Efficient recombination and safe energy storage control technology for echelon utilization of waste new energy batteries

Abstract

The invention discloses an efficient recombination and safe energy storage control technology for waste new energy battery echelon utilization, and a waste battery pretreatment and performance evaluation battery health detection system. Advanced diagnostic tools such as internal resistance testing, capacity testing, cycle performance testing and an X-ray imaging technology are used for comprehensively checking the health state of a battery; especially battery internal structure and potential damage. And a standardized battery detection method is adopted to ensure that the detection result is accurate and can be copied. By optimizing a plurality of links of battery evaluation, restoration, recombination, management, safety control and the like, the utilization efficiency of the battery is improved, and the safety and the stability of the system are enhanced. Besides, the intelligent battery management system and the thermal management technology can ensure long-term safe operation of the battery pack, and the modularized and intelligent scheduling technology can improve the flexibility and economy of the energy storage system, so that the wide application of the waste battery echelon utilization technology is promoted.

Description

Technical Field

[0001] The present invention relates to the field of new energy and renewable energy technologies, and specifically to efficient recombination and safe energy storage control technology for the cascade utilization of waste new energy batteries. Background Art

[0002] The efficient reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries refers to the technology that uses waste new energy batteries (such as lithium batteries, sodium batteries, etc.) for secondary energy storage applications through battery performance evaluation, repair and reorganization after they are retired. This technology not only realizes the efficient utilization of battery resources and extends the battery life cycle, but also ensures the safety and efficiency of batteries during the energy storage process through advanced battery management systems (BMS) and intelligent control technologies, avoiding safety hazards such as overcharging and over-discharging. By optimizing battery performance, waste batteries can be reused in areas such as grid regulation, renewable energy storage, and home and commercial energy storage, providing technical support for the recycling of green energy and the development of smart grids.

[0003] In the existing technology, although the efficient reorganization and safe energy storage control technology of waste new energy batteries has important value in battery resource recovery and reuse, it still has some shortcomings and challenges, mainly including the following aspects:

[0004] Battery performance evaluation is not accurate

[0005] Lack of unified standards: The performance evaluation of used batteries usually relies on a variety of methods and testing standards, but there is currently a lack of unified standards and a complete testing system, which may lead to deviations in the evaluation results of batteries. This may cause the performance of the reassembled battery pack to fail to meet expectations, thus affecting its secondary use effect;

[0006] Difficulty in detecting aging and damage: The aging process of batteries is relatively complex, and traditional testing methods are difficult to fully evaluate the true state of the battery, especially the damage or minor defects inside the battery may be difficult to detect;

[0007] Battery safety issues

[0008] Insufficient thermal management: If the battery management system (BMS) fails to effectively control temperature and manage heat during the recycling of used batteries, it may cause battery overheating, increasing safety risks such as fire and explosion.

[0009] Battery imbalance problem: In cascade utilization, the capacity, internal resistance and other characteristics of different battery cells vary greatly. If the battery balancing management cannot be effectively performed, some batteries may be over-discharged or over-charged, thus affecting the safety and life of the overall system;

[0010] Cycle life issues: The remaining service life of used batteries is short. Although their service life can be extended through cascade utilization, the capacity of these batteries decays rapidly after multiple cycles, and there are still certain safety risks. In particular, the battery pack may be unstable during long-term use.

[0011] Low efficiency and high cost of restructuring

[0012] The reorganization process is complex: waste batteries need to undergo strict testing, screening, repair and assembly during the reorganization process. These processes not only take up a lot of time and labor costs, but also have high technical requirements. Current technical means have not yet achieved sufficient efficiency;

[0013] Cost issue: Even if the waste batteries are recycled, the cost of reorganization and treatment is still high, including multiple links such as battery disassembly, performance testing, repair and pairing. Especially when the battery performance is uneven, a more complex battery management system may be required to ensure its safe and efficient operation.

[0014] There is no uniform technical standard for recycling and reuse

[0015] Lack of a sound recycling system: The current recycling system for used batteries is still imperfect, especially in terms of battery recycling, which lacks unified industry standards and specifications. Batteries from different manufacturers and models face different technical requirements and adaptation issues in recycling, making the recycling process complex and difficult to scale;

[0016] Battery management system (BMS) technology is immature

[0017] Poor system compatibility: In the process of recycling waste batteries, due to the wide variety of battery types and models, the existing battery management system (BMS) may not be able to adapt well to different types of batteries, resulting in poor compatibility of management and control systems, affecting the stability and safety of the energy storage system after recycling;

[0018] Lack of intelligence: Although some advanced battery management systems can monitor battery temperature, voltage, current and other parameters, current intelligent control technology is still limited and cannot accurately predict the remaining life and health status of the battery in real time, affecting the long-term reliability of the energy storage system.

[0019] Inefficient use of resources

[0020] Resource waste: During the cascade utilization process, some used batteries may not be effectively utilized due to large performance differences or irreparable problems. This resource waste is common in existing technologies, which fail to maximize the potential value of batteries.

