.3mm thick, and graphene composite materials (volume resistivity ≤10^-3Ω•cm, elastic deformation 20-30%), doped PEDOT:PSS conductive polymer materials (conductivity>1000 S / cm) or beryllium copper alloy (yield strength ≥500MPa) and other material solutions can be used. This system uses a composite material of 8-12 layers of graphene and silicone rubber, which has excellent lateral conductivity (>5000 S / cm). When the connection contact head 41 enters the connection hole 4312, the conductive elastic layer generates an elastic pressure of 2-3N, ensuring that the contact resistance is <0.3mΩ, and reliably supports the instantaneous current transmission of ≥100A.

[0039] Refer to all the attached documents. In order to realize the compact integration of the mode adjustment mechanism 42 and the fouling layer cleaning structure 43, the operation installation disk 44 adopts a symmetrical design. Its core structure includes two installation disks 441 formed by precision injection molding. A cylindrical installation space 442 (diameter 82-85mm, axial clearance 0.2-0.3mm) for installing the adjustment disk 421 is formed between the two disks. An annular sealing groove (depth 1.5mm, width 2mm) is provided on the inner wall of the space for sealing ring installation. The connecting through hole 4411 on the installation disk 441 is precisely machined to maintain high-precision coaxiality with the four through holes 4312. The contact friction arc segment 431 and the contact point friction arc segment 432 are integrated in the same installation disk 441 by means of positioning pins and pressure plates. This design not only realizes the precise coaxial installation of the two friction components, but also provides IP54 protection for the contact point 4221 through the lip seal ring, effectively preventing the deposition of environmental pollutants (particle size>10μm). In addition, the synchronous rotation (speed ratio 1:1) of the two friction components can be achieved through the single-point drive operation mounting plate 44 (torque 1.2-1.5N•m), and the efficiency and reliability of dirt cleaning are improved in combination with the ratchet positioning mechanism.

[0040] The fine structure of the mounting disc 441 adopts an integrated design. The arc groove 4412 is precisely matched with the thickness of the contact friction arc segment 431 and the contact friction arc segment 432, and the matching clearance is controlled at 0.05-0.1mm. Both arc segments are precisely machined in arc shape and are precisely installed in the arc groove 4412 through the positioning boss (height 2mm). The contact friction arc segment 432 passes through the arc groove 4412 through a precisely machined through hole (aperture tolerance H7), and maintains a working clearance of 0.2-0.3mm with the contact 4221. This integrated design makes the installation of the contact friction arc segment 431 and the contact friction arc segment 432 more compact.

[0041] In order to achieve precise control of the adjustment disc 421, a special transmission mechanism is designed for the system. A circular end face edge of the adjustment disc 421 is integrated with a full circumference adjustment gear 51, which is processed by precision carburizing and quenching process. The gear and the gear transmission rod 52 (module 1.5, number of teeth 20) made of 20CrMnTi form a 2:1 reduction transmission, and the side clearance of the gear pair is controlled at 0.1-0.15mm. The gear transmission rod 52 is supported by deep groove ball bearings (6202-2Z) at both ends and extends to the front part through the main support tube 11 (axial movement ≤0.5mm). The system provides two control schemes: when manually controlled, it is connected to the adjustment operating component at the front of the car through the SAE 6-tooth spline, and the operating torque is ≤2N•m; when automatically controlled, it can be directly driven by a stepper motor (such as 42 stepper motor, torque ≥0.4N•m) or a servo motor (power 50-100W) to achieve remote automatic control. This design enables the system to automatically complete the optimal switching of the battery pack according to the real-time monitoring data (division accuracy ±1°). In order to improve the protection performance of the system, the mounting disc 441 near the side of the adjustment gear 51 is designed with a 45° fan-shaped clearance notch 53, and a sealing lip (thickness 1mm) of nitrile rubber is set on the edge of the notch to ensure the gear meshing (contact coefficient 1.2-1.4) while providing IP54 dustproof effect (seal ring compression rate 15-20%).

