Integrated host high-voltage box control method

Abstract

The invention discloses an integrated host high-voltage box control method, and relates to the technical field of battery management, an acquisition module, a bidirectional equalization module, a master-slave communication module and a master control module are integrated in a host high-voltage box, an integrated control unit is constructed, and high-performance equalization control of cells in a battery pack is realized; a three-level hierarchical topological structure of an electric core level, a slave control level and a master control level is adopted for control, an acquisition module is connected with a plurality of electric cores through a relay and an acquisition wire harness, a bidirectional equalization module acquires voltage and temperature of the electric cores through an embedded ADC chip and feeds back the voltage and temperature to a master control module in a communication mode, and charge and discharge equalization of the electric cores is executed in combination with a passive equalization circuit and an active equalization circuit; the main control module is internally provided with a multi-core processor, and is used for estimating the health state of the battery and formulating an equalization strategy, and sending an equalization instruction to the bidirectional equalization module, so that point-to-point equalization control of the module and a battery cell is realized; the technical advantages of structure integration, centralized control, balance and high efficiency are achieved, and the system is suitable for energy storage application of new energy automobiles and energy storage systems.

Description

Technical Field

[0001] The present invention relates to the technical field of battery management, and in particular to a method for controlling an integrated host high voltage box. Background Art

[0002] With the rapid development of new energy vehicles and energy storage industries, the performance and life of lithium battery PACK (battery pack) as a core energy storage component directly determine the reliability and economy of the entire vehicle or energy storage equipment. In order to improve the performance of the battery system, the battery management system (Battery Management System, referred to as BMS) has become an indispensable part, mainly used for the collection of battery cell voltage, current, temperature and charge and discharge balance management.

[0003] The equalization technologies widely used in the industry are currently divided into two categories: passive equalization and active equalization.

[0004] Passive balancing mainly consumes the excess electrical energy of high-voltage cells through resistance discharge to achieve consistent voltage of each cell. Although this method has a simple circuit structure and low cost, it has low energy utilization and poor efficiency in high-capacity, high-rate battery packs.

[0005] Active balancing achieves balancing by transferring electric energy or charging low-voltage batteries, which has higher energy utilization rate, but the circuit is complex, the cost is high, and the size is large, making it difficult to integrate into existing structures.

[0006] Currently, most commercial battery systems only support discharge equalization. In actual applications, when some battery cells have inconsistent power due to manufacturing differences or different working conditions, it is impossible to restore the overall consistency by actively replenishing energy. In the long run, this will aggravate capacity loss and affect the overall battery capacity and service life of the entire battery pack.

[0007] In addition, it is difficult for existing slave control modules to realize active balancing function. On the one hand, after adding the active balancing circuit, the volume and weight of the slave control module exceed the allowable range of the battery pack structure. On the other hand, the cost increases significantly, which is not conducive to large-scale low-cost application.

[0008] In terms of BMS system structure, the main control module and the slave control module are often distributed in different positions of the battery pack and are connected by complex wiring harnesses, which not only increases the difficulty of installation and maintenance, but also increases the system failure rate.

[0009] Therefore, the existing battery management system has:

[0010] 1. Redundant architecture and decentralized control: The slave control modules are located at the cells in the battery pack. Their separate layout leads to waste of hardware resources, communication delays, low space utilization, and low system integration.

[0011] 2. Difficulty in achieving active balancing: The existing architecture cannot be compatible with the charge-discharge dual-mode balancing function at low cost. On the slave control module, relying on additional modules to increase charging balance will lead to a sharp increase in the volume and cost of the battery pack.

[0012] 3. Poor system maintainability: The decentralized slave control module and wiring harness design make fault location, module maintenance, and replacement inefficient, difficult to maintain, and the balancing method is single, restricting the full-life cycle management of the battery system.

[0013] In summary, it is found that the existing technology has at least the following technical problems:

[0014] The existing battery management system has technical problems such as a complex battery pack structure, redundant acquisition and control module architectures, lack of integration of passive and active balancing, decentralized control, and low integration. Summary of the Invention

[0015] The purpose of the present invention is to provide an integrated host high-voltage box control method to solve the technical problems of the existing battery management system, such as a complex battery pack structure, redundant acquisition and control module architectures, lack of integration of passive and active balancing, decentralized control, and low integration.

[0016] The many technical effects that can be produced by the preferred technical solutions provided by the present invention are described in detail below.