[0021] Environmental impact and sustainability issues

[0022] Environmental pollution during the treatment process: Although the recycling of used batteries helps to reduce resource waste, batteries may release harmful substances (such as heavy metals such as lead and cadmium) during the disassembly, reassembly and recycling process. If not handled properly, they may pollute the environment and affect its sustainability.

[0023] To this end, we propose efficient reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries. Summary of the invention

[0024] To achieve the above purpose, the present invention provides the following technical solution: efficient reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries, comprising the following steps:

[0025] S1: Waste battery pretreatment and performance evaluation

[0026] S1.1: Battery health detection system: Use advanced diagnostic tools such as internal resistance test, capacity test, cycle performance test and X-ray imaging technology to comprehensively check the health status of the battery, especially the internal structure and potential damage of the battery. Use standardized battery detection methods to ensure that the test results are accurate and reproducible;

[0027] S1.2: Data analysis and AI prediction: Use artificial intelligence algorithms to analyze the historical usage data and test results of batteries, predict the remaining life and remaining capacity of the batteries, and accurately screen reusable batteries. This helps improve evaluation efficiency and reduce manual errors;

[0028] S1.3: Hierarchical recycling mechanism: Used batteries are classified into different levels according to the health status of the batteries. Batteries with higher levels will be used for cascade utilization, while batteries with lower levels will be dismantled to recycle raw materials or be eliminated;

[0029] S2: Battery repair and reorganization technology

[0030] S2.1: Battery repair system: For batteries with degraded performance, advanced repair technologies are used, such as balanced charging, tab welding repair, and replacement of failed battery cells, to restore some of the battery's performance. In particular, for batteries with more severe capacity attenuation, the battery chemical properties are restored through directional charging and discharging cycles;

[0031] S2.2: Intelligent recombination platform: Design an intelligent battery recombination platform to reasonably combine the repaired batteries according to different specifications, capacities and health conditions. Through intelligent pairing algorithms, ensure that the performance differences of each group of batteries are minimized, and ensure the balance and stability of the entire battery group;

[0032] S2.3: Battery matching and reinforcement: During the reassembly process, considering the performance differences between different batteries, an intelligent control method is used for real-time battery monitoring to ensure the consistent working status of the batteries in the battery pack. For the parallel or series assembly of different batteries, hardware design such as anti-overcharge and over-discharge protection modules are used to ensure the overall safety of the battery pack;

[0033] S3: Intelligent battery management system (BMS) and optimized control

[0034] S3.1: Multi-level battery management system (BMS): By optimizing the battery management system (BMS), accurate monitoring and control of the battery pack can be achieved. BMS can detect important parameters such as battery voltage, temperature, internal resistance, and charging status in real time, and adjust the charging and discharging strategy through intelligent algorithms to optimize the battery efficiency;

[0035] S3.2: Thermal management system: To avoid safety hazards caused by battery overheating, an efficient thermal management system is designed, using liquid cooling or air cooling technology to keep the temperature of the battery pack within a safe range. The thermal state of the battery is monitored in real time through a temperature sensor, and the thermal management strategy is automatically adjusted;

[0036] S3.3: Intelligent balanced charging: Intelligent balanced technology is used to ensure that the voltage and capacity of each battery cell remain consistent. Through dynamic balanced current control, it prevents a battery cell from overcharging or over-discharging and causing the entire battery pack to fail;

[0037] S4: Safe energy storage control technology

[0038] S4.1: Intelligent early warning system: By integrating sensors and IoT technology, various safety indicators of the battery pack (such as temperature, voltage, depth of discharge, etc.) are monitored in real time. When an abnormality occurs, the system can automatically alarm and take corresponding protective measures, such as automatically disconnecting the battery pack, adjusting the charging and discharging strategy, etc.

[0039] S4.2: Fault self-diagnosis and self-repair: Integrated self-diagnosis technology detects internal faults of the battery pack in real time, and isolates or replaces faulty battery cells through the system self-repair function. By enhancing the fault identification and recovery capabilities of the battery pack, the reliability and sustainability of the entire system are improved;

[0040] S4.3: Isolation and protection mechanism: Design a redundant battery pack protection mechanism. When a battery unit fails, the system can automatically disconnect and isolate the failed unit to ensure the normal operation of other battery units and avoid a single battery failure causing the entire system to crash.

[0041] S5: Integration and optimization of cascaded energy storage systems

[0042] S5.1: Modular energy storage system: Design a modular energy storage system so that the energy storage equipment for the cascade utilization of waste batteries can be flexibly expanded and adjusted according to demand. Each energy storage unit can operate independently or be combined with other units to form a large energy storage system, improving the flexibility and maintainability of the system;

[0043] S5.2: Intelligent scheduling and optimization algorithm: Use intelligent scheduling algorithms to optimize the energy storage system in real time, so that the battery pack can be charged and discharged according to the grid demand or the fluctuation of renewable energy. The optimization algorithm can dynamically adjust the battery's working mode according to factors such as battery health, temperature, and charging and discharging efficiency, thereby improving the overall efficiency of the energy storage system;

