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

Abstract

The present invention relates to the technical field of electric vehicle power systems, and discloses a battery pack dynamic management and self-cleaning switching system and a battery pack dynamic management method. The system includes: a vehicle frame, which includes a main support pipe and multiple groups of side bracket groups; a mounting box body arranged in the mounting positions formed by the side bracket groups; multiple battery packs installed in the mounting box body and arranged in a "field" shape; and a multi-power selective connection device installed in the vehicle frame. The multi-power selective connection device includes multiple groups of communicating contacts, a mode adjustment mechanism, a fouling layer cleaning structure, an operation mounting plate, and a transmission mechanism. The system further includes a monitoring system and a power supply control system. The control method of the present invention includes a real-time monitoring step, an abnormality judgment step, a mode switching step, and a fouling cleaning step. The system realizes the functions of real-time monitoring, dynamic switching, and fault isolation of the battery pack, and solves the contact reliability problem in the traditional multi-battery switching system.

Description

Technical Field

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

[0002] In two-wheeled electric vehicles, lead-acid batteries are the currently commonly used power sources, and generally 4 or 5 12V batteries are connected in series to power the vehicle. In actual use, if a certain battery in the battery pack has a serious abnormality or poor contact, it will affect the working state of the entire series circuit. More dangerously, users often cannot detect this abnormal condition 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 also may cause the vehicle to suddenly lose power during driving, bringing great trouble to users and even posing a safety hazard in serious cases.

[0003] To solve the above problems, a system that can detect the state of single cells and flexibly adjust the battery connection method is needed. Through such a system, not only can battery abnormalities be detected in time and corresponding measures be taken, but also batteries with large performance differences can be charged 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 such a detection and flexible charging solution requires arranging numerous electronic components, complex circuits, and multiple switches, etc. These switches and contacts are prone to oxidation and spark corrosion during frequent switching, resulting in uneven contact surfaces, affecting the effective contact of the contact surfaces, increasing the resistance, which will not only cause heating problems but also affect the charging effect. In addition, the complex circuit system also increases the fault points, improving the maintenance difficulty and maintenance cost.

[0005] In view of the above problems, the present invention proposes a solution that uses a mechanical structure to replace electronic components to complete circuit switching. Through a special mechanical structure design, this solution can not only achieve battery state detection and flexible charging methods, but also, when a battery abnormality is detected, can timely notify the user to switch to a temporary step-down riding mode, enabling the vehicle to safely reach the repair point and avoiding the trouble of breaking down on the way. At the same time, the contact design of this solution is convenient for cleaning and maintenance, significantly improving 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 fouling layer self-cleaning design, and realizes the functions of real-time monitoring, dynamic switching and fault isolation of the battery pack through an integrated multi-power selective connection device, effectively solving the contact reliability problem in the traditional multi-battery switching system, improving the heat dissipation efficiency of the system at the same time, and 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:

[0008] A frame, the frame includes a main support pipe and a plurality of groups of side bracket groups connected to the main support pipe, the side bracket groups are arranged in a three-sided surrounding shape and form an installation position for placing batteries;

[0009] An installation box body arranged in the installation position, the installation box body has a drain hole and a ventilation structure;

[0010] A plurality of battery packs installed in the installation box body, the plurality of battery packs are designed in a "field" - shaped layout, and there is a heat dissipation space between the plurality of battery packs;

[0011] A multi-power selective connection device installed in the frame, the multi-power selective connection device includes:

[0012] A plurality of groups of connecting contacts for electrically connecting with the plurality of battery packs, and the surface of the connecting contacts is coated with a conductive elastic layer;

[0013] A mode adjustment mechanism, the mode adjustment mechanism includes an adjustment disc, both ends of the adjustment disc are equally spaced with a plurality of contacts along the circumferential direction, and the plurality of contacts form several groups of gear position contact combinations; a plurality of communication areas are provided on the outer peripheral wall of the adjustment disc, and a power-off friction area is provided between the communication areas;

[0014] A fouling layer cleaning structure, the fouling layer cleaning structure is arranged between the adjustment disc and the connecting contacts for cleaning the fouling on the surfaces of the connecting contacts and the contacts;

[0015] An operation installation disc for installing the adjustment disc and the fouling layer cleaning structure; and

[0016] A transmission mechanism, the transmission mechanism includes an adjustment gear arranged at the edge of the end face of the adjustment disc, and a gear transmission rod meshing with the adjustment gear;

[0017] 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.

