Battery safety control system and method and pure electric mine car
By collecting the battery temperature, current and cooling power, and combining the convective heat exchange coefficient to judge the battery safety degree, the problem of inaccurate judgment of battery safety in the prior art is solved, and effective prediction and prevention measures for battery safety are achieved.
Patent Information
- Application Number
- CN202510479986.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-17
- Publication Date
- 2025-06-27
AI Technical Summary
The prior art is difficult to accurately judge the safety of the battery, resulting in a failure or accident caused by abnormal temperature of the battery.
By collecting the battery temperature, current and cooling power of the thermal management system, and combining the convection heat transfer coefficient, the battery temperature at the next moment is predicted, the battery safety degree is judged, and corresponding safety operations are performed based on the estimated safety degree.
It has achieved the advance prediction of the battery safety status in advance and timely preventive measures to avoid battery failure or accidents caused by abnormal temperatures, and ensure the normal operation of the vehicle.
Smart Images
Figure CN120207118A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of mining machinery, and particularly to a battery safety control system, method and pure electric mining truck. Background Art
[0002] Mining dump trucks play a very important role in the process of engineering construction and resource development, and are one of the key equipment for earthwork construction and open-pit mine mining. With the continuous development of new energy technologies, pure electric mining dump trucks have emerged as the times require. They not only conform to the current development concept of green mining, but also provide a new solution for building an environment-friendly green mine.
[0003] As a key component of pure electric mining trucks, the safety of the battery box has always been the focus of the industry. Under abnormal usage conditions such as overcharging, overheating, impact, and short circuit, the temperature of the battery rises abnormally, which will trigger a series of chemical reactions inside the battery. These reactions will not only cause phenomena such as battery swelling, smoking, and the opening of the safety valve, but also release a large amount of heat, further increasing the temperature of the entire battery. As the temperature continues to rise, each chemical reaction becomes more intense, and the battery temperature rises uncontrollably and rapidly, ultimately possibly causing combustion or explosion, resulting in serious safety accidents.
[0004] Therefore, accurately judging the battery safety level and taking corresponding measures based on the safety level are crucial for avoiding the occurrence of serious safety accidents. Summary of the Invention
[0005] In order to solve the technical problems existing in the prior art, a first aspect of this application provides a battery safety control method, including the following steps: Step S1: Obtain the current temperature and current of the battery, obtain the current cooling power of the thermal management system, and send them to the vehicle controller; Step S2: Obtain the corresponding convective heat transfer coefficient based on the current temperature and current of the battery and the current cooling power of the thermal management system; Step S3: Calculate the battery temperature at the next moment based on the convective heat transfer coefficient; Step S4: Judge the battery safety level based on the battery temperature at the next moment. Among them, the battery safety level judgment includes: judging whether the battery temperature at the next moment is greater than or equal to the third threshold. If so, perform the third-level vehicle safety operation through the vehicle controller. If not, continue to judge whether the battery temperature at the next moment is greater than or equal to the second threshold. If so, perform the second-level vehicle safety operation through the vehicle controller. If not, continue to judge whether the battery temperature at the next moment is greater than or equal to the first threshold. If so, perform the first-level vehicle safety operation through the vehicle controller. If not, end the judgment.
[0006] Further, in step S4, the third-level vehicle safety operation includes the display instrument emitting a red light alarm and prompting for a parking inspection and repair. At the same time, a five-minute countdown for powering off the high voltage is started when parking. After the countdown ends, the vehicle controller controls the high voltage control box to perform the operation of powering off the high voltage. The second-level vehicle safety operation includes the display instrument emitting a yellow light alarm and prompting the driver to stop and rest and then restart. The first-level vehicle safety operation includes the vehicle controller sending CAN bus information to the battery thermal management system to increase the cooling power.
[0007] Further, before step S1, there is also step S0 of establishing a convective heat transfer coefficient set. The establishment of the convective heat transfer coefficient set includes: recording the battery temperature values, battery currents, and cooling powers of the thermal management system at different times during the whole process of charging the SOC from 0% to 100% multiple times, and recording the battery temperature values, battery currents, and cooling powers of the thermal management system at different times and working conditions during the whole process of vehicle driving multiple times; using the data samples of the battery temperature values, battery currents, and cooling powers of the thermal management system to perform data fitting by the least squares method to obtain the convective heat transfer coefficient set.