[0044] S5.3: Grid regulation and power feedback: Through two-way interaction with the grid, the grid regulation system is designed so that the energy storage system of waste battery recycling can not only provide power storage services for the grid, but also feed back power to the grid when the grid load is low, further improving the stability of the grid;

[0045] S6: Environmentally friendly and sustainable design

[0046] S6.1: Green recycling and waste treatment: Strengthen the green recycling technology of used batteries, design environmentally friendly recycling channels, and avoid used batteries entering landfills or being illegally disposed of, thereby polluting the environment. Design efficient disassembly processes to ensure that harmful substances in used batteries are effectively recycled and reduce environmental pollution;

[0047] S6.2: Life Cycle Assessment: Conduct a life cycle assessment (LCA) of the entire battery recycling system to ensure that the environmental impact of the technology is minimized and the goal of sustainable development is achieved.

[0048] Preferably, step S1 includes an internal resistance test: using a precise battery internal resistance tester to test the internal resistance of the battery. An increase in internal resistance usually means a decrease in battery performance. The health status of the battery is determined based on the internal resistance value. Capacity test: through a standard charge and discharge test (such as a C / 5 discharge or C / 10 discharge test), the actual capacity of the battery is measured, and the difference between the actual capacity and the initial design capacity is compared to evaluate whether the battery is suitable for cascade utilization. Cycle performance test: multiple charge and discharge cycle tests are performed to check the cycle stability and degree of decay of the battery. Professional battery testing equipment is used to simulate the actual performance of the battery in long-term use. X-ray imaging technology: high-resolution X-ray imaging technology is used to perform non-destructive testing on the inside of the battery to identify whether there are cracks, short circuits, diaphragm damage and other problems inside the battery. It also includes the establishment of a database: collecting historical usage data of batteries of different brands and models, including information such as the number of charges, charging cycles, battery temperature changes, and depth of discharge. AI algorithm training: using machine learning (such as support vector machines, neural networks, etc.) algorithms to train prediction models. Through known battery health status data, the algorithm can predict future performance changes and remaining life of the battery. Real-time data monitoring: Combine the real-time data of the battery (temperature, voltage, current, internal resistance, etc.) with the AI ​​model to make real-time predictions and timely evaluate the health status of the battery. Battery grading: According to the health status of the battery, it is divided into different levels (such as A, B, and C) according to its usable life. A-level batteries can be directly used for cascade utilization, B-level batteries need to be repaired or adjusted appropriately, and C-level batteries are used for recycling or disassembly. Grading storage and management: Establish independent storage areas for batteries of different levels, and ensure that no battery damage or leakage occurs during storage.

[0049] Preferably, the battery repair in step S2 includes balanced charging: for batteries with performance degradation, balanced charging technology is used. During the charging process, different charging currents are provided to each battery cell to ensure that each cell reaches the optimal charging state. Pole ear welding repair: for battery cells with poor internal contact, laser welding technology is used to repair the pole ears (the positive and negative connection parts of the battery) to ensure that the battery cells are in good contact and avoid battery damage caused by poor contact. Failed cell replacement: if the battery cell is obviously damaged or performance degraded, the battery can be repaired by replacing the cell. Use battery cells of the same specifications to replace the failed cells and perform battery balancing. Battery reorganization algorithm: Develop an optimized pairing algorithm based on battery health status, battery capacity, internal resistance and voltage differences. By calculating the optimized combination, batteries with similar performance are paired together to reduce the performance differences between batteries. Modular reorganization: According to the battery health status and target applications (such as home energy storage, commercial energy storage, etc.), battery cells are combined into multiple modules. The capacity, internal resistance and voltage differences of the battery cells of each module should be minimized. Mechanized assembly and testing: The reorganized battery pack is automatically assembled using a mechanized platform to ensure that each battery cell is connected in the correct state, and automatic online testing is performed to ensure that there are no failed cells. Hardware reinforcement: The connection points of the battery cells are reinforced with high-strength materials (such as copper alloys, battery welding brackets, etc.) to avoid poor contact caused by vibration or temperature changes during the use of the battery pack. Performance difference detection: The performance of each battery cell is monitored in real time through high-precision sensors and battery management systems (BMS). Once a cell is found to be abnormal, it is immediately isolated or replaced.

[0050] Preferably, in step S3, real-time monitoring: the voltage, temperature, current and other data of the battery pack are collected by sensors, and the BMS monitors the health status of the battery in real time. The data is uploaded to the cloud platform through the wireless communication module for remote monitoring. Battery balancing: The BMS has a built-in battery balancing algorithm, which can automatically adjust the charging current to ensure that the voltage of each battery cell is consistent and avoid overcharging or over-discharging of a single battery cell. Data storage and analysis: The battery usage data and performance data are stored in the database for subsequent data analysis and optimization. Combined with the AI ​​algorithm, long-term performance prediction is performed. Liquid cooling system: A liquid cooling system is designed to provide uniform temperature control for the battery pack. The coolant is circulated through the pump system to take away the heat in the battery pack to ensure that the battery remains within a safe temperature range during the charging and discharging process. Temperature sensor: Multiple temperature sensors are installed inside and outside the battery pack to monitor the temperature of the battery in real time, and the working state of the cooling system is automatically adjusted through the BMS. Dynamic balanced charging control: The charging current is dynamically adjusted according to the actual voltage and health status of the battery cell. For cells with lower voltage, the charging current is increased; for cells with higher voltage, the charging current is reduced to ensure that the battery pack remains balanced during the charging process.

