A new energy automobile power battery thermal balance integrated monitoring system

Abstract

The application discloses a new energy automobile power battery thermal balance integrated monitoring system. In the application, a data buffer module effectively isolates a signal source from subsequent circuits through the characteristics of high input impedance and low output impedance, ensures the stability and integrity of the signal in the transmission process, and a self-adaptive gain controller module further optimizes the quality of the signal by monitoring and automatically adjusting the amplifier gain in real time, so that the output signal is ensured to be in a suitable dynamic range, distortion caused by too small signal is prevented, and saturation caused by too large signal is avoided. A data noise suppression module uses a low-pass active filter and a noise gate technology to specifically reduce noise components in the signal, and further improves the quality and definition of the signal. An anti-aliasing filter module effectively removes signal components higher than the Nyquist frequency before signal sampling, prevents aliasing from occurring, and ensures the accuracy of the sampling data.

Description

Technical Field

[0001] This invention belongs to the field of new energy vehicle battery technology, specifically a thermal balance integrated monitoring system for new energy vehicle power batteries. Background Technology

[0002] The thermal balance monitoring system for new energy vehicle power batteries is a key technology for ensuring the safe and efficient operation of power batteries. It precisely controls the battery's operating state by monitoring parameters such as temperature, current, and voltage in real time, preventing overheating or overcooling and ensuring the battery operates within its optimal temperature range. This system includes temperature sensors, data acquisition units, control strategies, and actuators, enabling dynamic management of heat generation and dissipation during charging and discharging. The design of the monitoring system must comprehensively consider factors such as the battery's thermal characteristics, ambient temperature, and vehicle operating conditions to optimize the power battery's thermal balance and improve the range, safety performance, and lifespan of new energy vehicles. With the rapid development of new energy vehicles, the performance and safety of power batteries, as their core components, are receiving increasing attention. Power batteries generate heat during charging and discharging; excessively high or low temperatures can affect battery performance, lifespan, and even cause safety issues. Therefore, thermal balance management of power batteries has become a crucial aspect of new energy vehicle technology.

[0003] However, existing power battery thermal balance management systems have many shortcomings. Due to the complexity of the battery's operating environment and interference during signal transmission, traditional systems often struggle to accurately and in real-time acquire battery operating status data. Secondly, the data processing and control algorithms are relatively simple, making it difficult to achieve precise control of the battery's thermal state. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated monitoring system for thermal balance of power batteries in new energy vehicles in order to solve the problems mentioned above.

[0005] The technical solution adopted in this invention is as follows: a thermal balance integrated monitoring system for power batteries of new energy vehicles, the system comprising: a new energy vehicle thermal management data acquisition module, a new energy vehicle thermal management data conditioning module, a thermal management data processing and control module, an actuator module, a communication module, a power management module, and a human-machine interaction module;

[0006] The output of the new energy vehicle thermal management data acquisition module is directly connected to the input of the new energy vehicle thermal management data conditioning module via a data cable, and is used to transmit the collected raw battery status data.

[0007] The output of the new energy vehicle thermal management data conditioning module is connected to the input of the thermal management data processing and control module via a data cable to provide pre-processed battery data.

[0008] The output of the communication module is connected to a remote monitoring center or user terminal via a communication line.

[0009] The output of the power management module is connected to the power input of the new energy vehicle thermal management data acquisition module, the new energy vehicle thermal management data conditioning module, the thermal management data processing and control module, the actuator module, the communication module and the human-machine interaction module via a power cable, so as to provide a stable power supply to each module.

[0010] The input terminal of the human-computer interaction module is connected to the output terminal of the thermal management data processing and control module via a data cable; the output terminal of the human-computer interaction module is connected to the input terminal of the thermal management data processing and control module via a control cable, for sending user operation commands.

[0011] In a preferred embodiment, the new energy vehicle thermal management data acquisition module includes a temperature sensor, a current sensor, a voltage sensor, and a humidity sensor. The temperature sensor, employing an NTC thermistor or a PT100 platinum resistance thermometer, is positioned at multiple key locations within the battery pack, including the battery cells, heat sinks, and the battery pack casing, to monitor temperature distribution in different areas. The current sensor, employing a Hall effect sensor, is installed at the output terminal of the battery pack to measure the battery's charging and discharging current in real time. The voltage sensor assesses the battery's state of charge by measuring the terminal voltage of the battery cells through a voltage divider circuit or by directly measuring the voltage. The humidity sensor monitors the ambient humidity inside the battery pack to prevent short-circuit risks caused by excessive humidity. These sensors convert the acquired analog signals into digital signals and transmit them via a data bus to the new energy vehicle thermal management data conditioning module for processing. The design of the new energy vehicle thermal management data acquisition module requires high precision, high response speed, and good anti-interference capabilities to ensure the accuracy and effectiveness of subsequent data processing and control.