[0017] To solve the above technical problems, the present invention provides the following technical solutions:

[0018] The present invention provides an integrated host high-voltage box control method, including: Structurally, a collection module, a bidirectional equalization module, a master-slave communication module, and a main control module are installed in the integrated host high-voltage box to form an integrated control unit; and in terms of control, a hierarchical topology structure is adopted, including a cell level, a slave control level, and a main control level. From the main control level to the cell level in sequence, the cells are scanned and monitored, and point-to-point equalization control is performed; at the cell level, each cell of the battery pack is directly connected to the collection module through a collection harness, and the collection module sequentially or selectively connects the cells to the bidirectional equalization module through relays; at the slave control level, the bidirectional equalization module integrates a passive equalization circuit, an active equalization circuit, and an ADC chip is embedded; the passive equalization circuit and the active equalization circuit independently perform charge equalization or discharge equalization on the cells or cell groups through energy consumption or transfer methods such as resistors and capacitors; the relays of the collection module cooperate with the ADC chip to scan multiple cells, for real-time collecting the voltage and temperature of the cells, and directly feedback to the main control module through point-to-point communication of the master-slave communication module; at the main control level, the main control module has a multi-core processor built-in, performs global SOC or SOH estimation on the battery pack, fault diagnosis of a single cell, and generation of an equalization control strategy, communicates with the bidirectional equalization module through the master-slave communication module, and outputs instructions corresponding to the battery state and the equalization control strategy to the bidirectional equalization module, and calls the passive equalization circuit and the active equalization circuit to perform discharge or charge equalization on the cells.

[0019] In one embodiment, when the bidirectional equalization module performs discharge equalization and charge equalization through the passive equalization circuit and the active equalization circuit, the maximum equalization current reaches 5A, and the equalization response time is less than 10ms.

[0020] In one embodiment, based on the real-time state of the cells collected by the bidirectional equalization module, the main control module dynamically generates an equalization control strategy, screens the target cells to be equalized through the priority queue algorithm and arranges the priority order, sequentially generates independent equalization instructions for the target cells, and specifies the energy transfer path of the cells to the bidirectional equalization module; after receiving the equalization instructions, the bidirectional equalization module switches the passive equalization circuit and the active equalization circuit through the built-in H-bridge circuit to switch the equalization mode, and controls the equalization current by adjusting the PWM duty cycle.

[0021] In one embodiment, a plurality of battery cells form a battery cell group; the balancing strategy includes: primary balancing: when the voltage difference between adjacent battery cells is greater than 10 mV, the bidirectional balancing module autonomously starts discharging or charging balancing of local battery cells without the intervention of the balancing control strategy of the main control module; secondary balancing: when the difference in the estimated SOC data between battery cell groups is greater than 3%, the main control module coordinates the bidirectional balancing module and the acquisition module, and connects a plurality of target battery cells or battery cell groups through a relay to perform energy transfer across battery cells or battery cell groups in cooperation with charging balancing; tertiary balancing: at the tail stage of the charging or discharging cycle, the main control module starts global balancing, performs energy transfer across battery cells or battery cell groups, and makes the voltage levels of the battery cells or battery cell groups in the battery pack consistent through charging balancing.

[0022] In one embodiment, the energy transfer paths include between battery cell - battery cell, between battery cell group - battery cell group, between battery cell - resistor or capacitor - battery cell, between battery cell group - resistor or capacitor - battery cell group, between battery cell - resistor or capacitor - battery cell group, and between battery cell group - resistor or capacitor - battery cell.

[0023] In one embodiment, multiple layers are provided inside the integrated mainframe high - voltage box, including a battery cell connection layer arranged from bottom to top. The battery cell connection layer is equipped with an acquisition module, and the acquisition module is provided with an acquisition wire harness interface; a wire harness connection port is arranged on the outer wall of the integrated mainframe high - voltage box, and the acquisition wire harness interface is arranged at a corresponding position of the wire harness connection port, and the acquisition wire harness is inserted into the acquisition wire harness interface; a slave control layer, in which a bidirectional balancing module is installed. The bidirectional balancing module and the acquisition module are connected to the master - slave communication module through pins and sockets; a master control layer, in which a power management unit and a main control module are installed. The main control module is connected to the master - slave communication module through pins and sockets, the main control module and the power management unit are connected through a bus, and the power management unit exchanges information and provides independent power supply with the main control module; the main control module exchanges information and provides independent power supply with the master - slave communication module and the bidirectional balancing module, and the bidirectional balancing module exchanges information and provides independent power supply with the acquisition module; the power management unit is electrically connected to the input and output ends of the battery pack, and the power management unit regulates the input and output of the battery pack according to the estimated global SOC or SOH data of the battery pack fed back by the main control module.