[0018] Advantages: 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, and at the same time protect 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 fouling layer cleaning structure, the contact reliability problem in the traditional system is solved, ensuring the long - term stable operation of the system.

[0019] 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.

[0020] Advantages: The design of hollow steel pipes 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 distance between the battery packs ensures sufficient heat dissipation space, improving the heat dissipation efficiency and structural stability of the system.

[0021] Preferably, the thickness of the conductive elastic layer is 0.2 - 0.3 mm and it is made of graphene composite material.

[0022] Advantages: 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 system durability is improved. The setting of the elastic layer provides a stable contact pressure, thus improving the reliability and service life of the overall connection.

[0023] Preferably, the fouling layer cleaning structure includes:

[0024] A contact friction arc section for cleaning the fouling of the communication contact head; and

[0025] A contact friction arc segment for cleaning the fouling on the contacts;

[0026] Wherein, the contact friction arc segment and the contact friction arc segment are symmetrically installed on both sides of the operation mounting plate.

[0027] Beneficial effects: By adopting a double-sided cleaning structure and a symmetrical installation design, not only the cleaning efficiency is improved, ensuring the uniformity and stability of cleaning, but also the realization of the automatic cleaning function extends the maintenance cycle of the system and reduces the maintenance cost.

[0028] Preferably, the contact friction arc segment includes: a first friction surface for contacting the communicating contact head, and 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 through holes, and the through holes correspond to the communicating contact heads one by one.

[0029] Beneficial effects: Through the precise control of the surface roughness and the one-to-one correspondence design of the through holes, combined with the design characteristics of the arc structure, not only the reliability of the cleaning effect is ensured, but also the stability of the electrical connection is guaranteed, while improving the cleaning uniformity and the overall working efficiency.

[0030] Preferably, the communicating area of the adjusting 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 micro-grooves with a depth of 0.1 mm and a pitch of 0.5 mm.

[0031] Beneficial effects: Through the application of gold-plated copper alloy and the use of tungsten carbide matrix material, 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.

[0032] The present invention also provides a battery pack dynamic management method using the above multi-power selective connection device, including the following steps: a real-time monitoring step, including: monitoring the voltage parameters of a plurality of battery packs, and the monitoring range of the voltage parameters is 10.5 - 14.4 V; monitoring the current parameters of a plurality of battery packs, and the monitoring range of the current parameters is -50 A to +50 A; monitoring the temperature parameters of a plurality of battery packs, and the monitoring range of the temperature parameters is -20 °C to 60 °C; monitoring the internal resistance parameters of a plurality of battery packs, and the monitoring range of the internal resistance parameters is 5 - 15 mΩ;

[0033] An abnormal judgment step, including: judging whether the voltage is lower than 10.5 V; judging whether the temperature exceeds 55 °C; judging whether the discharge current exceeds 45 A; judging whether the internal resistance mutation exceeds 30%;

[0034] Mode switching steps, including: when abnormal parameters are detected, controlling the regulating disc to rotate to switch the connection mode of the battery pack; controlling the rotation speed of the regulating disc within the range of 60 - 120 rpm; ensuring the positioning accuracy of the regulating disc within the range of ±1°.

[0035] Scaling cleaning steps, including: automatically performing scaling cleaning when switching the connection mode of the battery pack; performing scaling cleaning according to a preset maintenance plan; cleaning under a pressure of 0.6 - 0.8 MPa.

[0036] Beneficial effects: Through the comprehensive parameter monitoring range setting and specific abnormal judgment criteria, combined with precise control parameters and cleaning pressure requirements, the safety, reliability, and stability of the system operation have been comprehensively improved, effectively ensuring the efficient management and long-term stable operation of the battery pack; at the same time, through the integration of the automatic scaling cleaning function, the system maintenance cost has been reduced and the operation efficiency has been improved.