[0051] Preferably, in the step S4, the abnormality detection algorithm: develop a real-time monitoring algorithm, when the battery pack has abnormalities such as over-temperature, over-voltage, over-current, over-discharge, etc., the system automatically alarms and takes corresponding measures (such as power off, restart, start cooling system, etc.), IoT integration: through the Internet of Things technology, the status of the battery pack is uploaded to the cloud platform for analysis in real time. The cloud platform combines historical data with current data, can timely warn and give safety suggestions, fault detection and isolation: use high-precision sensors to detect the health of each unit in the battery pack, and judge the fault type of the battery unit in real time. When a faulty unit is found, it is automatically isolated through the BMS system to ensure the overall stable operation of the battery pack, automatic repair mechanism: for minor battery unit failures, the BMS system can automatically adjust the working state of the battery unit, and repair the faulty unit by reducing the charging current or adjusting the temperature, physical isolation design: design a physical isolation structure for each battery unit to ensure that when a battery unit fails, the fault is not transmitted to other battery units, protection circuit design: design protection circuits, such as over-current protection, over-voltage protection, short-circuit protection, etc., to deal with extreme situations and avoid fire or explosion of the battery pack.

[0052] Compared with the prior art, the present invention provides a highly efficient reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries, which has the following beneficial effects:

[0053] The efficient reorganization and safe energy storage control technology for the cascade utilization of old new energy batteries not only improves the utilization efficiency of batteries, but also enhances the safety and stability of the system by optimizing multiple links such as battery evaluation, repair, reorganization, management, and safety control. In addition, the intelligent battery management system and thermal management technology can ensure the long-term safe operation of the battery pack. At the same time, modularization and intelligent scheduling technology can improve the flexibility and economy of the energy storage system, thereby promoting the widespread application of the cascade utilization technology of waste batteries. DETAILED DESCRIPTION

[0054] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0055] Example

[0056] Implementation example of efficient reorganization and safe energy storage control technology for cascade utilization of waste new energy batteries

[0057] The efficient reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries includes the following steps:

[0058] S1: Waste battery pretreatment and performance evaluation

[0059] S1.1: Battery health detection system: Use advanced diagnostic tools such as internal resistance test, capacity test, cycle performance test and X-ray imaging technology to comprehensively check the health status of the battery, especially the internal structure and potential damage of the battery. Use standardized battery detection methods to ensure that the test results are accurate and reproducible;

[0060] S1.2: Data analysis and AI prediction: Use artificial intelligence algorithms to analyze the historical usage data and test results of batteries, predict the remaining life and remaining capacity of the batteries, and accurately screen reusable batteries. This helps improve evaluation efficiency and reduce manual errors;

[0061] S1.3: Hierarchical recycling mechanism: Used batteries are classified into different levels according to the health status of the batteries. Batteries with higher levels will be used for cascade utilization, while batteries with lower levels will be dismantled to recycle raw materials or be eliminated;

[0062] S2: Battery repair and reorganization technology

[0063] S2.1: Battery repair system: For batteries with degraded performance, advanced repair technologies are used, such as balanced charging, tab welding repair, and replacement of failed battery cells, to restore some of the battery's performance. In particular, for batteries with more severe capacity attenuation, the battery chemical properties are restored through directional charging and discharging cycles;

[0064] S2.2: Intelligent recombination platform: Design an intelligent battery recombination platform to reasonably combine the repaired batteries according to different specifications, capacities and health conditions. Through intelligent pairing algorithms, ensure that the performance differences of each group of batteries are minimized, and ensure the balance and stability of the entire battery group;

[0065] S2.3: Battery matching and reinforcement: During the reassembly process, considering the performance differences between different batteries, an intelligent control method is used for real-time battery monitoring to ensure the consistent working status of the batteries in the battery pack. For the parallel or series assembly of different batteries, hardware design such as anti-overcharge and over-discharge protection modules are used to ensure the overall safety of the battery pack;

[0066] S3: Intelligent battery management system (BMS) and optimized control

[0067] S3.1: Multi-level battery management system (BMS): By optimizing the battery management system (BMS), accurate monitoring and control of the battery pack can be achieved. BMS can detect important parameters such as battery voltage, temperature, internal resistance, and charging status in real time, and adjust the charging and discharging strategy through intelligent algorithms to optimize the battery efficiency;

[0068] S3.2: Thermal management system: To avoid safety hazards caused by battery overheating, an efficient thermal management system is designed, using liquid cooling or air cooling technology to keep the temperature of the battery pack within a safe range. The thermal state of the battery is monitored in real time through a temperature sensor, and the thermal management strategy is automatically adjusted;

[0069] S3.3: Intelligent balanced charging: Intelligent balanced technology is used to ensure that the voltage and capacity of each battery cell remain consistent. Through dynamic balanced current control, it prevents a battery cell from overcharging or over-discharging and causing the entire battery pack to fail;

[0070] S4: Safe energy storage control technology

[0071] S4.1: Intelligent early warning system: By integrating sensors and IoT technology, various safety indicators of the battery pack (such as temperature, voltage, depth of discharge, etc.) are monitored in real time. When an abnormality occurs, the system can automatically alarm and take corresponding protective measures, such as automatically disconnecting the battery pack, adjusting the charging and discharging strategy, etc.