[0012] In a preferred embodiment, the thermal management data processing and control module uses a PID algorithm to control the power output of the heat sink or heater to maintain the battery temperature within a set range. The specific calculations include:

[0013] Calculation of the difference between the set value and the actual value:

[0014] SP setting: Ideal operating temperature of the battery.

[0015] Actual value PV: Real-time monitored battery temperature.

[0016] Difference e: e = SP - PV.

[0017] PID calculations:

[0018] The proportional term P is proportional to the current difference, P = Kp * e.

[0019] The integral term I is proportional to the cumulative effect of historical differences, I = Ki * ∫edt.

[0020] The differential term D is proportional to the rate of change of the difference, D = Kd * de / dt.

[0021] Control instruction generation

[0022] Control variable CV: CV = P + I + D. Adjust the power output of the radiator or heater based on CV.

[0023] but:

[0024] CV=Kp*e+Ki*∫edt+Kd*de / dt

[0025] Where Kp represents the scaling factor, which determines the strength of the response to the current difference.

[0026] Ki represents the integral coefficient, which determines the strength of the response to the cumulative effect of historical differences.

[0027] Kd represents the differential coefficient, which determines the strength of the response to the rate of change of the difference.

[0028] 'e' represents the difference, which is the difference between the set value and the actual value.

[0029] ∫e dt represents the integral of the difference, which represents the cumulative effect of historical differences.

[0030] de / dt represents the derivative of the difference, and de represents the rate of change of the difference.

[0031] CV stands for Control Variable, which is the command value output to the actuator to adjust the power of the radiator or heater.

[0032] In a preferred embodiment, the data buffer module ensures that the current and voltage signals maintain their original characteristics during transmission, without attenuation or distortion. By using high input impedance and low output impedance, the direct connection between the current and voltage signal source and subsequent circuits is effectively isolated, preventing the signal source from being affected by load changes. Simultaneously, the driver section is responsible for enhancing the signal's driving capability, providing sufficient current and voltage so that the signal can overcome the impedance of the transmission line and be transmitted over long distances to the subsequent processing unit. During this process, the driver also matches the characteristics of the line to ensure the stability and integrity of the signal during transmission.

[0033] In a preferred embodiment, the adaptive gain controller module monitors the amplitude of the input signal in real time and automatically adjusts the gain of the amplifier to keep the output signal within a certain dynamic range and avoid signal distortion or saturation.

[0034] The calculation method for the adaptive gain controller is as follows:

[0035] Set a target output signal amplitude A_target, measure the current input signal amplitude A_input, and calculate the gain adjustment coefficient K. The calculation formula is: K = A_target / A_input;

[0036] Then adjust the gain G of the variable gain amplifier according to K, using the following formula:

[0037] G_adjusted = K * G_initial; where G_initial is the initial gain of the amplifier. This process may require a microprocessor or digital signal processor to implement the adaptive algorithm.

[0038] In a preferred embodiment, the data noise suppression module reduces or eliminates noise components in the signal using a second-order low-pass active filter and a noise gate. The active filter is designed with appropriate filter parameters based on the frequency characteristics of the signal and noise, allowing only signals within a specific frequency range to pass through while suppressing noise at other frequencies. The noise gate controls the passage of noise by setting a threshold; when the signal is below the threshold, the noise gate closes, thus preventing noise from passing through; when the signal is above the threshold, the noise gate opens, allowing the signal to pass through. In this way, the noise suppression circuit module effectively improves the signal quality and clarity.

[0039] The transfer function of the second-order low-pass active filter is calculated as follows:

[0040]

[0041] Where ωn = 2πf_n is the natural frequency, f_n is the cutoff frequency of the filter, and ζ is the damping ratio. Appropriate ωn and ζ need to be selected during the design process to meet the filtering requirements.

[0042] In a preferred embodiment, the weak signal amplification module includes:

[0043] Input stage: The weak signal first passes through a low-noise operational amplifier input stage. This cascade is designed with high input impedance to avoid drawing too much current from the signal source.