[0008] Further, in step S3, the battery temperature at the next moment is calculated using the following formula: T next =T current +(I 2 *R internal -P cool )*Δt / m*C*k, where, T next is the battery temperature at the next moment (°C), T current is the current battery temperature (°C), I is the battery current (A), positive for charging and negative for discharging, R internal is the internal resistance of the battery (Ω), P cool is the cooling power of the thermal management system (W), Δt is the time step (seconds), m is the battery mass (kg), C is the specific heat capacity of the battery (J / (kg·°C)), k is the convective heat transfer coefficient.
[0009] The second aspect of the present application provides a battery safety control system for implementing the battery safety control method described in any one of the above, including a battery management system, a thermal management system, an instrument system, a vehicle controller, and a high voltage control box. The battery management system is used to monitor the current, voltage and temperature of the battery in real time, and perform data interaction with the vehicle controller through the CAN communication module; The thermal management system is used to adjust the battery operating temperature according to the instructions of the vehicle controller, and includes a thermal management controller, a cooling water pump, a cooling fan and a plate heat exchanger; The vehicle controller is used to coordinate the operation of the thermal management system, the instrument system and the high-voltage control box according to the data transmitted by the battery management system, and includes a temperature prediction module, a battery safety degree judgment module and a convective heat transfer coefficient determination module; The instrument system is used to display key vehicle information and alarm prompts to the operator; The high-voltage control box is used for the distribution, control and protection of the vehicle's high-voltage electricity.
[0010] Furthermore, the battery management system includes a current acquisition module, a temperature acquisition module and a CAN communication module. Among them, the current acquisition module uses a high-precision Hall current sensor, which is installed in the output circuit of the battery and can monitor the charge and discharge current of the battery in real time.
[0011] Furthermore, the temperature acquisition module includes a plurality of thermistor temperature sensors arranged inside and around the battery.
[0012] The third aspect of the present application provides a pure electric mining truck, including the above battery safety control system.
[0013] Compared with the prior art, the beneficial effects of the present application are: By collecting the battery temperature, current and the cooling power of the thermal management system, and combining the convective heat transfer coefficient, the present application can predict the battery temperature at the next moment. This prediction mechanism enables the vehicle to anticipate the safety state of the battery in advance, take preventive measures in time, and avoid failures or accidents caused by abnormal battery temperature. At the same time, according to the estimated battery safety degree, the system sets three levels of thresholds, corresponding to different safety operations respectively. This hierarchical processing method can not only effectively deal with safety hazards of different levels, but also avoid over-reaction resulting in resource waste or unnecessary shutdowns, ensuring the normal operation of the vehicle. Description of the Drawings
[0014] Figure 1 is a flowchart of the battery safety control method of the present application; Figure 2 is a flowchart of step 4 of the battery safety control method of the present application; Figure 3 is a schematic diagram of the battery safety control system of the present application; Detailed Embodiments
[0015] To facilitate the understanding of this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of this application. Obviously, the described embodiments are only a part of the embodiments of this application, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in this application without making creative efforts belong to the scope of protection of this application.
[0016] Referring to Figure 3 As shown, a battery safety control system provided in this embodiment includes a battery management system (BMS system), a thermal management system, an instrument system, a vehicle controller, and a high-voltage control box.
[0017] The battery management system is used to monitor the current, voltage, and temperature of the battery in real time and perform data interaction with the vehicle controller through the CAN communication module. The thermal management system is used to adjust the battery operating temperature according to the instructions of the vehicle controller, including a thermal management controller, a cooling water pump, a cooling fan, and a plate heat exchanger. The vehicle controller is used to coordinate the work of the thermal management system, the instrument system, and the high-voltage control box according to the data transmitted by the battery management system, including a temperature prediction module, a battery safety degree judgment module, and a convective heat transfer coefficient determination module. The instrument system is used to display key vehicle information and alarm prompts to the operator. The high-voltage control box is used for the distribution, control, and protection of the vehicle's high-voltage electricity.
[0018] Specifically, the battery management system includes a current acquisition module, a voltage acquisition module, a temperature acquisition module and a CAN communication module. Among them, the current acquisition module uses a high-precision Hall current sensor, which is installed in the output circuit of the battery and can monitor the battery's charge and discharge current in real time. During the operation of the mine car, whether it is heavy-loaded uphill or unloaded cruising, the current acquisition module can accurately capture the current changes and provide data support for the subsequent battery status analysis. The voltage acquisition module obtains the voltage signal through the sampling circuit connected to the two ends of the battery cell, and then the high-precision analog-to-digital converter converts the acquired analog voltage signal into a digital signal, and the converted digital signal is transmitted to the vehicle controller. The temperature acquisition module includes multiple thermistor temperature sensors set inside and around the battery. Considering that the heating conditions of the battery in the mine car under different working conditions vary greatly, the high precision and multi-point monitoring capabilities of the temperature acquisition module are crucial. The temperature acquisition module includes a temperature sensor set inside and around the battery that can capture the temperature change trend in time when the mine car is frequently started and stopped or running at high load. The CAN communication module is responsible for packaging and sending the current, voltage, and temperature data collected by the battery management system in accordance with the CAN bus protocol format. At the same time, it can also receive instructions from the vehicle controller to ensure efficient and reliable communication between the battery management system and the vehicle controller.