[0024] In one embodiment, the acquisition wire harness is composed of an FPC circuit board and a connector. Connectors are connected to both ends of the FPC circuit board, and the two connectors are respectively connected to the battery cell and the acquisition wire harness interface.

[0025] In one embodiment, each acquisition harness interface supports hot-plugging to disconnect or connect the acquisition harness; when hot-plugging the acquisition harness, the relay corresponding to the acquisition harness interface on the acquisition module automatically disconnects, so that the connection path between the battery cells corresponding to the hot-plugged acquisition harness in the acquisition module and the bidirectional equalization module is synchronously disconnected, giving the bidirectional equalization module the status information of the corresponding battery cell being offline. The bidirectional equalization module transmits the status information of the corresponding battery cell being offline to the main control module, and the main control module feeds it back to the power management unit, enabling the power management unit to adjust the power management data.

[0026] In one embodiment, multiple bidirectional equalization modules are provided in the slave control layer, and the multiple bidirectional equalization modules are electrically connected to the master-slave communication module; the main control module periodically scans the health status of the currently used bidirectional equalization module. When it detects that the currently used bidirectional equalization module fails, it automatically switches to the standby bidirectional equalization module through the master-slave communication module, realizing the automatic replacement of the bidirectional equalization module, marking the position of the faulty bidirectional equalization module, and feeding back the fault information of the bidirectional equalization module to the power management unit; redundant pin socket slots are reserved on the master-slave communication module, supporting the expansion of the bidirectional equalization module or the acquisition module, and isolating the faulty module.

[0027] In one embodiment, the main control module is software-compatible with the battery cell types through a built-in algorithm and automatically configures the equalization strategy algorithm for the connected battery cell types.

[0028] The beneficial effects of the present invention are as follows:

[0029] Through the integrated host high-voltage box control method, with the dual optimization of the structure and the control method, the following multiple technical effects are achieved:

[0030] (1) High structural integration degree and simplified system architecture: Integrating the acquisition module, the bidirectional equalization module, the master-slave communication module, and the main control module into the high-voltage box to form a compact control unit, reducing the dispersion of multiple slave control modules in each battery cell or battery cell group in the battery pack in the traditional battery management system, reducing the complexity of the battery pack and the battery management system, and avoiding the structural redundancy of the battery pack.

[0031] (2) Achieving efficient bidirectional equalization control: The bidirectional equalization module integrates a passive equalization circuit and an active equalization circuit, and can independently perform charge equalization and discharge equalization. The equalization current can reach 5A, and the response time is less than 10ms, improving the energy balance efficiency between battery cells and extending the overall life of the battery cells and the battery pack.

[0032] (3) The hierarchical topology structure improves the control accuracy: Adopting the hierarchical topology structure of the battery cell level, the slave control level, and the master control level, realizing the hierarchical control from the master control level to the battery cell level, being able to perform precise scanning monitoring and point-to-point equalization control on the battery cells, and improving the control accuracy and response speed of the system.

[0033] (4) Modular structure enhances maintainability: The acquisition module and the bidirectional equalization module adopt standardized interfaces. The acquisition module is connected to the battery cells through an acquisition harness, supporting hot-swap replacement, which is convenient for maintenance and upgrade. During maintenance, it is not necessary to open the battery pack to repair and replace the acquisition module, bidirectional equalization module, and main control module, reducing system downtime and improving maintainability.

[0034] (5) Optimize the harness design to reduce interference and cost: Using FPC circuit boards and connectors to replace traditional copper cable harnesses can reduce the cable length by 90%, reduce the occupancy of the internal volume of the battery pack, and at the same time reduce the manufacturing cost.

[0035] (6) Intelligent control strategy improves system performance: The main control module is built-in with a multi-core processor, dynamically generating an equalization control strategy based on the real-time state of the battery cells, screening the target battery cells to be equalized through a priority queue algorithm, and specifying the energy transfer path, realizing intelligent energy management.