[0044] Gain Stage: After the input stage, the signal is passed to the gain stage, where the desired gain is set via an external resistor network. The gain stage is designed to ensure flat gain across the desired frequency range, avoiding fluctuations in the frequency response.

[0045] Output stage: The amplified signal passes through the output stage, which is designed with low output impedance to ensure that the signal can drive subsequent circuits or loads.

[0046] Power supply decoupling: Decoupling capacitors are added to the entire amplifier circuit to reduce the impact of power supply noise on amplifier performance.

[0047] Filters: Sometimes filters are integrated into amplifiers to further suppress noise and interference and ensure signal purity;

[0048] The formula for calculating the linear amplification process is as follows:

[0049] Vout = A·Vin;

[0050] Vout is the amplifier's output voltage; Vin is the amplifier's input voltage. A is the amplifier's gain, defined as the ratio of the output voltage to the input voltage.

[0051] The gain A of the amplifier is set by an external resistor. The formula for configuring a non-inverting amplifier is: A = 1 + R f / R i Where: R f It is the resistance value of the feedback resistor; R i It is the resistance value of the input resistor.

[0052] In a preferred embodiment, the anti-aliasing filter module uses a fourth-order Butterworth low-pass filter to filter out signal components with frequencies higher than the Nyquist frequency before sampling, preventing aliasing. Its transfer function is calculated as follows:

[0053]

[0054] The selection of ωn and ζ needs to be determined based on the sampling rate fs. ωn is set to πfs / 2 to ensure that the filter has sufficient attenuation at the Nyquist frequency.

[0055] In a preferred embodiment, the actuator module includes a radiator, a heater, a fan, and a pump. The radiator may employ air cooling or liquid cooling, improving heat dissipation efficiency by increasing the heat dissipation area and optimizing the heat dissipation path. The heater uses an electrothermal film or heating rod to provide necessary heating for the battery in low-temperature environments. The fan forces airflow, enhancing the radiator's heat dissipation effect. The pump is used in the liquid cooling system to drive coolant circulation, achieving efficient heat exchange.

[0056] The communication module employs multiple communication protocols and interfaces, including CAN, LIN, Ethernet, and Wi-Fi. The CAN bus enables fast and reliable communication between the battery management system and other vehicle control systems. The LIN bus connects low-speed devices, including sensors and actuators. Ethernet and Wi-Fi facilitate remote monitoring and data analysis, transmitting battery status information to a cloud server and receiving remote commands and parameter settings from the server. The communication module also features fault diagnosis and alarm functions, capable of real-time monitoring of the communication line status and issuing alarm signals in case of faults. The design of the communication module requires high bandwidth, low latency, and good compatibility to ensure real-time, accurate, and secure data transmission.

[0057] In a preferred embodiment, the power management module includes a power conversion circuit, a voltage regulator, a power monitoring circuit, and a backup power supply. The power conversion circuit converts the higher voltage supplied by the vehicle into the lower voltage required by the system for use by sensors, microcontrollers, and communication modules. The voltage regulator ensures stable output voltage, unaffected by input voltage fluctuations and load changes. The power monitoring circuit monitors power supply voltage and current in real time to prevent overvoltage, undervoltage, and overcurrent faults. The backup power supply uses a supercapacitor or small battery to provide short-term power backup in the event of main power failure, ensuring safe system shutdown and preventing data loss and equipment damage.

[0058] The human-machine interface module includes a display screen, buttons, a touchscreen, and an audible alarm device. The display screen, using an LCD or LED display, shows real-time data on battery temperature, current, voltage, and SOC, as well as system status and fault information. The buttons and touchscreen allow users to set parameters, select modes, and perform manual control operations. The audible alarm device sounds an alarm when an abnormal situation is detected, alerting the user.

[0059] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0060] 1. In this invention, the data buffer module, with its high input impedance and low output impedance, effectively isolates the signal source from subsequent circuits, ensuring the stability and integrity of the signal during transmission and avoiding signal attenuation or distortion caused by load changes. The adaptive gain controller module further optimizes signal quality by real-time monitoring and automatic adjustment of the amplifier gain, ensuring the output signal remains within a suitable dynamic range, preventing distortion caused by excessively low signal strength and saturation caused by excessively high signal strength. Furthermore, the data noise suppression module utilizes a low-pass active filter and noise gate technology to specifically reduce noise components in the signal, further improving signal quality and clarity. The weak signal amplification module specifically amplifies weak signals, ensuring their clarity and identifiability, enabling the system to capture more subtle changes in battery state. Finally, the anti-aliasing filter module effectively removes signal components above the Nyquist frequency before signal sampling, preventing aliasing and ensuring the accuracy of the sampled data.