[0037] Preferably, the mode switching steps include:

[0038] Manual control mode: By operating the start operation component at the front of the vehicle; driving the installation disc to rotate by pulling the pulling rope, the stroke of the pulling rope is 15 - 20 mm; driving the regulating disc to rotate by operating the regulating operation component with an operating torque not exceeding 2 N•m; or Automatic control mode: Driving the installation disc to rotate by a servo motor; driving the regulating disc to rotate by a stepper motor or a servo motor; the system response time does not exceed 200 ms.

[0039] Beneficial effects: Through the design of two control modes, manual and automatic, combined with precise stroke control and fast response characteristics, it not only ensures the flexibility and reliability of the system operation, but also improves the efficiency of the switching process; at the same time, through the limitation of the operating torque and the requirement of fast response time, the safety of the operation and the real-time performance of the system are ensured.

[0040] Preferably, the connection modes in the mode switching steps include:

[0041] Standard working mode: 48V mode: Four batteries are connected in series for standard working conditions.

[0042] 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 working conditions.

[0043] Diagnostic working mode: Single battery mode: For the performance evaluation of a single battery.

[0044] Beneficial effects: Through the design of working modes with multiple voltage levels and the function of automatically skipping faulty batteries, the flexible application of the system under different working conditions is realized, the reliability and adaptability of the system are improved. At the same time, through the setting of the diagnostic mode, it is convenient to detect and handle battery faults in a timely manner, effectively ensuring the continuity and stability of power supply.

[0045] Compared with the prior art, the technical solution of the present invention has the following advantages:

[0046] Through innovative structural design and intelligent control methods, the present invention realizes the following overall beneficial effects: (1) Adopting a "field"-shaped battery layout and a frame design surrounded by three sides, combined with an installation box body for drainage and ventilation, not only improves the structural stability and heat dissipation efficiency, but also facilitates installation and maintenance; (2) The set 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, 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. Description of the Drawings

[0047] 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 in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0048] Figure 1 It is the overall flow block diagram of the system of the present invention;

[0049] Figure 2 It is the flow block diagram of the cleaning part of the system of the present invention;

[0050] Figure 3 It is the flow block diagram of the mode switching part of the system of the present invention;

[0051] Figure 4 It is the flow block diagram of the monitoring part of the system of the present invention;

[0052] Figure 5 It is the structural schematic diagram of the present invention when applied to an electric vehicle frame;

[0053] Figure 6 It is the internal structural schematic diagram of the switching device of the present invention cooperating with the battery pack;

[0054] Figure 7For Figure 6 The partial enlarged view at position I in

[0055] Figure 8 The structural schematic diagram of the mode adjustment mechanism of the present invention;

[0056] Figure 9 The structural schematic diagram of the fouling layer cleaning structure of the present invention installed on the operation installation part;

[0057] Figure 10 The structural schematic diagram of the fouling layer cleaning structure of the present invention;

[0058] Figure 11 The structural schematic diagram of the connection between the adjustment disc and the electrical contact block of the present invention.

[0059] Reference numerals: vehicle frame 10, main support pipe 11, side bracket group 12, installation position 121, installation box body 13, steering support frame 18, battery pack 21, external connection wire 22, connection frame 30, multi-power selective connection device 40, communication contact head 41, mode adjustment mechanism 42, fouling layer cleaning structure 43, operation installation disc 44, adjustment disc 421, gear position contact combination 422, contact 4221, contact friction arc section 431, first friction surface 4311, connection through hole 4312, contact friction arc section 432, second friction surface 4321, installation disc 441, connection through hole 4411, arc groove 4412, installation space 442, protruding connection block 443, pulling rope 444, protective baffle 45, adjustment gear 51, gear transmission rod 52, relief notch 53, electrical connection wire 61, electrical contact block 62, elastic member 63, communication area 71, power-off friction area 72, third friction surface 721, placement housing 80, arc notch 81, electrical transmission wire 90. Detailed implementation manners

[0060] The following will combine Figures 1 - 7 The preferred embodiments of the present invention will be described in detail. It should be noted that the following description is only the preferred embodiments of the present invention, rather than a limitation to 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 protection scope of the present invention should be subject to the appended claims.