[0042] The mechanical operating system design of the operating mounting plate 44 also includes a quick switching mechanism. The edges of the two mounting discs 441 are connected with a protruding connection block 443 through high-strength bolts (strength grade 8.8). The protruding connection block 443 is designed with a precision positioning groove for fixing the wire rope, and the high-strength pulling rope 444 is connected through a special ferrule. The guide system of the pulling rope 444 adopts a guide wheel group supported by a sealed bearing (6000-2RS) to ensure smooth transmission and extend the service life. When the manual control solution is selected, the pulling rope 444 is connected to the starting operating component of the front part of the vehicle; when the electric control solution is adopted, a small servo motor (torque 0.2-0.4N•m) can be configured to achieve automatic control, and the system response time is ≤200ms.

[0043] The peripheral wall structure design of the adjustment disk 421 integrates the power supply control function. The connection area 71 is evenly spaced every 45° along the circumference of the disk, and is made of a highly conductive composite material. The options include: gold-plated copper alloy (conductivity ≥ 90% IACS), doped silicon-based materials (resistivity ≤ 0.01 Ω•cm) or graphene composite materials (surface resistance < 0.1 Ω). This system uses a gold-plated copper alloy with a purity of ≥ 99.9% (plating thickness 3-5μm). The peripheral wall of the adjustment disk 421 is equipped with two sets of electrical connection devices, including an electrical connection wire 61 with a specification of 16mm² and an electrical contact block 62 made of a silver-plated copper alloy (purity ≥ 99.9%). One group is responsible for connecting the motor and sensor system at the rear of the vehicle, and the other group is connected to the low-power equipment at the front of the vehicle (such as an LCD display, power consumption ≤ 2W). By precisely controlling the rotation of the adjusting disk 421 (angle error ≤±1°), reliable contact (contact resistance ≤0.2mΩ) or disconnection between the connecting area 71 and the electrical contact block 62 is achieved. When the system needs to be temporarily powered off, the non-conductive area can be aligned with the electrical contact block 62, effectively reducing the standby power consumption (≤0.1W).

[0044] The outer peripheral wall of the adjustment disc 421 also integrates an innovative power-off friction zone 72 design, which is staggered with the connection zone 71. The power-off friction zone 72 is made of tungsten carbide matrix material (hardness HRA90), and the surface is processed with special fine grooves (depth 0.1mm, spacing 0.5mm) to form a third friction surface 721, which can effectively remove oxides and deposits (thickness ≤ 0.05mm) on the surface of the electrical contact block 62. To ensure contact reliability, the electrical contact block 62 is gold-plated (thickness 2-3μm) and flexibly connected to the electrical connection line 61 through an elastic member 63 (elastic coefficient 10N / mm), and the elastic pressure is controlled at 2-3N to ensure stable contact resistance. All electrical connection lines 61 of the system adopt a partition wiring design and are installed in a placement shell 80 with a flame retardant grade of V0. The arc-shaped notch 81 of the placement shell 80 and the installation disc 441 adopt an interference fit (interference amount 0.1-0.2mm) to achieve an IP54 protection level. In addition, the monitoring system's electrical conductive wire 90 (cross-sectional area 2.5mm²) also adopts the same protection scheme. The core functional components of the system are protected by a 2mm thick PC / ABS protective baffle 45 (flame retardant grade V0), which is fixed to the connecting frame 30 by 4 M4 bolts and adopts a through-hole design with a plum blossom arrangement (aperture 12mm, spacing 30mm) or a 120° fan-shaped opening (radius 25mm) to ensure wiring convenience.

[0045] The battery switching and fouling cleaning process of this system is as follows: Basic operation process: 1. Startup process: In manual control: operate the start operating component of the front part of the vehicle, and pull the pull rope 444 (stroke 15-20mm) to drive the two mounting discs 441 to rotate synchronously In automatic control: the control system drives the servo motor to achieve precise synchronous rotation of the two mounting discs 441 2. Contact establishment: The connecting contact head 41 slides into the corresponding connecting hole 4312 and the connecting hole 4411 at a speed of 0.2-0.3 m / s. Positioning accuracy ≤ 0.1mm, contact pressure maintained at 0.6-0.8MPa The monitoring system collects battery status in real time through high-precision sensors: Voltage monitoring: resolution ±0.01V Current monitoring: range 0-100A, accuracy 0.5% 3. Mode switching: Manual mode: Adjust the operating components through the front of the vehicle (maximum operating torque 2N•m) Automatic mode: via stepper motor or servo motor (speed 60-120rpm) Drive the adjustment disc 421 to rotate accurately to the target position (positioning accuracy ±1°) The position contact assembly 422 forms a stable contact with the communication contact head 41 (contact resistance ≤ 0.3 mΩ).