[0061] 2. In this invention, an algorithm is used to precisely control the battery temperature. By calculating the difference between the set value and the actual value, and through the synergistic effect of proportional, integral, and derivative terms, the system generates precise control commands to drive the actuator module to adjust the radiator, heater, and thermal management system. This control method not only responds quickly but also effectively suppresses overshoot and oscillation, enabling the battery temperature to reach the set value rapidly and stably. Precise thermal balance control helps extend battery life, improve battery performance, and ensure that the vehicle maintains optimal condition under various operating conditions. Attached Figure Description

[0062] Figure 1 This is an overall system block diagram of the present invention;

[0063] Figure 2 This is a system block diagram of the thermal management data conditioning module for new energy vehicles in this invention;

[0064] Figure 3 This is a block diagram of the temperature control logic in this invention. Detailed Implementation

[0065] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0066] Reference Figure 1-3 ,

[0067] A new energy vehicle power battery thermal balance integrated monitoring system includes: a new energy vehicle thermal management data acquisition module, a new energy vehicle thermal management data conditioning module, a thermal management data processing and control module, an actuator module, a communication module, a power management module, and a human-machine interaction module.

[0068] The thermal management data conditioning module for new energy vehicles is internally equipped with a data buffer module, an adaptive gain controller module, a data noise suppression module, a weak signal amplification module, and an anti-aliasing filter module.

[0069] The thermal management data acquisition module for new energy vehicles first collects key operating data of the battery pack in real time through temperature, current, voltage and humidity sensors;

[0070] The thermal management data conditioning module for new energy vehicles processes signals to ensure the accuracy and availability of the data.

[0071] The microcontroller unit of the thermal management data processing and control module uses a thermal balance control algorithm to analyze and calculate the data, and generate corresponding control commands. These commands are sent to the actuator module to drive the radiator, heater, and thermal management system to adjust the battery temperature and achieve thermal balance.

[0072] The communication module is responsible for transmitting battery status information to other vehicle systems and remote servers, enabling data sharing and remote monitoring, and receiving external commands and parameter settings.

[0073] The human-computer interaction module provides an interface for interaction between the user and the system, displays real-time data, and allows manual operation.

[0074] The power management module converts the vehicle's power supply to the voltage required by the system and provides short-term power backup in the event of a main power failure, ensuring a safe system shutdown.

[0075] The specific implementation steps include:

[0076] System initialization: After power-on, the central processing unit performs a self-test to ensure that all modules are working properly. It reads preset initial settings such as battery parameters, temperature thresholds, and control strategies.

[0077] Temperature data acquisition: The temperature sensor network is activated to collect temperature data of each battery cell in real time.

[0078] The sensor converts the temperature signal into an electrical signal and transmits it to the data acquisition and transmission module via a data cable.

[0079] Data transmission and processing: The data acquisition and transmission module performs preliminary processing on the temperature data, such as filtering and amplification. The processed data is then transmitted in real-time to the central processing unit via a communication protocol. Upon receiving the data, the central processing unit performs further processing and analysis, such as data smoothing and trend prediction.

[0080] Thermal State Calculation and Assessment: The central processing unit runs a thermal balance control algorithm to calculate the battery's thermal state based on the collected temperature data. It assesses whether the battery is within its normal operating temperature range and determines whether the cooling system needs to be activated.

[0081] Control command generation: Based on the thermal state calculation results, the central processing unit generates corresponding control commands. These commands include fan speed adjustment and coolant circulation speed control, among others.

[0082] Cooling system regulation: The cooling system receives control commands and adjusts the fan speed and coolant circulation speed. The heat generated by the battery is effectively dissipated into the environment through the radiator and coolant circulation system.

[0083] Real-time monitoring and feedback: The system continuously monitors battery temperature and the operating status of the cooling system. Real-time data is fed back to the central processing unit, forming a closed-loop control system.

[0084] Alarm and Protection: An alarm mechanism will be activated immediately upon detecting abnormal battery temperature or a cooling system malfunction. Emergency protection measures, such as reducing charging current or disconnecting power, will be taken to prevent accidents.

[0085] Data recording and storage: The system records and stores real-time monitoring data, control commands, and alarm information in the central processing unit or external storage devices. This facilitates subsequent data analysis and system optimization.