[0019] In addition, the thermal management system is used to adjust the operating temperature of the battery to ensure that the battery is always within the appropriate operating temperature range, thereby improving the performance and life of the battery. Specifically, the thermal management system includes a thermal management controller, a cooling water pump, a cooling fan and a plate heat exchanger. Among them, the thermal management controller is connected to the vehicle controller to receive instructions from the vehicle controller and accurately control the cooling water pump, cooling fan and other actuators. Preferably, the cooling water pump adopts a high-performance DC brushless water pump, and the cooling water pump is used to extract the coolant from the coolant tank and transport it to the plate heat exchanger through a pipeline to provide power support for battery heat dissipation. During the operation of the mine car, the cooling water pump automatically adjusts the speed according to the instructions of the thermal management controller to adapt to different heat dissipation requirements. The cooling fan is installed in front of the radiator. When the battery temperature rises and heat dissipation needs to be strengthened, the cooling fan is started under the control of the thermal management controller to introduce outside air into the radiator to take away the heat in the coolant. The speed of the cooling fan can be adjusted in multiple levels according to the instructions of the thermal management controller to achieve the best heat dissipation effect and energy saving. The plate heat exchanger is used to achieve heat exchange between the coolant and the outside air or cooling medium through the heat conduction between the metal plates, effectively reducing the battery temperature.
[0020] In addition, the vehicle controller includes a temperature prediction module, a battery safety level judgment module, and a convective heat transfer coefficient determination module. Among them, the convective heat transfer coefficient determination module is used to calculate the current convective heat transfer coefficient through the convective heat transfer coefficient model, in combination with the current temperature, current current of the battery, and the cooling power of the thermal management system. The temperature prediction module is used to predict the battery temperature at the next moment based on the convective heat transfer coefficient. The battery safety level judgment module is used to perform step-by-step judgment according to the safety threshold set in advance based on the battery temperature at the next moment obtained by the temperature prediction module, and quickly trigger the corresponding safety operation process to ensure battery safety.
[0021] The instrument system includes an instrument display, which can clearly and intuitively display various alarm messages.
[0022] The high-voltage control box is used to distribute, control, and protect the vehicle's high-voltage electricity according to the instructions of the vehicle controller.
[0023] Reference Figures 1-2 As shown, the present application also discloses a battery safety control method, including the following steps: Step S1: Obtain the current temperature and current current of the battery, obtain the current cooling power of the thermal management system, and send them to the vehicle controller; Step S2: Obtain the corresponding convective heat transfer coefficient based on the current temperature, current current of the battery, and the current cooling power of the thermal management system; Step S3: Calculate the battery temperature at the next moment based on the convective heat transfer coefficient; Step S4: Perform battery safety level judgment based on the battery temperature at the next moment. Among them, the battery safety level judgment includes: judging whether the battery temperature at the next moment is greater than or equal to the third threshold. If so, perform the third-level vehicle safety operation through the vehicle controller. If not, continue to judge whether the battery temperature at the next moment is greater than or equal to the second threshold. If so, perform the second-level vehicle safety operation through the vehicle controller. If not, continue to judge whether the battery temperature at the next moment is greater than or equal to the first threshold. If so, perform the first-level vehicle safety operation through the vehicle controller. If not, end the judgment.
[0024] Specifically, when the battery temperature at the next moment is greater than or equal to the third threshold, it indicates that the battery is in an extremely dangerous overheating state, which may cause serious safety accidents; the vehicle controller immediately sends a red light alarm instruction to the instrument display through the CAN bus and prompts "The battery temperature is too high, please stop for maintenance", and at the same time starts a five-minute countdown for parking and turning off the high voltage. During the countdown, the instrument display shows the remaining time in real time to remind the driver to stop in time; after the countdown ends, the high-voltage control box performs the operation of turning off the high voltage according to the instructions of the vehicle controller, cutting off the connection between the power battery and the vehicle's high-voltage system to ensure the safety of the vehicle and the battery.