[0046] The monitoring system uses a 32-bit microprocessor to monitor key battery parameters in real time, including voltage (10.5-14.4V), charge and discharge current (-50A to +50A), temperature (-20℃ to 60℃) and internal resistance (5-15mΩ). When abnormal conditions such as battery voltage below 10.5V, temperature above 55℃, discharge current above 45A or internal resistance mutation exceeding 30% occur, the system automatically triggers the protection mechanism. The scale cleaning process is automatically executed when the mode is switched or regularly performed according to the maintenance plan. It can effectively remove 0.02-0.05mm thick oxidation and spark corrosion scale at a pressure of 0.6-0.8MPa, ensuring that the contact resistance is always kept below 0.5mΩ and the power transmission efficiency reaches more than 99.5%. The system supports multiple working modes: standard 48V mode (four batteries in series), 36V emergency mode (three batteries in series, automatically skipping the faulty battery), 24V emergency mode (two batteries in series) and diagnostic mode for single battery performance evaluation. Each mode has a corresponding contact connection strategy to ensure reliable operation of the system under various working conditions.

[0047] A series of core technical safeguard measures are adopted in the specific design and implementation of the system. Each set of contacts is equipped with a clear polarity identification and integrated with an anti-reverse connection protection mechanism; a sufficient safety distance is maintained between the contacts to prevent the risk of short circuit; the cleaning structure design ensures that all contact positions can be covered. The switching mechanism adopts a unidirectional rotation design to avoid poor contact caused by repeated switching; an overlapping area is set during the contact transition to ensure power supply continuity; all gears are equipped with clear markings and reliable positioning structures.

[0048] It should be noted that the specific parameters involved in this system are all preferred implementation schemes and can be appropriately adjusted according to actual application requirements. For example: the battery specifications can be selected with different voltage levels according to the vehicle requirements, the contact safety distance can be adjusted accordingly based on the working voltage level, the size and pressure of the friction cleaning structure can be optimized according to the use environment, the reduction ratio and operating torque of the transmission mechanism can be adjusted based on the requirements of operation convenience, and the sampling frequency and accuracy of the monitoring system can be set according to the application scenario requirements.

[0049] This embodiment is mainly optimized for the application scenario of two-wheeled electric vehicles. On the premise of ensuring safety and reliability, all technical parameters can be reasonably adjusted to adapt to different application requirements.

[0050] Embodiment 2 In this embodiment, the intelligent battery pack dynamic management and self-cleaning switching system is applied to large electric logistics vehicles. Since logistics vehicles have high requirements for cruising range and load capacity, the system is configured with 6 groups of 72V battery units and adopts a "pin" shaped three-row layout design. The battery units are fixed under the vehicle frame through strengthened bottom brackets, and the brackets are made of aluminum alloy profiles (6063-T5), with the characteristics of light weight and high strength (bending strength ≥ 160MPa).

[0051] The multi-power selective connection device 40 has carried out the following optimized designs for high-voltage and high-current scenarios: Improvement of the connection contact head system: The contact head is made of copper-chromium-zirconium alloy (hardness HV200 - 240), and the silver plating layer thickness is increased to 8 - 10μm; the single contact area is increased to 20mm², and the contact resistance is reduced to 0.2mΩ; Integration of the cooling system: There are micro-channels (diameter 2mm) designed inside the connection contact head 41, and forced cooling is achieved through circulating liquid (thermal conductivity ≥ 0.8W / m•K); the contact pressure is increased to 1.0 - 1.2MPa to ensure stable conductive performance under the condition of large current (≥ 200A).