[0061] Embodiment 1:

[0062] Refer to Figures 1 - 5, This embodiment provides a battery pack dynamic management and self-cleaning switching system, which is mainly applied to the field of electric vehicles, especially suitable for two-wheeled electric vehicles powered by multiple battery packs. Through the innovative multi-power selective connection device 40, the system realizes the functions of real-time monitoring, dynamic switching, and fault isolation of the battery pack, and integrates a unique contact self-cleaning mechanism, effectively solving 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 pipe of the vehicle frame, ensuring both the compactness of the vehicle structure and the convenience of maintenance and operation.

[0063] The multi-power selective connection device 40 is installed in the vehicle frame 10 of the two-wheeled electric vehicle. The vehicle frame 10 is connected to the steering support frame 18. The vehicle 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, multiple groups of symmetric side support groups 12 are connected. Among them, the side support 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 support group is fixedly connected by welding, and reinforcing rib plates are added at key nodes. Multiple groups of side support groups 12 are arranged in a three-sided surrounding shape and form an installation position 121 for placing the battery. 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.

[0064] The power supply architecture of this system adopts a "field" - shaped layout design, configuring four 12V battery units, and dividing them into two groups of battery packs 21 on the left and right 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 wire 22 equipped for each battery unit uses a waterproof type quick - plug electrical connector.

[0065] Reference Figures 2 - 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 fouling layer cleaning structure 43, and an integrated operation installation disk 44. The technical features of each component are as follows:

[0066] Connected contacts 41: Adopt a symmetric layout. Each group of connected contacts 41 is equipped with a corresponding fouling 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.

[0067] The modular design of the system supports the flexible configuration of the number of connecting contacts 41 according to actual application requirements, maintaining a symmetrical distribution on both sides of the mode adjustment mechanism 42.

[0068] Key component design of the mode adjustment mechanism 42:

[0069] Adjustment disc 421: Made of wear-resistant engineering plastic, with a diameter of 80 - 100 mm and a thickness of 15 - 20 mm;

[0070] Contact distribution: A plurality of contacts 4221 are evenly distributed at equal intervals along the circumferential direction at both ends of the adjustment disc 421 (only the contacts at one end of the adjustment disc are shown in the figure). The contacts are made of silver-plated copper alloy, and the contact resistance ≤ 0.3 mΩ;

[0071] Gear combination: A plurality of contacts 4221 form several groups of gear contact combinations 422. The contacts 4221 of each group of gear contact combinations 422 are symmetrically distributed at both ends of the adjustment disc 421, and the number of contacts matches the number of connecting contacts 41;

[0072] Circuit design: Each group of gear contact combinations 422 realizes the circuit connection of different modes through the wires (cross-sectional area ≥ 2.5 mm²) inside the adjustment disc 421. The contacts 4221 can be reused in different groups of gear contact combinations 422 to improve space utilization;

[0073] When an abnormal state occurs in a certain battery in the battery pack (voltage < 10.5 V or current fluctuation exceeds the rated value by ± 20%), the system can drive the adjustment disc 421 to rotate through a stepper motor (angle 0 - 360°, step angle 15°) to realize 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 contacts is maintained within the range of 0.6 - 0.8 MPa.

[0074] Reference Figure 7 、 Figures 8 - 9 Refer to [reference], 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 contacts 41, and two contact friction arc segments 432 for cleaning the fouling of the contacts 4221; these friction components are symmetrically installed on both sides of the operation mounting plate 44 and are respectively located between the adjustment disc 421 and their corresponding connecting contacts 41. The contact friction arc segment 431 is made of tungsten carbide material with a hardness not lower than HRA90 and is designed with four through holes 4312, corresponding to the connecting contacts 41 one by one. Its key technical parameters are as follows:

[0075] The first friction surface 4311: Contacts the connecting contact 41, and the surface roughness Ra value is 0.8 - 1.2 μm;

[0076] The second friction surface 4321: Contacts the contact 4221 and adopts the same surface treatment process;

[0077] All friction contact surfaces are treated with anti-oxidation, and the service life is ≥ 10,000 reciprocating motions. The relative movement cleaning between the first friction surface 4311 of the contact friction arc segment 431 and the connecting contact head 41 is realized by operating the rotation of the mounting disc 44. By adjusting the rotation of the disc 421, the second friction surface 4321 of the contact point friction arc segment 432 cleans the contact point 4221 by friction.