[0036] (7) Enhance the safety and reliability of the system: The main control module periodically scans the health status of the bidirectional equalization modules at the slave control level, automatically switches to the standby bidirectional equalization module when a fault is detected, and marks the location of the faulty module, enhancing the fault tolerance and reliability of the system operation.

[0037] In summary, through structural integration, control optimization, and intelligent management, the present invention significantly improves the performance, reliability, and maintainability of the battery management system. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions of the present invention, the drawings required for the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0039] Figure 1 is a schematic structural diagram of the integrated mainframe high-voltage box of the present invention connected to multiple battery cells;

[0040] Figure 2 is a schematic structural diagram of the integrated mainframe high-voltage box of the present invention connected to multiple battery cell groups. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0041] To more clearly understand the integrated host high-voltage box control method of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. It should be understood that these embodiments are only used to illustrate the implementation details of the technical solutions of the present invention, rather than limiting the protection scope of the present invention.

[0042] In the specific embodiments, an integrated host high-voltage box control method is provided. By integrating a collection module, a bidirectional equalization module, a master-slave communication module, and a main control module in the host high-voltage box, an integrated control unit is constructed to achieve high-performance equalization control of the battery cells in the battery pack. In terms of control, a three-level hierarchical topology structure of cell level, slave control level, and main control level is adopted. The collection module is connected to multiple battery cells through a relay and a collection wire harness. The bidirectional equalization module collects the voltage and temperature of the battery cells through an embedded ADC chip and communicates and feeds back to the main control module. Combining passive and active equalization circuits, it performs charge and discharge equalization of the battery cells. The main control module is built-in with a multi-core processor to estimate the battery health state and formulate an equalization strategy, and sends an equalization instruction to the bidirectional equalization module to enable point-to-point equalization control between the module and the battery cells. It realizes the technical advantages of structural integration, control concentration, and high-efficiency equalization, and is applicable to energy storage scenarios of new energy vehicles and energy storage systems. It effectively solves the technical problems existing in the existing battery management system, such as complex battery pack structure, redundant architecture of collection and control modules, lack of integration of passive and active equalization, decentralized control, and low integration degree.

[0043] The first embodiment of the integrated host high-voltage box control method is as Figure 1 and Figure 2 shown. This method is applicable to application scenarios that require refined management of battery PACKs, such as electric vehicle power battery systems and energy storage power station systems. Its core lies in that, structurally, a collection module, a bidirectional equalization module, a master-slave communication module, and a main control module are installed in the integrated host high-voltage box to form a control unit with highly integrated functions; it realizes precise monitoring and equalization control of battery cells or battery cell groups in the high-voltage battery PACK.

[0044] Multiple layers are provided in the integrated host high-voltage box, including, from bottom to top: a battery cell connection layer, on which a collection module is installed, and the collection module is provided with a collection wire harness interface; a wire harness connection port is provided on the outer wall of the integrated host high-voltage box, and the collection wire harness interface is set at the corresponding position of the wire harness connection port, and the collection wire harness is inserted into the collection wire harness interface; the collection module is connected to each battery cell of the battery pack through the collection wire harness of the FPC, and is used to collect the voltage and temperature of the battery cells.

[0045] Specifically, the collection wire harness is composed of an FPC circuit board and a connector. Connectors are connected to both ends of the FPC circuit board, and the two connectors are respectively connected to the battery cell and the collection wire harness interface.

[0046] When in application, the FPC board (Flexible Printed Circuit) replaces the traditional copper cable harness, which can reduce the cable length of the battery cell connection layer from the battery cell to the high-voltage box of the integrated host, and in the circuit, such as on the acquisition module, reduces signal interference through impedance matching design.

[0047] Slave control layer, a two-way equalization module is installed in the slave control layer. The two-way equalization module and the acquisition module are connected to the master-slave communication module through pins and sockets; the two-way equalization module is used to perform discharge or charge equalization operations on the battery cells.

[0048] When in application, the passive equalization circuit consumes the energy of the battery cell through a resistor to equalize the battery cells with a high voltage level; the active equalization circuit transfers energy between the battery cells through capacitive elements, and transfers the energy of the battery cells with a high voltage level to the battery cells with a low voltage level; a single two-way equalization module cooperates with the relay control circuit of the acquisition module to be turned on, and can independently perform point-to-point charge and discharge equalization on multiple battery cells.