[0072] S4.2: Fault self-diagnosis and self-repair: Integrated self-diagnosis technology detects internal faults of the battery pack in real time, and isolates or replaces faulty battery cells through the system self-repair function. By enhancing the fault identification and recovery capabilities of the battery pack, the reliability and sustainability of the entire system are improved;

[0073] S4.3: Isolation and protection mechanism: Design a redundant battery pack protection mechanism. When a battery unit fails, the system can automatically disconnect and isolate the failed unit to ensure the normal operation of other battery units and avoid a single battery failure causing the entire system to crash.

[0074] S5: Integration and optimization of cascaded energy storage systems

[0075] S5.1: Modular energy storage system: Design a modular energy storage system so that the energy storage equipment for the cascade utilization of waste batteries can be flexibly expanded and adjusted according to demand. Each energy storage unit can operate independently or be combined with other units to form a large energy storage system, improving the flexibility and maintainability of the system;

[0076] S5.2: Intelligent scheduling and optimization algorithm: Use intelligent scheduling algorithms to optimize the energy storage system in real time, so that the battery pack can be charged and discharged according to the grid demand or the fluctuation of renewable energy. The optimization algorithm can dynamically adjust the battery's working mode according to factors such as battery health, temperature, and charging and discharging efficiency, thereby improving the overall efficiency of the energy storage system;

[0077] S5.3: Grid regulation and power feedback: Through two-way interaction with the grid, the grid regulation system is designed so that the energy storage system of waste battery recycling can not only provide power storage services for the grid, but also feed back power to the grid when the grid load is low, further improving the stability of the grid;

[0078] S6: Environmentally friendly and sustainable design

[0079] S6.1: Green recycling and waste treatment: Strengthen the green recycling technology of used batteries, design environmentally friendly recycling channels, and avoid used batteries entering landfills or being illegally disposed of, thereby polluting the environment. Design efficient disassembly processes to ensure that harmful substances in used batteries are effectively recycled and reduce environmental pollution;

[0080] S6.2: Life Cycle Assessment: Conduct a life cycle assessment (LCA) of the entire battery recycling system to ensure that the environmental impact of the technology is minimized and the goal of sustainable development is achieved.

[0081] Specifically, step S1 includes an internal resistance test: use a precision battery internal resistance tester to test the internal resistance of the battery. An increase in internal resistance usually means a decrease in battery performance. The health of the battery is determined based on the internal resistance value. Capacity test: measure the actual capacity of the battery through a standard charge and discharge test (such as a C / 5 discharge or C / 10 discharge test), compare the difference with the initial design capacity, and evaluate whether the battery is suitable for cascade utilization. Cycle performance test: perform multiple charge and discharge cycle tests to check the cycle stability and degree of decay of the battery. Use professional battery testing equipment to simulate the actual performance of the battery in long-term use. X-ray imaging technology: use high-resolution X-ray imaging technology to perform non-destructive testing on the inside of the battery to identify whether there are cracks, short circuits, diaphragm damage, etc. inside the battery. It also includes the establishment of a database: collect historical usage data of batteries of different brands and models, including information such as the number of charges, charging cycles, battery temperature changes, and depth of discharge. AI algorithm training: use machine learning (such as support vector machines, neural networks, etc.) algorithms to train prediction models. Through known battery health status data, the algorithm can predict future performance changes and remaining life of the battery. Real-time data monitoring: Combine the real-time data of the battery (temperature, voltage, current, internal resistance, etc.) with the AI ​​model to make real-time predictions and timely evaluate the health status of the battery. Battery grading: According to the health status of the battery, it is divided into different levels (such as A, B, and C) according to its usable life. A-level batteries can be directly used for cascade utilization, B-level batteries need to be repaired or adjusted appropriately, and C-level batteries are used for recycling or disassembly. Grading storage and management: Establish independent storage areas for batteries of different levels, and ensure that no battery damage or leakage occurs during storage.