[0078] This innovative self-cleaning design effectively solves the fouling problem in traditional systems caused by factors such as environmental oxidation and electric spark corrosion. Through regular or automatic cleaning during switching, the surface roughness of the contact points can be maintained below Ra 1.6μm, and the contact resistance can be controlled within 0.5mΩ. This design is expected to extend the battery service life by 30 - 50% and ensure that the power supply voltage fluctuation is ≤ ±2%.

[0079] The design of the contact friction arc segment 431 not only has a cleaning function but also integrates an electrical isolation function. A complete staying space is designed in the area outside the through-hole 4312 to accommodate a connecting contact head 41, and the fouling is removed by a surface friction force of 3 - 5N. The system uses step rotation to achieve precise positioning. With the ratchet structure, the positioning accuracy can reach ±0.5° and has a self-locking function to ensure that the connecting contact head 41 can be completely located in the staying space to achieve reliable electrical isolation. In terms of optimizing the contact interface, the inner wall of the through-hole 4312 is designed with a 15° chamfer (depth 0.5 - 0.8mm) and is anodized. One end of the connecting contact head 41 close to the contact point 4221 is designed with a spherical surface and plated with a 3 - 5μm gold layer, controlling the friction coefficient between 0.1 - 0.15 and the operating force below 5N to ensure a smooth and reliable conversion process. To improve the electrical conductivity, the surface of the connecting contact head 41 is coated with a 0.2 - 0.3mm thick conductive elastic layer, and material solutions such as graphene composite materials (volume resistivity ≤ 10^-3Ω•cm, elastic strain 20 - 30%), doped PEDOT:PSS conductive polymer materials (conductivity > 1000 S / cm), or beryllium copper alloy (yield strength ≥ 500MPa) can be selected. 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 connecting contact head 41 enters the through-hole 4312, the conductive elastic layer generates an elastic pressure of 2 - 3N to ensure that the contact resistance < 0.3mΩ and reliably support the instantaneous current transmission of ≥ 100A.

[0080] Referring to all the attached figures, in order to achieve the compact integration of the mode adjustment mechanism 42 and the fouling layer cleaning structure 43, the operation installation disk 44 adopts a symmetric design. Its core structure includes two installation disks 441 formed by precision injection molding. A cylindrical installation space 442 (with a diameter of 82 - 85 mm and an axial clearance of 0.2 - 0.3 mm) for installing the adjustment disk 421 is formed between the two disks. An annular sealing groove (with a depth of 1.5 mm and a width of 2 mm) is provided on the inner wall of the space for installing the sealing ring. The connection through holes 4411 on the installation disk 441 are precisely machined to maintain high-precision coaxiality with the four connection through holes 4312. The contact friction arc section 431 and the contact point friction arc section 432 are integrated into the same installation disk 441 by means of a positioning pin and a pressing plate. This design not only realizes the precise coaxial installation of the two friction components, but also provides IP54-level protection for the contact point 4221 through a lip-shaped sealing ring, effectively preventing the deposition of environmental pollutants (particle size > 10 μm). In addition, by driving the operation installation disk 44 with a single point (torque 1.2 - 1.5 N•m), the synchronous rotation of the two friction components (speed ratio 1:1) can be achieved, and the efficiency and reliability of fouling cleaning are improved with the cooperation of the ratchet positioning mechanism.

[0081] The fine structure of the installation disk 441 adopts an integrated design scheme. The arc-shaped groove 4412 provided therein is precisely matched with the thickness of the contact friction arc section 431 and the contact point friction arc section 432, and the fitting clearance is controlled within 0.05 - 0.1 mm. Both arc-shaped sections adopt a precisely machined circular arc shape and are precisely installed in the arc-shaped groove 4412 through positioning bosses (with a height of 2 mm). The contact point friction arc section 432 penetrates through the arc-shaped groove 4412 through a precisely machined through hole (hole diameter tolerance H7) and maintains a working clearance of 0.2 - 0.3 mm with the contact point 4221. This integrated design makes the installation of the contact friction arc section 431 and the contact point friction arc section 432 more compact.