[0052] Optimization of the scale deposit cleaning structure: The cleaning arc section is made of nano-ceramic material (hardness HRA95), and the surface is sprayed with a molybdenum disulfide lubricating layer (thickness 2-3μm); the micro-groove depth is increased to 0.15mm, and the spacing is reduced to 0.3mm to improve the cleaning effect; an automatic lubrication system is added, and high-performance conductive grease is regularly sprayed through a micro-injection device (flow rate 0.1-0.2ml / min); Mode adjustment mechanism upgrade: The diameter of the adjustment disc is increased to 120-150mm and is made of carbon fiber composite material, which reduces weight by 30%; the gear contact combination adopts a modular design and supports 8 different battery series and parallel combinations; the drive system uses a servo motor (power 200W) with a response time of ≤100ms; a new CAN bus communication interface is added to transmit system operating parameters in real time.

[0053] Monitoring system enhancements: The voltage monitoring range is extended to 60-85V; the current monitoring accuracy is improved to 0.2%; a new battery pack energy management algorithm is added, which can dynamically adjust the discharge strategy according to load demand.

[0054] Fault warning function: Based on deep learning algorithm, it can predict possible battery abnormalities 30-50 hours in advance.

[0055] Remote monitoring function: Data can be uploaded to the cloud through the 4G module, supporting remote diagnosis and maintenance.

[0056] This system is particularly suitable for long-distance logistics and delivery scenarios. Through intelligent scheduling algorithms, it can achieve: dynamic balancing of the battery pack, extending the service life by 20-30%; automatically adjusting the output power according to road conditions, increasing the driving range by 15-25%; supporting rapid switching of emergency modes to ensure reliable completion of delivery tasks; and improving the overall system efficiency to 99.8%, reducing annual maintenance costs by 40%.

Claims

1. A battery pack dynamic management and self-cleaning switching system, characterized in that: Including: A frame, the frame includes a main support pipe and multiple groups of side support groups connected to the main support pipe. The side support groups are arranged in a three-sided surrounding shape and form an installation position for placing a battery. An installation box body disposed within the installation position. The installation box body has a drain hole and a ventilation structure. Multiple battery packs installed within the installation box body. The multiple battery packs are designed in a "field" shape layout, and there is a heat dissipation space between the multiple battery packs. A multi-power selective connection device installed within the frame. The multi-power selective connection device includes: Multiple groups of connecting contacts for electrically connecting with the multiple battery packs. The surface of the connecting contacts is coated with a conductive elastic layer. A mode adjustment mechanism. The mode adjustment mechanism includes an adjustment disc. At both ends of the adjustment disc, multiple contacts are equally spaced along the circumferential direction. The multiple contacts form several groups of gear position contact combinations. Multiple connection areas are provided on the outer peripheral wall of the adjustment disc, and a power-off friction area is provided between the connection areas. A dirt accumulation layer cleaning structure disposed between the adjustment disc and the connecting contacts for cleaning the dirt on the surfaces of the connecting contacts and the contacts. An operation installation disc for installing the adjustment disc and the dirt accumulation layer cleaning structure. And a transmission mechanism. The transmission mechanism includes an adjustment gear provided at the edge of the end face of the adjustment disc and a gear transmission rod meshing with the adjustment gear. A monitoring system. The monitoring system includes: A voltage monitoring unit for monitoring the voltage of the battery pack. A current monitoring unit for monitoring the charging and discharging current of the battery pack. A temperature monitoring unit for monitoring the temperature of the battery pack. An internal resistance monitoring unit for monitoring the internal resistance of the battery pack. And a control unit for controlling the mode adjustment mechanism to perform mode switching according to the monitoring data. A power supply control system. The power supply control system includes: Two groups of electrical connection devices provided on the outer peripheral wall of the adjustment disc. Each group of electrical connection devices includes an electrical connection line and an electrical contact block. An elastic member provided between the electrical contact block and the electrical connection line. And a placement housing for accommodating the electrical connection line. The placement housing forms a sealed fit with the operation installation disc.

2. The battery pack dynamic management and self-cleaning switching system according to claim 1, characterized in that: The side support groups are made of hollow steel pipes. The diameter of the main support pipe is 30 - 40 mm, and the diameter of the secondary support pipe is 20 - 25 mm. The distance between the battery packs is 30 - 50 mm.