[0086] Through the specific implementation steps described above, this application has successfully achieved integrated monitoring of the thermal balance of automotive power batteries, yielding significant application results:

[0087] This application monitors the temperature of each battery cell in real time to ensure the accuracy and timeliness of temperature data.

[0088] This application effectively controls battery temperature, avoids overheating or overcooling, extends battery life, and maintains stable performance.

[0089] This application aims to promptly detect abnormal temperatures and cooling system malfunctions, and to take effective measures to prevent safety accidents.

[0090] This application optimizes battery performance through thermal balance control, thereby improving the driving range and driving stability of electric vehicles.

[0091] The thermal management data acquisition module for new energy vehicles includes temperature sensors, current sensors, voltage sensors, and humidity sensors. Temperature sensors, employing NTC thermistors or PT100 platinum resistance thermometers, are positioned at multiple key locations within the battery pack, such as battery cells, heat sinks, and the battery pack casing, to monitor temperature distribution in different areas. Current sensors, using Hall effect sensors, are installed at the battery pack's output terminal to measure the battery's charging and discharging current in real time. Voltage sensors assess the battery's state of charge (SOC) by using a voltage divider circuit or directly measuring the terminal voltage of the battery cells. Humidity sensors monitor the ambient humidity inside the battery pack to prevent short-circuit risks caused by excessive humidity. These sensors convert the acquired analog signals into digital signals and transmit them via a data bus to the new energy vehicle thermal management data conditioning module for processing. The design of the new energy vehicle thermal management data acquisition module requires high precision, high response speed, and strong anti-interference capabilities to ensure the accuracy and effectiveness of subsequent data processing and control.

[0092] The thermal management data processing and control module uses a PID algorithm to control the power output of the heat sink or heater to maintain the battery temperature within a set range, such as... Figure 3 As shown, the specific calculations include:

[0093] Calculation of the difference between the set value and the actual value:

[0094] SP setting: Ideal operating temperature of the battery.

[0095] Actual value PV: Real-time monitored battery temperature.

[0096] Difference e: e = SP - PV.

[0097] PID calculations

[0098] The proportional term P is proportional to the current difference, P = Kp * e.

[0099] The integral term I is proportional to the cumulative effect of historical differences, I = Ki * ∫edt.

[0100] The differential term D is proportional to the rate of change of the difference, D = Kd * de / dt.

[0101] Control command generation

[0102] Control variable CV: CV = P + I + D. Adjust the power output of the radiator or heater based on CV.

[0103] but:

[0104] CV=Kp*e+Ki*∫edt+Kd*de / dt

[0105] Where Kp represents the scaling factor, which determines the strength of the response to the current difference.

[0106] Ki represents the integral coefficient, which determines the strength of the response to the cumulative effect of historical differences.

[0107] Kd represents the differential coefficient, which determines the strength of the response to the rate of change of the difference.

[0108] 'e' represents the difference, which is the difference between the set value and the actual value.

[0109] ∫e dt represents the integral of the difference, which represents the cumulative effect of historical differences.

[0110] de / dt represents the derivative of the difference, and de represents the rate of change of the difference.

[0111] CV stands for Control Variable, which is the command value output to the actuator to adjust the power of the radiator or heater.

[0112] Specifically, it includes:

[0113] Input module:

[0114] Upper-level input: Set value SP (Battery target temperature range)

[0115] Lower-level feedback: Actual value PV (real-time monitoring value from the temperature sensor)

[0116] Core computing module:

[0117] Difference calculation: e = SP - PV (temperature deviation generation)

[0118] PID three-channel parallel computation:

[0119] Proportional channel: Directly amplifies the current deviation (P = Kp × e)

[0120] Integral channel: Accumulated historical deviation (I = Ki × ∫e dt, eliminating steady-state error)

[0121] Differential channel: Prediction bias trend (D = Kd × de / dt, suppressing overshoot)

[0122] Output control module:

[0123] Summer composition CV = P + I + D

[0124] The actuator converts CV into a power command (PWM duty cycle / current signal).

[0125] Adjusting heat exchange power via radiators (cooling) or heaters (heating)

[0126] Closed-loop feedback module:

[0127] Battery temperature changes are continuously monitored by sensors; real-time PV feedback forms a closed-loop control, dynamically correcting the output.