[0082] To achieve precise control of the adjustment disc 421, a dedicated transmission mechanism is designed for the system. An adjustment gear 51 with a complete circumference is integrally machined on the edge of a circular end face of the adjustment disc 421 and is processed using a precision carburizing and quenching process. This gear forms a speed reduction transmission with a gear transmission rod 52 made of 20CrMnTi (module 1.5, number of teeth 20) in a ratio of 2:1, and the backlash of the gear pair is controlled within 0.1 - 0.15 mm. Both ends of the gear transmission rod 52 are supported by deep groove ball bearings (6202-2Z) and extend through the main support tube 11 (axial end play ≤ 0.5 mm) to the front part of the vehicle head. The system provides two control schemes: during manual control, it is connected to the adjustment operating component at the vehicle head through a SAE 6-tooth spline, and the operating torque ≤ 2 N•m; during automatic control, a stepper motor (such as a 42 stepper motor, torque ≥ 0.4 N•m) or a servo motor (power 50 - 100 W) can be selected for direct drive to achieve remote automation control. This design enables the system to automatically complete the optimized switching of the battery pack according to real-time monitoring data (indexing accuracy ±1°). To improve the protection performance of the system, a 45° fan-shaped relief notch 53 is designed on the mounting disc 441 near the adjustment gear 51, and a sealing lip made of nitrile rubber (thickness 1 mm) is provided at the edge of the notch, providing an IP54-level dustproof effect (seal compression rate 15 - 20%) while ensuring gear meshing (contact ratio coefficient 1.2 - 1.4).

[0083] The mechanical operating system design of the operation mounting disc 44 also includes a quick-switching mechanism. On the edges of two mounting discs 441, protruding connecting blocks 443 are connected by high-strength bolts (strength grade 8.8). The protruding connecting blocks 443 are designed with precision positioning grooves for fixing steel wire ropes, and high-strength pulling ropes 444 are connected through special ferrules. The guiding system of the pulling ropes 444 is supported by a set of guide wheels supported by sealed bearings (6000-2RS) to ensure smooth transmission and extend the service life. When the manual control scheme is selected, the pulling rope 444 is connected to the starting operating component at the front part of the vehicle head; when the electric control scheme is adopted, a small servo motor (torque 0.2 - 0.4 N•m) can be configured to achieve automation control, and the system response time ≤ 200 ms.

[0084] The structural design of the outer peripheral wall of the adjustment disk 421 integrates the power supply control function. Connecting areas 71 are evenly distributed at intervals of 45° along the circumference of the disk. They are made of high-conductivity composite materials, and optional solutions include: gold-plated copper alloy (conductivity ≥ 90% IACS), doped silicon-based material (resistivity ≤ 0.01 Ω•cm), or graphene composite material (surface resistance < 0.1 Ω). This system selects a gold-plated copper alloy with a purity ≥ 99.9% (coating thickness 3 - 5μm). Two sets of electrical connection devices are configured on the outer peripheral wall of the adjustment disk 421, including electrical connection wires 61 with a specification of 16mm² and electrical contact blocks 62 made of silver-plated copper alloy (purity ≥ 99.9%). One set is responsible for connecting the motor and sensor system at the rear of the vehicle, and the other set connects low-power devices at the front of the vehicle (such as LCD displays, power consumption ≤ 2W). By precisely controlling the rotation of the adjustment disk 421 (angle error ≤ ±1°), reliable contact (contact resistance ≤ 0.2mΩ) or disconnection between the connecting area 71 and the electrical contact block 62 can be achieved. When the system needs to be temporarily powered off, the non-conductive area can be aligned with the electrical contact block 62 to effectively reduce the standby power consumption (≤ 0.1W).