[0082] Specifically, the battery repair in step S2 includes balanced charging: for batteries with performance degradation, balanced charging technology is used. During the charging process, different charging currents are provided to each battery cell to ensure that each cell reaches the optimal charging state. Pole ear welding repair: for battery cells with poor internal contact, laser welding technology is used to repair the pole ears (the positive and negative connection parts of the battery) to ensure that the battery cells are in good contact and avoid battery damage caused by poor contact. Failed cell replacement: If the battery cell is obviously damaged or performance degraded, the battery can be repaired by replacing the cell. Use battery cells of the same specifications to replace the failed cells and perform battery balancing. Battery reorganization algorithm: Develop an optimized pairing algorithm based on battery health status, battery capacity, internal resistance and voltage differences. By calculating the optimized combination, batteries with similar performance are paired together to reduce the performance differences between batteries. Modular reorganization: According to the battery health status and target applications (such as home energy storage, commercial energy storage, etc.), battery cells are combined into multiple modules. The capacity, internal resistance and voltage differences of the battery cells of each module should be minimized. Mechanized assembly and testing: The reorganized battery pack is automatically assembled using a mechanized platform to ensure that each battery cell is connected in the correct state, and automatic online testing is performed to ensure that there are no failed cells. Hardware reinforcement: The connection points of the battery cells are reinforced with high-strength materials (such as copper alloys, battery welding brackets, etc.) to avoid poor contact caused by vibration or temperature changes during the use of the battery pack. Performance difference detection: The performance of each battery cell is monitored in real time through high-precision sensors and battery management systems (BMS). Once a cell is found to be abnormal, it is immediately isolated or replaced.

[0083] Specifically, in step S3, real-time monitoring: the voltage, temperature, current and other data of the battery pack are collected through sensors, and the BMS monitors the health status of the battery in real time. The data is uploaded to the cloud platform through the wireless communication module for remote monitoring. Battery balancing: The BMS has a built-in battery balancing algorithm that can automatically adjust the charging current to ensure that the voltage of each battery cell is consistent and avoid overcharging or over-discharging of a single battery cell. Data storage and analysis: The battery usage data and performance data are stored in the database for subsequent data analysis and optimization. Combined with AI algorithms, long-term performance prediction is performed. Liquid cooling system: A liquid cooling system is designed to provide uniform temperature control for the battery pack. The coolant is circulated through the pump system to take away the heat in the battery pack to ensure that the battery remains within a safe temperature range during the charging and discharging process. Temperature sensor: Multiple temperature sensors are installed inside and outside the battery pack to monitor the temperature of the battery in real time, and the working state of the cooling system is automatically adjusted through the BMS. Dynamic balanced charging control: The charging current is dynamically adjusted according to the actual voltage and health status of the battery cell. For cells with lower voltage, the charging current is increased; for cells with higher voltage, the charging current is reduced to ensure that the battery pack remains balanced during the charging process.

[0084] Specifically, in step S4, the abnormality detection algorithm: develop a real-time monitoring algorithm. When the battery pack has abnormalities such as over-temperature, over-voltage, over-current, over-discharge, etc., the system automatically alarms and takes corresponding measures (such as power off, restart, start cooling system, etc.). IoT integration: through the Internet of Things technology, the status of the battery pack is uploaded to the cloud platform for analysis in real time. The cloud platform combines historical data with current data to provide timely warnings and safety recommendations. Fault detection and isolation: use high-precision sensors to detect the health status of each cell in the battery pack and determine the type of fault of the battery cell in real time. When a faulty cell is found, it is automatically isolated through the BMS system to ensure the overall stable operation of the battery pack. Automatic repair mechanism: for minor battery cell faults, the BMS system can automatically adjust the working state of the battery cell and repair the faulty cell by reducing the charging current or adjusting the temperature. Physical isolation design: design a physical isolation structure for each battery cell to ensure that when a battery cell fails, the fault is not transmitted to other battery cells. Protection circuit design: design protection circuits, such as over-current protection, over-voltage protection, short-circuit protection, etc., to deal with extreme situations and avoid fire or explosion of the battery pack.

[0085] Through the above technical solutions, in the present invention, by optimizing multiple links such as battery evaluation, repair, reorganization, management, and safety control, not only the utilization efficiency of the battery is improved, but also the safety and stability of the system are enhanced. In addition, the intelligent battery management system and thermal management technology can ensure the long-term safe operation of the battery pack, while modularization and intelligent scheduling technology can improve the flexibility and economy of the energy storage system, thereby promoting the widespread application of waste battery cascade utilization technology.