[0128] The data buffer module ensures that the current and voltage signals maintain their original characteristics during transmission, without attenuation or distortion. By using high input impedance and low output impedance, it effectively isolates the direct connection between the current and voltage signal source and subsequent circuits, preventing the signal source from being affected by load changes. Simultaneously, the driver section is responsible for enhancing the signal's driving capability, providing sufficient current and voltage so that the signal can overcome the impedance of the transmission line and be transmitted over long distances to the subsequent processing unit. During this process, the driver also matches the characteristics of the line to ensure the stability and integrity of the signal during transmission.

[0129] The adaptive gain controller module monitors the amplitude of the input signal in real time and automatically adjusts the amplifier gain to keep the output signal within a certain dynamic range and avoid signal distortion or saturation.

[0130] The calculation method for the adaptive gain controller is as follows:

[0131] Set a target output signal amplitude A_target, measure the current input signal amplitude A_input, and calculate the gain adjustment coefficient K. The calculation formula is: K = A_target / A_input;

[0132] Then adjust the gain G of the variable gain amplifier according to K, using the following formula:

[0133] G_adjusted = K * G_initial; where G_initial is the initial gain of the amplifier. This process may require a microprocessor or digital signal processor to implement the adaptive algorithm.

[0134] The data noise suppression module reduces or eliminates noise components in the signal through a second-order low-pass active filter and a noise gate. The active filter, designed with appropriate parameters based on the frequency characteristics of the signal and noise, allows only signals within a specific frequency range to pass through, while suppressing noise at other frequencies. The noise gate controls the passage of noise by setting a threshold. When the signal is below the threshold, the noise gate closes, preventing noise from passing through; when the signal is above the threshold, the noise gate opens, allowing the signal to pass through. In this way, the noise suppression circuit module effectively improves signal quality and clarity.

[0135] The transfer function of the second-order low-pass active filter is calculated as follows:

[0136]

[0137] Where ωn = 2πf_n is the natural frequency, f_n is the cutoff frequency of the filter, and ζ is the damping ratio. Appropriate ωn and ζ need to be selected during the design process to meet the filtering requirements.

[0138] The weak signal amplification module includes:

[0139] Input stage: The weak signal first passes through a low-noise operational amplifier input stage. This cascade is designed with high input impedance to avoid drawing too much current from the signal source.

[0140] Gain Stage: The signal is passed to the gain stage after the input stage, where it is passed through an external resistor network (R). f and R f Use this information to set the desired gain. The gain stage should be designed to ensure that the gain is flat within the desired frequency range, avoiding fluctuations in the frequency response.

[0141] Output stage: The amplified signal passes through the output stage, which is designed with low output impedance to ensure that the signal can drive subsequent circuits or loads.

[0142] Power supply decoupling: Decoupling capacitors are added to the entire amplifier circuit to reduce the impact of power supply noise on amplifier performance.

[0143] Filters: Sometimes filters are integrated into amplifiers to further suppress noise and interference and ensure signal purity;

[0144] The formula for calculating the linear amplification process is as follows:

[0145] Vout = A·Vin;

[0146] Vout is the amplifier's output voltage; Vin is the amplifier's input voltage. A is the amplifier's gain, defined as the ratio of the output voltage to the input voltage.

[0147] The gain A of the amplifier is set by an external resistor. The formula for configuring a non-inverting amplifier is: A = 1 + R f / R i Where: R f It is the resistance value of the feedback resistor; R i It is the resistance value of the input resistor.

[0148] The anti-aliasing filter module uses a fourth-order Butterworth low-pass filter to filter out signal components with frequencies higher than the Nyquist frequency before sampling, preventing aliasing. Its transfer function is calculated as follows:

[0149]

[0150] The selection of ωn and ζ needs to be determined based on the sampling rate fs. ωn is set to πfs / 2 to ensure that the filter has sufficient attenuation at the Nyquist frequency.

[0151] The actuator module includes devices such as heat sinks, heaters, fans, and pumps. The heat sink may employ air cooling or liquid cooling, improving heat dissipation efficiency by increasing the heat dissipation area and optimizing the heat dissipation path. The heater can use an electric heating film or heating rod to provide necessary heating for the battery in low-temperature environments. The fan forces airflow, enhancing the heat dissipation effect of the heat sink. The pump is used in the liquid cooling system to drive the coolant circulation, achieving efficient heat exchange. The actuator module receives control commands from the thermal management data processing and control module, such as adjusting the power output of the heat sink or heater, changing the fan speed, or the pump flow rate. These actuators are controlled via PWM (Pulse Width Modulation) signals or analog signals to achieve precise temperature regulation. The actuator module is designed to be efficient, reliable, and responsive to ensure that the battery temperature reaches the set value quickly and stably.