[0085] The outer peripheral wall of the adjustment disk 421 also integrates the innovative design of the power-off friction area 72, which is arranged alternately with the connecting area 71. The power-off friction area 72 uses a tungsten carbide matrix material (hardness HRA90), and special micro-grooves (depth 0.1mm, spacing 0.5mm) are machined on the surface to form the third friction surface 721, which can effectively remove oxides and scale (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 is flexibly connected to the electrical connection wire 61 through an elastic member 63 (elastic coefficient 10N / mm), and the elastic pressure is controlled at 2 - 3N to ensure a stable contact resistance. All electrical connection wires 61 of the system adopt a partitioned wiring design and are installed in the placement housing 80 with a flame retardant rating of V0. The arc-shaped notch 81 of the placement housing 80 and the mounting disk 441 are in interference fit (interference amount 0.1 - 0.2mm) to achieve an IP54 protection level. In addition, the electrical transmission wire 90 (cross-sectional area 2.5mm²) of the monitoring system also adopts the same protection scheme. The core functional components of the system are protected by a PC / ABS protection baffle 45 with a thickness of 2mm (flame retardant rating V0). The protection baffle is fixed to the connecting frame 30 through 4 M4 bolts and adopts a through-hole design with a plum blossom arrangement (hole diameter 12mm, spacing 30mm) or a 120° fan-shaped opening (radius 25mm) to ensure the convenience of wiring.

[0086] The battery switching and scale cleaning working process of this system is as follows:

[0087] Basic operation process:

[0088] 1. Startup process:

[0089] During manual control: Operate the start operation component at the front of the vehicle head. By pulling the pulling rope 444 (travel 15 - 20 mm), drive the two mounting discs 441 to rotate synchronously.

[0090] During automatic control: The control system drives the servo motor to achieve precise synchronous rotation of the two mounting discs 441.

[0091] 2. Contact establishment:

[0092] The connecting contact head 41 slides into the corresponding connection hole 4312 and the connecting through - hole 4411 at a speed of 0.2 - 0.3 m / s.

[0093] The positioning accuracy ≤ 0.1 mm, and the contact pressure is maintained at 0.6 - 0.8 MPa.

[0094] The monitoring system collects the battery status in real - time through high - precision sensors:

[0095] Voltage monitoring: Resolution ±0.01 V

[0096] Current monitoring: Range 0 - 100 A, accuracy 0.5%

[0097] 3. Mode switching:

[0098] Manual mode: Through the adjustment operation component at the front of the vehicle head (maximum operating torque 2 N•m)

[0099] Automatic mode: Through the stepper motor or servo motor (rotation speed 60 - 120 rpm)

[0100] Drive the adjustment disc 421 to rotate precisely to the target position (positioning accuracy ±1°).

[0101] The gear contact combination 422 and the connecting contact head 41 form a stable contact (contact resistance ≤ 0.3 mΩ).

[0102] The monitoring system uses a 32-bit microprocessor to monitor the key parameters of the battery in real time, including voltage (10.5 - 14.4V), charge and discharge current (-50A to +50A), temperature (-20°C to 60°C), and internal resistance (5 - 15mΩ). When abnormal conditions such as the battery voltage being lower than 10.5V, the temperature exceeding 55°C, the discharge current exceeding 45A, or the internal resistance mutating by more than 30% occur, the system automatically triggers the protection mechanism. The scale cleaning process is automatically executed during mode switching or regularly according to the maintenance plan. Under a pressure of 0.6 - 0.8MPa, it can effectively remove the oxidation and spark corrosion scale with a thickness of 0.02 - 0.05mm, ensuring that the contact resistance always remains below 0.5mΩ and the power transmission efficiency reaches over 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 evaluating the performance of a single battery. Each mode has a corresponding contact connection strategy to ensure the reliable operation of the system under various working conditions.

[0103] 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 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 one-way rotation design to avoid poor contact caused by repeated switching; an overlap area is set during the contact transition to ensure power supply continuity; all gears are equipped with clear markings and reliable positioning structures.

[0104] 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 operation convenience requirements, and the sampling frequency and accuracy of the monitoring system can be set according to the application scenario requirements.

[0105] 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.