[0025] When the battery temperature at the next moment is greater than or equal to the second threshold, it indicates that the battery temperature is relatively high, presenting a certain safety hazard but not yet reaching an extremely dangerous level. At this time, the vehicle controller performs the second-level vehicle safety operation. The vehicle controller sends a yellow light alarm instruction to the instrument display and prompts "The battery temperature is too high. Please park and restart after a break". After receiving the prompt, the driver can choose a suitable location to park the vehicle, let the vehicle and the battery rest for a period of time, and then restart the vehicle after the battery temperature drops. This operation helps to relieve the overheating state of the battery, extend the battery life, and ensure the driving safety of the vehicle.
[0026] When the battery temperature at the next moment is greater than or equal to the first threshold, it indicates that the battery temperature begins to rise and measures need to be taken for prevention. The vehicle controller performs the first-level vehicle safety operation. The vehicle controller sends an instruction to the battery thermal management system through the CAN bus. The cooling water pump and cooling fan in the thermal management system will increase their speeds, increasing the flow rate of the coolant and the air velocity, thereby more effectively removing the heat generated by the battery and preventing the battery temperature from rising further. This hierarchical processing method can not only effectively address safety hazards at different levels but also avoid waste of resources or unnecessary shutdowns caused by overreactions, ensuring the normal operation of the vehicle.
[0027] In some embodiments, before step S1, it further includes step S0: establishing a convective heat transfer coefficient set. Establishing the convective heat transfer coefficient set includes: recording multiple times the battery temperature values, battery currents, and cooling powers of the thermal management system at different moments during the whole process of charging SOC from 0% to 100%, and recording multiple times the battery temperature values, battery currents, and cooling powers of the thermal management system at different moments and working conditions during the whole process of vehicle driving; using the data samples of the battery temperature values, battery currents, and cooling powers of the thermal management system to perform data fitting by the least squares method to obtain the convective heat transfer coefficient set.
[0028] Specifically, performing data fitting by the least squares method includes: sorting and screening the collected data samples to remove abnormal data and noise interference. Then, using the least squares method to perform piecewise fitting on these data. According to different ranges of the battery temperature, current, and cooling power of the thermal management system, the data is divided into multiple interval segments, and the corresponding convective heat transfer coefficients are fitted within each interval segment. For example, in the interval segment where the battery temperature is relatively low, the current is relatively small, and the cooling power of the thermal management system is relatively low, a convective heat transfer coefficient is fitted; in the interval segment where the battery temperature is relatively high, the current is relatively large, and the cooling power is relatively high, another convective heat transfer coefficient is fitted. Through piecewise fitting, the convective heat transfer relationship between the battery and the surrounding environment under different working condition combinations can be more accurately described, improving the accuracy and applicability of the convective heat transfer coefficient.
[0029] By recording and fitting a large amount of battery temperature, current, and cooling power data of the thermal management system during charging and driving, the convective heat transfer coefficient under different working conditions is obtained. This method based on actual data makes the convective heat transfer coefficient more conform to the actual operation of the vehicle, improves the accuracy of battery temperature prediction, and thus enhances the reliability of battery safety estimation.
[0030] In some embodiments, in step S3, the battery temperature at the next moment is calculated using the following formula: T next =T current +(I 2 *R internal -P cool )*Δt / m*C*k, where, T next is the battery temperature at the next moment (°C), T current is the current battery temperature (°C), I is the battery current (A), positive for charging and negative for discharging, R internal is the internal resistance of the battery (Ω), P cool is the cooling power of the thermal management system (W), Δt is the time step (seconds), m is the battery mass (kg), C is the specific heat capacity of the battery (J / (kg·°C)), k is the convective heat transfer coefficient.
[0031] By substituting these parameters into the formula, the temperature value of the battery at the next moment can be accurately calculated, providing a reliable basis for judging the battery safety. For example, when a mining truck is charging rapidly, the battery current is large and the heat generated by the internal resistance is more. At this time, the (IRinternal) term in the formula will increase significantly, resulting in an increase in the predicted battery temperature at the next moment. At the same time, the cooling power Pcool of the thermal management system will also be adjusted according to the actual situation to balance the heat generated by the battery and ensure that the battery temperature is within the safe range. Through this accurate temperature calculation method, abnormal changes in the battery temperature can be detected in time, and corresponding safety measures can be taken in advance to ensure the battery safety and reliable operation of the pure-electric mining truck.
[0032] The present application also discloses a pure-electric mining truck, including the above-mentioned battery safety control system.