[0152] The communication module employs multiple communication protocols and interfaces, including CAN (Controller Area Network), LIN (Linux Local Interconnect Network), Ethernet, and Wi-Fi. The CAN bus enables fast and reliable communication between the Battery Management System (BMS) and other vehicle control systems (such as the engine control unit and on-board charger). The LIN bus connects low-speed devices, such as sensors and actuators. Ethernet and Wi-Fi facilitate remote monitoring and data analysis, transmitting battery status information to a cloud server and receiving remote commands and parameter settings from the server. The communication module also features fault diagnosis and alarm functions, capable of real-time monitoring of the communication line status and issuing alarm signals in case of faults. The design of the communication module requires high bandwidth, low latency, and good compatibility to ensure the real-time performance, accuracy, and security of data transmission.

[0153] The power management module includes a power conversion circuit, a voltage regulator, a power monitoring circuit, and a backup power supply. The power conversion circuit converts the higher voltage (e.g., 12V or 24V) supplied by the vehicle to the lower voltage (e.g., 5V or 3.3V) required by the system for use by sensors, microcontrollers, and communication modules. The voltage regulator ensures stable output voltage, unaffected by input voltage fluctuations and load changes. The power monitoring circuit monitors power supply voltage and current in real time to prevent overvoltage, undervoltage, and overcurrent faults. The backup power supply uses supercapacitors or small batteries to provide short-term power backup in case of main power failure, ensuring safe system shutdown and preventing data loss and equipment damage. The power management module is designed to be highly efficient, stable, and possess good electromagnetic compatibility to ensure normal system operation under various conditions.

[0154] The human-machine interface (HMI) module includes a display screen, buttons, a touchscreen, and an audible alarm. The display screen can be an LCD or LED display, showing real-time data such as battery temperature, current, voltage, and SOC, as well as system status and fault information. The buttons and touchscreen allow users to perform parameter settings, mode selection, and manual control. The audible alarm sounds when an abnormality is detected, alerting the user. The HMI module also supports multilingual interfaces and graphical displays to enhance the user experience. Furthermore, the module can connect to mobile devices such as smartphones or tablets for remote monitoring and operation. The HMI module is designed to be intuitive, easy to use, and highly interactive to ensure users can easily access information and control the system.

[0155] As can be seen from the above, in this invention, the data buffer module, with its high input impedance and low output impedance, effectively isolates the signal source from subsequent circuits, ensuring the stability and integrity of the signal during transmission and avoiding signal attenuation or distortion caused by load changes. The adaptive gain controller module further optimizes signal quality by monitoring and automatically adjusting the amplifier gain in real time, ensuring the output signal is within a suitable dynamic range, preventing distortion caused by excessively small signals and saturation caused by excessively large signals. Furthermore, the data noise suppression module utilizes a low-pass active filter and noise gate technology to specifically reduce noise components in the signal, further improving signal quality and clarity. The weak signal amplification module specifically amplifies weak signals, ensuring their clarity and identifiability, enabling the system to capture more subtle changes in battery state. Finally, the anti-aliasing filter module effectively removes signal components above the Nyquist frequency before signal sampling, preventing aliasing and ensuring the accuracy of the sampled data.

[0156] This invention employs an algorithm for precise battery temperature control. By calculating the difference between the setpoint and the actual value, and through the synergistic effect of proportional, integral, and derivative terms, the system generates precise control commands to drive the actuator module to adjust the radiator, heater, and thermal management system. This control method not only responds quickly but also effectively suppresses overshoot and oscillation, enabling the battery temperature to reach the setpoint rapidly and stably. Precise thermal balance control helps extend battery life, improve battery performance, and ensure that the vehicle maintains optimal condition under various operating conditions.