[0049] Master control layer, a power management unit and a master control module are installed in the master control layer. The master control module is connected to the master-slave communication module through pins and sockets. The master control module and the power management unit are connected through a bus. The power management unit and the master control module exchange information and are independently powered; the master control module exchanges information and is independently powered with the master-slave communication module and the two-way equalization module, and the two-way equalization module exchanges information and is independently powered with the acquisition module; the power management unit is electrically connected to the input and output terminals of the battery pack. The power management unit regulates the input and output of the battery pack according to the global SOC or SOH estimation data of the battery pack fed back by the master control module.

[0050] When in application, the master control module is embedded with a multi-core processor, which supports the estimation of SOC (State of Charge) and SOH (State of Health) of the entire battery pack, and can diagnose the faults of single battery cells; the master control module exchanges data with the two-way equalization module through the master-slave communication module, and issues the equalization strategy in the form of an equalization instruction.

[0051] Regarding the connection methods of the acquisition module, the master-slave communication module, the master control module, the power management unit and the battery pack, the acquisition module, the two-way equalization module, and the master control module are connected to the master-slave communication module through a standardized pin and socket interface to achieve signal transmission and power supply;

[0052] Bus connection: The master control module and the power management unit communicate through a CAN (Controller Area Network) bus or an I 2 C (Inter-IC) bus to achieve data sharing and power management.

[0053] The total input or total output of the power management unit is electrically connected to external components, and the power management unit is electrically connected to the input and output terminals of the battery pack to achieve the management of the electrical energy exchange between the battery pack and external components.

[0054] The core lies in the control. A hierarchical topology structure is adopted, including the cell level, the slave control level, and the master control level. From the master control level to the cell level in sequence, the cells are scanned and monitored, and point-to-point equalization control is performed on the cells. At the cell level, each cell of the battery pack is directly connected to the acquisition module through a collection harness, and the acquisition module sequentially or selectively connects the cells to the bidirectional equalization module through relays.

[0055] During application, multiple single cells in the battery pack are connected to the acquisition module through an FPC board and a control connector. The acquisition module selectively connects each cell through a relay, forming a control path between the cell and the bidirectional equalization module.

[0056] At the slave control level, the bidirectional equalization module integrates a passive equalization circuit, an active equalization circuit, and an ADC chip is embedded. The passive equalization circuit and the active equalization circuit independently perform charge equalization or discharge equalization on the cells or cell groups through energy consumption or transfer methods such as resistors and capacitors. The relay of the acquisition module cooperates with the ADC chip to scan multiple cells, used to collect the voltage and temperature of the cells in real time, and directly feedback to the master control module through point-to-point communication of the master-slave communication module. At the master control level, the master control module has a multi-core processor built-in, which estimates the global SOC (state of charge) or SOH (state of health) of the battery pack, diagnoses the faults of individual cells, and generates an equalization control strategy. It communicates with the bidirectional equalization module through the master-slave communication module, and issues instructions corresponding to the battery state and equalization control strategy to the bidirectional equalization module, and calls the passive equalization circuit and the active equalization circuit to perform discharge or charge equalization on the cells.

[0057] Among them, the cell group is a cell group composed of multiple cells connected in parallel. The cell group is connected to the acquisition module through a collection harness. The acquisition module sequentially or selectively connects the cells or cell groups to the bidirectional equalization module through relays.

[0058] Specifically, the relay of the acquisition module is a circuit board relay. The ADC chip is an Analog-to-Digital Converter chip.

[0059] When the bidirectional equalization module performs discharge equalization and charge equalization through the passive equalization circuit and the active equalization circuit, the equalization current reaches a maximum of 5A, and the equalization response time is less than 10ms.

[0060] During application, the master control module conducts data interaction with the bidirectional equalization module through the master-slave communication module, and issues the equalization strategy in the form of instructions.

[0061] Regarding the balancing strategy of the above-mentioned main control module and the execution of specific charge and discharge balancing instructions of the bidirectional balancing module: Primary balancing: When the voltage difference between adjacent battery cells is greater than 10 mV, the bidirectional balancing module autonomously starts the discharge or charge balancing of local battery cells without the intervention of the balancing control strategy of the main control module.

[0062] During application, when the bidirectional balancing module detects that the voltage difference between adjacent battery cells is greater than 10 mV, the bidirectional balancing module, through its internal judgment mechanism, autonomously triggers the charge and discharge balancing operation of the relevant battery cells without the intervention of the main control module. The response time is less than 10 ms, and the maximum balancing current reaches 5 A.