[0086] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. Efficient reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries, characterized by: The following steps are involved: S1: Waste battery pretreatment and performance evaluation S1.1: Battery health detection system: Use advanced diagnostic tools such as internal resistance test, capacity test, cycle performance test and X-ray imaging technology to comprehensively check the health status of the battery, especially the internal structure of the battery and potential damage. Use standardized battery testing methods to ensure accurate and reproducible test results; S1.2: Data analysis and AI prediction: Use artificial intelligence algorithms to analyze the historical usage data and test results of batteries, predict the remaining life and remaining capacity of the batteries, and accurately screen reusable batteries. This helps improve evaluation efficiency and reduce manual errors; S1.3: Hierarchical recycling mechanism: Used batteries are classified into different levels according to the health status of the batteries. Batteries with higher levels will be used for cascade utilization, while batteries with lower levels will be dismantled to recycle raw materials or be eliminated; S2: Battery repair and reorganization technology S2.1: Battery repair system: For batteries with degraded performance, advanced repair technologies are used, such as balanced charging, tab welding repair, and replacement of failed battery cells, to restore some of the battery's performance. In particular, for batteries with more severe capacity attenuation, the battery's chemical properties are restored through directional charging and discharging cycles; S2.2: Intelligent recombination platform: Design an intelligent battery recombination platform to reasonably combine the repaired batteries according to different specifications, capacities and health conditions. Through intelligent pairing algorithms, ensure that the performance differences of each group of batteries are minimized, and ensure the balance and stability of the entire battery group; S2.3: Battery matching and reinforcement: During the reassembly process, considering the performance differences between different batteries, an intelligent control method is used for real-time battery monitoring to ensure the consistent working status of the batteries in the battery pack. For the parallel or series assembly of different batteries, hardware design such as anti-overcharge and over-discharge protection modules are used to ensure the overall safety of the battery pack; S3: Intelligent battery management system (BMS) and optimized control S3.1: Multi-level battery management system (BMS): By optimizing the battery management system (BMS), accurate monitoring and control of the battery pack can be achieved. BMS can detect important parameters such as battery voltage, temperature, internal resistance, and charging status in real time, and adjust the charging and discharging strategy through intelligent algorithms to optimize the battery efficiency; S3.2: Thermal management system: To avoid safety hazards caused by battery overheating, an efficient thermal management system is designed, using liquid cooling or air cooling technology to keep the temperature of the battery pack within a safe range. The thermal state of the battery is monitored in real time through a temperature sensor, and the thermal management strategy is automatically adjusted; S3.3: Intelligent balanced charging: Intelligent balanced technology is used to ensure that the voltage and capacity of each battery cell remain consistent. Through dynamic balanced current control, it prevents a battery cell from overcharging or over-discharging and causing the entire battery pack to fail; S4: Safe energy storage control technology S4.1: Intelligent early warning system: By integrating sensors and IoT technology, various safety indicators of the battery pack (such as temperature, voltage, depth of discharge, etc.) are monitored in real time. When an abnormality occurs, the system can automatically alarm and take corresponding protective measures, such as automatically disconnecting the battery pack, adjusting the charging and discharging strategy, etc. S4.2: Fault self-diagnosis and self-repair: Integrated self-diagnosis technology detects internal faults of the battery pack in real time, and isolates or replaces faulty battery cells through the system self-repair function. By enhancing the fault identification and recovery capabilities of the battery pack, the reliability and sustainability of the entire system are improved; S4.3: Isolation and protection mechanism: Design a redundant battery pack protection mechanism. When a battery unit fails, the system can automatically disconnect and isolate the failed unit to ensure the normal operation of other battery units and avoid a single battery failure causing the entire system to crash. S5: Integration and optimization of cascaded energy storage systems S5.1: Modular energy storage system: Design a modular energy storage system so that the energy storage equipment for the cascade utilization of waste batteries can be flexibly expanded and adjusted according to demand. Each energy storage unit can operate independently or be combined with other units to form a large energy storage system, improving the flexibility and maintainability of the system; S5.2: Intelligent scheduling and optimization algorithm: Use intelligent scheduling algorithms to optimize the energy storage system in real time, so that the battery pack can be charged and discharged according to the grid demand or the fluctuation of renewable energy. The optimization algorithm can dynamically adjust the battery's working mode according to factors such as battery health, temperature, and charging and discharging efficiency, thereby improving the overall efficiency of the energy storage system; S5.3: Grid regulation and power feedback: Through two-way interaction with the grid, the grid regulation system is designed so that the energy storage system of waste battery recycling can not only provide power storage services for the grid, but also feed back power to the grid when the grid load is low, further improving the stability of the grid; S6: Environmentally friendly and sustainable design S6.1: Green recycling and waste treatment: Strengthen the green recycling technology of used batteries, design environmentally friendly recycling channels, and avoid used batteries entering landfills or being illegally disposed of, thereby polluting the environment. Design efficient disassembly processes to ensure that harmful substances in used batteries are effectively recycled and reduce environmental pollution; S6.2: Life Cycle Assessment: Conduct a life cycle assessment (LCA) of the entire battery recycling system to ensure that the environmental impact of the technology is minimized and the goal of sustainable development is achieved.

2. The high-efficiency reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries according to claim 1 is characterized by: The step S1 includes an internal resistance test: using a precise battery internal resistance tester to test the internal resistance of the battery. An increase in internal resistance usually means a decrease in battery performance. The health of the battery is determined based on the internal resistance. Capacity test: through standard charge and discharge tests (such as C / 5 discharge or C / 10 discharge tests), the actual capacity of the battery is measured, and the difference between the actual capacity and the initial design capacity is compared to evaluate whether the battery is suitable for cascade utilization. Cycle performance test: multiple charge and discharge cycle tests are performed to check the cycle stability and decay degree of the battery. Use professional battery testing equipment to simulate the actual performance of the battery in long-term use. X-ray imaging technology: Use high-resolution X-ray imaging technology to perform non-destructive testing on the inside of the battery to identify whether there are cracks, short circuits, diaphragm damage, etc. inside the battery. It also includes the establishment of a database: collect historical usage data of batteries of different brands and models, including the number of charges, charging cycles, battery temperature changes, discharge depth and other information. AI algorithm training: Use machine learning (such as support vector machines, neural networks, etc.) algorithms to train prediction models. Through known battery health status data, the algorithm can predict future performance changes and remaining life of the battery. Real-time data monitoring: Combine the real-time data of the battery (temperature, voltage, current, internal resistance, etc.) with the AI ​​model for real-time prediction and timely evaluation of the health status of the battery. Battery grading: According to the health status of the battery, it is divided into different levels (such as A, B, and C) according to its available life. A-level batteries can be directly used for cascade utilization, B-level batteries need to be repaired or appropriately adjusted, and C-level batteries are used for recycling or disassembly. Grading storage and management: Establish independent storage areas for batteries of different levels and ensure that no battery damage or leakage occurs during storage.