3. The battery pack dynamic management and self-cleaning switching system according to claim 1, characterized in that: The dirt accumulation layer cleaning structure includes: A contact friction arc segment for cleaning the dirt on the connecting contacts. And a contact friction arc segment for cleaning the dirt on the contacts. Wherein, the contact friction arc segment and the contact friction arc segment are symmetrically installed on both side faces of the operation installation disc.

4. The battery pack dynamic management and self-cleaning switching system according to claim 3, characterized in that: The contact friction arc segment includes: A first friction surface for contacting with the connecting contacts. The surface roughness Ra value of the first friction surface is 0.8 - 1.2 μm. Wherein, multiple through holes are provided on the contact friction arc segment, and the through holes correspond to the connecting contacts one by one.

5. The battery pack dynamic management and self-cleaning switching system according to claim 1, characterized in that: The communication area of ​​the regulating disc is made of gold-plated copper alloy, the power-off friction area is made of tungsten carbide matrix material, and the surface of the power-off friction area is processed with fine grooves with a depth of 0.1 mm and a spacing of 0.5 mm.

6. A method for dynamic management of a battery pack using the multi-power selective connection device according to any one of claims 1 to 5, characterized in that: The following steps are involved: Real-time monitoring steps include: Monitoring voltage parameters of multiple battery packs, wherein the monitoring range of the voltage parameters is 10.5-14.4V; Monitoring current parameters of multiple battery packs, wherein the monitoring range of the current parameters is -50A to +50A; Monitoring temperature parameters of multiple battery packs, wherein the monitoring range of the temperature parameters is -20°C to 60°C; Monitoring the internal resistance parameters of multiple battery packs, wherein the monitoring range of the internal resistance parameters is 5-15mΩ; The abnormality judgment steps include: Determine whether the voltage is lower than 10.5V; Determine whether the temperature exceeds 55°C; Determine whether the discharge current exceeds 45A; Determine whether the internal resistance mutation exceeds 30%; The mode switching steps include: When abnormal parameters are detected, the control adjustment disk is rotated to switch the connection mode of the battery pack; Control the rotation speed of the adjusting disc within the range of 60-120 rpm; Ensure that the positioning accuracy of the adjustment disk is within the range of ±1°; The steps for cleaning the deposits include: Automatically clean the dirt when switching to the battery pack connection mode; Perform scale cleaning according to the preset maintenance schedule; Cleaning is carried out at a pressure of 0.6-0.8MPa.

7. The battery pack dynamic management method according to claim 6, characterized in that: The mode switching step comprises: Manual control mode: By operating the starting operating component of the front part of the vehicle; The installation disc is driven to rotate by pulling the pulling rope, and the travel of the pulling rope is 15-20mm; The adjusting disc is driven to rotate by the adjusting operating part with an operating torque not exceeding 2N•m; or in automatic control mode: The mounting disc is driven to rotate by a servo motor; The disc is driven and adjusted to rotate by a stepper motor or a servo motor; The system response time does not exceed 200ms.

8. The battery pack dynamic management method according to claim 6, characterized in that: The fouling cleaning step specifically includes: Cleaning the surface of the contact head by using the first friction surface of the contact friction arc segment; Cleaning the contact surface by the second friction surface of the contact friction arc segment; Remove oxidation and spark corrosion deposits with a thickness of 0.02-0.05mm; Check the contact resistance value and repeat the cleaning process when the contact resistance is greater than 0.5mΩ.

9. The battery pack dynamic management method according to claim 6, characterized in that: The connection modes in the mode switching step include: standard working mode: 48V mode: four batteries are connected in series, used for standard working conditions; emergency working mode: 36V mode: three batteries are connected in series, automatically skipping the faulty battery; 24V mode: two batteries are connected in series, used for emergency working conditions; diagnostic working mode: single battery mode: used for single battery performance evaluation.

10. The battery pack dynamic management method according to claim 6, characterized in that: After the mode switching step, a connection checking step is also included: Check the contact status between the connecting contact head and the connecting hole; Ensure that the contact pressure is maintained within the range of 0.6-0.8MPa; Ensure that the contact resistance does not exceed 0.3mΩ; Check whether the power transmission efficiency reaches above 99.5%.

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