[0033] The basic principles, main features and advantages of the present application have been shown and described above. Those skilled in the art should understand that the present application is not limited by the above embodiments, and what is described in the above embodiments and the specification only illustrates the principles of the present application. Without departing from the spirit and scope of the present application, the present application will have various changes and improvements, and these changes and improvements all fall within the scope of the present application claimed. The scope of protection claimed by the present application is defined by the appended claims and their equivalents.
Claims
1. A battery safety control method, characterized in that: The following steps are involved: Step S1, obtaining the current temperature and current current of the battery, obtaining the current cooling power of the thermal management system, and sending them to the vehicle controller; Step S2, obtaining a corresponding convection heat transfer coefficient based on the current temperature and current current of the battery and the current cooling power of the thermal management system; Step S3, calculating the battery temperature at the next moment based on the convection heat transfer coefficient; Step S4, judging the battery safety based on the battery temperature at the next moment, wherein the battery safety judgment includes: judging whether the battery temperature at the next moment is greater than or equal to a third threshold value, if so, performing a third-level vehicle safety operation through the vehicle controller, if not, continuing to judge whether the battery temperature at the next moment is greater than or equal to a second threshold value, if so, performing a second-level vehicle safety operation through the vehicle controller, if not, continuing to judge whether the battery temperature at the next moment is greater than or equal to a first threshold value, if so, performing a first-level vehicle safety operation through the vehicle controller, if not, ending the judgment.
2. The battery safety control method according to claim 1, characterized in that: In step S4, the third-level vehicle safety operation includes the display instrument emitting a red light alarm, prompting the driver to stop for maintenance, and starting a five-minute countdown to stop and lower the high voltage. After the countdown ends, the vehicle controller controls the high-voltage control box to lower the high voltage electricity; the second-level vehicle safety operation includes the display instrument emitting a yellow light alarm, and prompting the driver to stop for a rest and restart. The first-level vehicle safety operation includes the vehicle controller sending CAN bus information to the battery thermal management system to increase the cooling power.
3. The battery safety control method according to claim 1, characterized in that: Before step S1, step S0 is also included, establishing a set of convective heat transfer coefficients, wherein the establishing the set of convective heat transfer coefficients includes: repeatedly recording the battery temperature value, battery current and cooling power of the thermal management system at different times during the entire process of charging SOC from 0% to 100%, and repeatedly recording the battery temperature value, battery current and cooling power of the thermal management system at different times and working conditions during the entire process of vehicle driving; using data samples of the battery temperature value, battery current and cooling power of the thermal management system to perform data fitting using the least squares method to obtain the set of convective heat transfer coefficients.
4. The battery safety control method according to claim 1, characterized in that: In step S3, the battery temperature at the next moment is calculated using the following formula: T next =T current +(I 2 *R internal -P cool )*Δt / m*C*k, where T next is the battery temperature at the next moment (°C), T current is the current battery temperature (°C), I is the battery current (A), charging is positive and discharging is negative, R internal is the internal resistance of the battery (Ω), P cool is the cooling power of the thermal management system (W), Δt is the time step (seconds), m is the mass of the battery (kg), C is the specific heat capacity of the battery (J / (kg·°C)), k is the convective heat transfer coefficient.
5. A battery safety control system for implementing the battery safety control method according to any one of claims 1 to 4, characterized in that: Including battery management system, thermal management system, instrument system, vehicle controller and high-voltage control box, The battery management system is used to monitor the current, voltage and temperature of the battery in real time, and to exchange data with the vehicle controller through the CAN communication module; The thermal management system is used to adjust the battery operating temperature according to the instructions of the vehicle controller, including a thermal management controller, a cooling water pump, a cooling fan and a plate heat exchanger; The vehicle controller is used to coordinate the operation of the thermal management system, the instrument system and the high-voltage control box according to the data transmitted by the battery management system, and includes a temperature estimation module, a battery safety judgment module and a convection heat transfer coefficient determination module; The instrument system is used to display key vehicle information and alarm prompts to the operator; The high voltage control box is used for the distribution, control and protection of the high voltage electricity of the whole vehicle.
6. The battery safety control system according to claim 5, characterized in that: The battery management system includes a current acquisition module, a temperature acquisition module and a CAN communication module, wherein the current acquisition module uses a high-precision Hall current sensor installed in the output circuit of the battery and can monitor the charging and discharging current of the battery in real time.
7. The battery safety control system according to claim 5, characterized in that: The temperature acquisition module includes a plurality of thermistor temperature sensors arranged inside and around the battery.
8. A pure electric mining car, characterized in that: Comprising a battery safety control system as described in any one of claims 5-7.