[0157] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the term "comprising" or any other variations thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0158] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated monitoring system for thermal balance of power batteries in new energy vehicles, characterized in that: The system includes: a new energy vehicle thermal management data acquisition module, a new energy vehicle thermal management data conditioning module, a thermal management data processing and control module, an actuator module, a communication module, a power management module, and a human-machine interaction module; The output of the new energy vehicle thermal management data acquisition module is directly connected to the input of the new energy vehicle thermal management data conditioning module via a data cable, and is used to transmit the collected raw battery status data. The output of the new energy vehicle thermal management data conditioning module is connected to the input of the thermal management data processing and control module via a data cable to provide pre-processed battery data. The output of the communication module is connected to a remote monitoring center or user terminal via a communication line. The output of the power management module is connected to the power input of the new energy vehicle thermal management data acquisition module, the new energy vehicle thermal management data conditioning module, the thermal management data processing and control module, the actuator module, the communication module and the human-machine interaction module via a power cord. The input terminal of the human-computer interaction module is connected to the output terminal of the thermal management data processing and control module via a data cable; the output terminal of the human-computer interaction module is connected to the input terminal of the thermal management data processing and control module via a control cable. The data conditioning module internally includes a data buffer module, an adaptive gain controller module, a data noise suppression module, a weak signal amplification module, and an anti-aliasing filter module; Among them, the data buffer module isolates the signal source from the subsequent circuit through its high input impedance and low output impedance characteristics; the adaptive gain controller module further optimizes the signal quality by monitoring and automatically adjusting the amplifier gain in real time to keep the output signal within a suitable dynamic range; the data noise suppression module uses low-pass active filters and noise gate technology to reduce noise components in the signal; the weak signal amplification module amplifies weak signals to ensure the clarity and recognizability of these signals; and the anti-aliasing filter module removes signal components with frequencies higher than the Nyquist frequency before signal sampling to prevent aliasing. The data processing and control module uses a PID algorithm to control the power output of the radiator or heater in order to maintain the battery temperature within a set range.

2. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The new energy vehicle thermal management data acquisition module includes a temperature sensor, a current sensor, a voltage sensor, and a humidity sensor; the temperature sensor is an NTC thermistor or a PT100 platinum resistance thermometer, which is arranged in the battery cells, heat sink, and battery pack casing of the battery pack. The current sensor is a Hall effect sensor and is installed at the output end of the battery pack; The voltage sensor is installed at the wiring point of the voltage divider circuit or battery cell.

3. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The thermal management data processing and control module has two output ports: One port of the thermal management data processing and control module is connected to the control input terminal of the actuator module via a control line; Another port of the thermal management data processing and control module is connected to the input of the communication module via a data cable.

4. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The adaptive gain controller module is internally equipped with a microprocessor or digital signal processor that implements the adaptive algorithm.

5. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The data noise suppression module is internally equipped with an active filter and a noise gate; The active filter is a second-order low-pass active filter, and the transfer function of the second-order low-pass active filter is calculated as follows: ； Where ωn=2πf_n is the natural frequency, f_n is the cutoff frequency of the filter, and ζ is the damping ratio; appropriate ωn and ζ need to be selected during the design to meet the filtering requirements.

6. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The weak signal amplification module includes: an input stage, a gain stage, an output stage, a power supply decoupling module, and a filter; The input stage is a low-noise operational amplifier; The gain stage is a module that sets the required gain through an external resistor network; The output stage has low output impedance; The power decoupling module is a decoupling capacitor; The filter is a filter for further suppressing noise and interference; The calculation formula for the linear amplification process of the weak signal amplification module is as follows: Vout = A·Vin; Vout is the amplifier's output voltage; Vin is the amplifier's input voltage; A is the amplifier's gain, defined as the ratio of the output voltage to the input voltage. The amplifier's gain A is set by an external resistor. The formula for configuring a non-inverting amplifier is: A = 1 + R f / R i Where: R f It is the resistance value of the feedback resistor; R i It is the resistance value of the input resistor.

7. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The transfer function of the anti-aliasing filter module is calculated as follows: ； The selection of ωn and ζ needs to be determined based on the sampling rate fs, with ωn set to πfs / 2.

8. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The actuator module includes a radiator, a heater, a fan, and a pump; the radiator is an air-cooled or liquid-cooled radiator; the heater is an electric heating film or a heating rod; The communication module includes CAN, LIN, Ethernet, and Wi-Fi; the CAN bus enables communication between the battery management system and other vehicle control systems; the LIN bus connects low-speed devices; Ethernet and Wi-Fi transmit battery status information to the cloud server, and simultaneously receive remote commands and parameter settings from the server.

9. The integrated monitoring system for thermal balance of power batteries in new energy vehicles as described in claim 1, characterized in that: The power management module includes a power conversion circuit, a voltage regulator, a power monitoring circuit, and a backup power supply; the power conversion circuit converts the higher voltage supplied by the vehicle into the lower voltage required by the system; the voltage regulator ensures the stability of the output voltage; The power monitoring circuit monitors the power supply voltage and current in real time. The human-computer interaction module includes a display screen, buttons, a touch screen, and an audible alarm device.

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