[0063] Secondary balancing: When the difference in SOC estimation data between battery cell groups is greater than 3%, the main control module coordinates the bidirectional balancing module and the acquisition module, and connects multiple target battery cells or battery cell groups through a relay to perform charge balancing cooperation and execute the energy transfer across battery cells or battery cell groups.

[0064] Tertiary balancing: At the tail stage of the charge or discharge cycle, the main control module starts global balancing, executes the energy transfer across battery cells or battery cell groups, and makes the voltage levels of the battery cells or battery cell groups in the battery pack consistent through charge balancing.

[0065] During application, the main control module initiates the global balancing program, issues the balancing strategy, and performs voltage equalization operation on the entire battery pack. By executing layer by layer and segment by segment, it ensures that all battery cells or battery cell groups reach the same voltage level.

[0066] Specifically, the main control module dynamically generates a balancing control strategy based on the real-time state of the battery cells collected by the bidirectional balancing module, screens the target battery cells to be balanced through the priority queue algorithm and arranges the priority order, generates independent balancing instructions for the target battery cells in sequence, and specifies the energy transfer path for the battery cells of the bidirectional balancing module; after receiving the balancing instructions, the bidirectional balancing module switches the passive balancing circuit and the active balancing circuit through the built-in H-bridge circuit to switch the balancing mode, and controls the balancing current by adjusting the PWM (pulse width modulation) duty cycle.

[0067] Regarding the above-mentioned energy transfer paths, including but not limited to: between battery cell - battery cell, between battery cell group - battery cell group, between battery cell - resistor or capacitor - battery cell, between battery cell group - resistor or capacitor - battery cell group, between battery cell - resistor or capacitor - battery cell group, between battery cell group - resistor or capacitor - battery cell.

[0068] During application, the energy transfer path is calculated and determined by the main control module, and the connection of the energy path is controlled to be connected or disconnected through the relay of the acquisition module, and the passive balancing circuit and the active balancing circuit of the bidirectional balancing module are used to assist in the energy transfer.

[0069] Regarding the connection between the above-mentioned acquisition harness and the acquisition module, each acquisition harness interface supports hot plugging to disconnect or connect the acquisition harness; when hot plugging the acquisition harness, the relay corresponding to the acquisition harness interface on the acquisition module automatically disconnects, so that the connection path between the battery cells of the acquisition harness with hot plugging in the acquisition module and the bidirectional equalization module is synchronously disconnected, sending the status information of the corresponding battery cells being offline to the bidirectional equalization module. The bidirectional equalization module transmits the status information of the corresponding battery cells being offline to the main control module, and is fed back by the main control module to the power management unit, enabling the power management unit to adjust the power management data.

[0070] Regarding the online replaceable setting of the bidirectional equalization module, multiple bidirectional equalization modules are provided in the slave control layer, and the multiple bidirectional equalization modules are electrically connected to the master-slave communication module; the main control module periodically scans the health status of the currently used bidirectional equalization module. When a fault of the currently used bidirectional equalization module is detected, it automatically switches to the standby bidirectional equalization module through the master-slave communication module, realizing the automatic replacement of the bidirectional equalization module, marking the position of the faulty bidirectional equalization module, and feeding back the fault information of the bidirectional equalization module to the power management unit; redundant pin socket slots are reserved on the master-slave communication module, supporting the expansion of the bidirectional equalization module or the acquisition module, and isolating the faulty module.

[0071] In order for the integrated mainframe high-voltage box to match different types of battery cells, so as to adapt to different types of battery packs, the main control module is soft compatible with the battery cell types through built-in algorithms and automatically configures the equalization strategy algorithm for the connected battery cell types without adjusting the hardware circuit.

[0072] During application, in order to adapt to the access and use of different models of battery cells, the main control module has a built-in battery cell type recognition algorithm; the battery cell type is recognized by detecting the basic electrical parameters of the battery cell, such as internal resistance, voltage curve characteristics, etc.; it can be soft compatible with mainstream battery cell types such as ternary lithium and lithium iron phosphate, and automatically loads the adapted equalization algorithm template according to the battery cell type without manual intervention, enhancing the adaptive scalability and flexibility of the system.