3. The high-efficiency reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries according to claim 1 is characterized by: The battery repair in step S2 includes balanced charging: for batteries with performance degradation, balanced charging technology is used. During the charging process, different charging currents are provided to each battery cell to ensure that each cell reaches the optimal charging state. Pole ear welding repair: for battery cells with poor internal contact, laser welding technology is used to repair the pole ears (the positive and negative connection parts of the battery) to ensure that the battery cells are in good contact and avoid battery damage caused by poor contact. Failed cell replacement: if the battery cell is obviously damaged or performance degradation occurs, the battery can be repaired by replacing the cell. Use battery cells of the same specifications to replace the failed cells and perform battery balancing. Battery reorganization algorithm: Develop an optimized pairing algorithm based on battery health status, battery capacity, internal resistance and voltage differences. By calculating the optimized combination, batteries with similar performance are paired together to reduce the performance differences between batteries. Modular reorganization: According to the battery health status and target applications (such as home energy storage, commercial energy storage, etc.), battery cells are combined into multiple modules. The capacity, internal resistance and voltage differences of the battery cells of each module should be minimized. Mechanized assembly and testing: The reorganized battery pack is automatically assembled using a mechanized platform to ensure that each battery cell is connected in the correct state, and automatic online testing is performed to ensure that there are no failed cells. Hardware reinforcement: The connection points of the battery cells are reinforced with high-strength materials (such as copper alloys, battery welding brackets, etc.) to avoid poor contact caused by vibration or temperature changes during the use of the battery pack. Performance difference detection: The performance of each battery cell is monitored in real time through high-precision sensors and battery management systems (BMS). Once a cell is found to be abnormal, it is immediately isolated or replaced.

4. The high-efficiency reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries according to claim 1 is characterized by: Real-time monitoring in step S3: The voltage, temperature, current and other data of the battery pack are collected by sensors, and the BMS monitors the health status of the battery in real time. The data is uploaded to the cloud platform through the wireless communication module for remote monitoring. Battery balancing: The BMS has a built-in battery balancing algorithm, which can automatically adjust the charging current to ensure that the voltage of each battery cell is consistent and avoid overcharging or over-discharging of a single battery cell. Data storage and analysis: The battery usage data and performance data are stored in the database for subsequent data analysis and optimization. Combined with the AI ​​algorithm, long-term performance prediction is performed. Liquid cooling system: A liquid cooling system is designed to provide uniform temperature control for the battery pack. The coolant is circulated through the pump system to take away the heat in the battery pack to ensure that the battery remains within a safe temperature range during the charging and discharging process. Temperature sensor: Multiple temperature sensors are installed inside and outside the battery pack to monitor the temperature of the battery in real time, and the working state of the cooling system is automatically adjusted through the BMS. Dynamic balanced charging control: The charging current is dynamically adjusted according to the actual voltage and health status of the battery cell. For cells with lower voltage, the charging current is increased; for cells with higher voltage, the charging current is reduced to ensure that the battery pack remains balanced during the charging process.

5. The high-efficiency reorganization and safe energy storage control technology for the cascade utilization of waste new energy batteries according to claim 1 is characterized by: Abnormal detection algorithm in step S4: develop a real-time monitoring algorithm. When the battery pack has abnormalities such as over-temperature, over-voltage, over-current, over-discharge, etc., the system automatically alarms and takes corresponding measures (such as power off, restart, start cooling system, etc.). IoT integration: through the Internet of Things technology, the status of the battery pack is uploaded to the cloud platform for analysis in real time. The cloud platform combines historical data with current data to provide timely warnings and safety suggestions. Fault detection and isolation: use high-precision sensors to detect the health status of each unit in the battery pack and determine the fault type of the battery unit in real time. When a faulty unit is found, it is automatically isolated through the BMS system to ensure the overall stable operation of the battery pack. Automatic repair mechanism: for minor battery unit failures, the BMS system can automatically adjust the working state of the battery unit and repair the faulty unit by reducing the charging current or adjusting the temperature. Physical isolation design: design a physical isolation structure for each battery unit to ensure that when a battery unit fails, the fault is not transmitted to other battery units. Protection circuit design: design protection circuits, such as over-current protection, over-voltage protection, short-circuit protection, etc., to deal with extreme situations and avoid fire or explosion of the battery pack.