[0106] Embodiment 2

[0107] 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 relatively 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).

[0108] The multi-power selective connection device 40 has carried out the following optimization designs for high-voltage and large-current scenarios:

[0109] Improvement of the connection contact head system:

[0110] The contact head is made of copper-chromium-zirconium alloy material (hardness HV200-240), and the thickness of the silver plating layer 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 realized through circulating liquid (thermal conductivity ≥ 0.8W / m•K); the contact point pressure is increased to 1.0-1.2MPa to ensure stable conductive performance under the condition of large current (≥ 200A).

[0111] Optimization of the fouling cleaning structure:

[0112] The cleaning arc section is made of nano-ceramic material (hardness HRA95), and a molybdenum disulfide lubricating layer (thickness 2-3μm) is sprayed on the surface; the depth of the micro-grooves 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);

[0113] Upgrade of the mode adjustment mechanism:

[0114] The diameter of the adjustment disc is increased to 120-150mm, made of carbon fiber composite material, with a weight reduction of 30%; the gear contact point combination adopts a modular design, supporting 8 different battery series-parallel combinations; the drive system selects a servo motor (power 200W), and the response time ≤ 100ms; a new CAN bus communication interface is added to transmit the system operation parameters in real time.

[0115] Enhancement of the monitoring system:

[0116] 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 the load demand.

[0117] Fault warning function: Based on the deep learning algorithm, it can predict possible battery anomalies 30-50 hours in advance.

[0118] Remote monitoring function: Data is uploaded to the cloud through a 4G module, supporting remote diagnosis and maintenance.

[0119] This system is especially suitable for long-distance logistics distribution scenarios. Through intelligent scheduling algorithms, it can achieve: dynamic balance of battery packs, extending the service life by 20 - 30%; automatically adjusting the output power according to road conditions, increasing the cruising range by 15 - 25%; supporting quick switching to the emergency mode to ensure reliable completion of distribution tasks; the overall system efficiency is increased to 99.8%, and the annual maintenance cost is reduced by 40%.

Claims

1. A battery pack dynamic management and self-cleaning switching system, characterized in that: Comprising: A frame, the frame including multiple groups of side support groups, the side support groups forming mounting positions for placing batteries; An installation box body disposed within the mounting position; Multiple battery packs installed within the installation box body, the multiple battery packs being designed in a "field" - shaped layout; A multi - power selective connection device installed within the frame, the multi - power selective connection device including: Multiple groups of connecting contacts for electrically connecting with the multiple battery packs; A mode adjustment mechanism, the mode adjustment mechanism including an adjustment disc, multiple contacts being equally spaced along the circumferential direction at both ends of the adjustment disc, the multiple contacts forming several groups of gear - position contact combinations; multiple connection areas are provided on the outer peripheral wall of the adjustment disc, and power - off friction areas are provided between the connection areas; the power - off friction area has a self - cleaning function and can remove oxides and dirt on the contact surface during mode switching; the gear - position contact combinations adopt a modular design to achieve different series - parallel combinations of batteries; A dirt 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 mounting disc for mounting the adjustment disc and the dirt layer cleaning structure; and A transmission mechanism, the transmission mechanism including 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 being used to monitor the state of the battery, including: A control unit for controlling the mode adjustment mechanism to perform mode switching according to the monitoring data.

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, wherein 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 layer cleaning structure includes: A contact friction arc section for cleaning the dirt on the connecting contacts; and A contact friction arc section for cleaning the dirt on the contacts; Wherein, the contact friction arc section and the contact friction arc section are symmetrically installed on both side surfaces of the operation mounting disc.

4. The battery pack dynamic management and self-cleaning switching system according to claim 3, characterized in that: The contact friction arc section includes: A first friction surface for contacting the connecting contacts, the surface roughness Ra value of the first friction surface being 0.8 - 1.2 μm; Wherein, multiple through - holes are provided in the contact friction arc section, 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 connection areas of the adjustment disc are made of gold - plated copper alloy, the power - off friction area is made of tungsten carbide matrix material, and micro - grooves with a depth of 0.1 mm and a pitch of 0.5 mm are machined on the surface of the power - off friction area.

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