[0073] Through the integrated mainframe high-voltage box control method, with the dual optimization of the structure and the control method, the following multiple technical effects are achieved: high structural integration and simplified system architecture: integrating the acquisition module, the bidirectional equalization module, the master-slave communication module and the main control module into the high-voltage box to form a compact control unit, reducing the dispersion of multiple slave control modules in each battery cell or battery cell group in the battery pack in the traditional battery management system, reducing the complexity of the battery pack and the battery management system, and avoiding the structural redundancy of the battery pack.

[0074] Achieving efficient bidirectional equalization control: The bidirectional equalization module integrates passive equalization circuits and active equalization circuits, and can independently perform charge equalization and discharge equalization, improving the energy balance efficiency between battery cells and extending the overall life of the battery cells and the battery pack.

[0075] Hierarchical topology structure improves control accuracy: Adopting a hierarchical topology structure of cell level, slave control level and master control level, realizing hierarchical control from the master control level to the cell level, enabling precise scanning monitoring and point-to-point equalization control of the cells, and improving the control accuracy and response speed of the system.

[0076] Modular structure enhances maintainability: The acquisition module and the bidirectional equalization module adopt standardized interfaces. The acquisition module is connected to the cells through an acquisition wire harness, supporting hot pluggable replacement, facilitating maintenance and upgrade. During maintenance, it is not necessary to open the battery pack to repair and replace the acquisition module, bidirectional equalization module and master control module, reducing the system downtime and improving the maintainability.

[0077] Optimizing the wire harness design to reduce interference and cost: Using FPC circuit boards and connectors to replace traditional copper cable wire harnesses can reduce the cable length by 90%, reduce the occupation of the internal volume of the battery pack, further reduce the structural redundancy of the battery pack, and at the same time reduce the manufacturing cost.

[0078] Among them, the FPC circuit board and the connector can also be sleeved with bellows for physical signal anti-interference, or reduce signal interference through impedance matching design of the circuit.

[0079] Intelligent control strategy improves system performance: The master control module is built with a multi-core processor, dynamically generating an equalization control strategy based on the real-time state of the cells, screening the target cells to be equalized through a priority queue algorithm, and specifying the energy transfer path, realizing intelligent energy management.

[0080] Enhancing the security and reliability of the system: The master control module periodically scans the health status of the bidirectional equalization modules at the slave control level, automatically switches to the standby bidirectional equalization module when a fault is detected, and marks the location of the faulty module, enhancing the fault tolerance and operation reliability of the system.

[0081] In summary, through structural integration, control optimization and intelligent management, the present invention significantly improves the performance, reliability and maintainability of the battery management system.

[0082] The technical features of the above embodiments can be combined arbitrarily. For the sake of concise description, not all possible combinations of the technical features in the above embodiments are described.

Claims

1. An integrated host high-voltage box control method, characterized in that it includes: Structurally, a collection module, a two-way equalization module, a master-slave communication module, and a main control module are installed in the integrated host high-voltage box to form an integrated control unit; And in terms of control, a hierarchical topology structure is adopted, including the cell level, the slave control level, and the master control level. From the master control level to the cell level in sequence, the cells are scanned and monitored and point-to-point equalization control is performed; At the cell level, each cell of the battery pack is directly connected to the collection module through a collection wire harness, and the collection module sequentially or selectively connects the cells to the two-way equalization module through relays; At the slave control level, the two-way equalization module integrates a passive equalization circuit, an active equalization circuit, and an ADC chip is embedded; the passive equalization circuit and the active equalization circuit independently perform charge equalization or discharge equalization on the cells or cell groups through energy consumption or transfer methods such as resistors and capacitors; The relay of the collection module cooperates with the ADC chip to scan multiple cells, is used to collect the voltage and temperature of the cells in real time, and directly feeds back to the main control module through point-to-point communication of the master-slave communication module; At the master control level, the main control module is built with a multi-core processor, performs global SOC or SOH estimation on the battery pack, fault diagnosis of a single cell, and generates an equalization control strategy. It communicates with the two-way equalization module through the master-slave communication module, and outputs instructions corresponding to the battery state and equalization control strategy to the two-way equalization module, and calls the passive equalization circuit and the active equalization circuit to perform discharge or charge equalization on the cells.

2. The integrated host high-voltage box control method according to claim 1, characterized in that When the two-way equalization module performs discharge equalization and charge equalization through the passive equalization circuit and the active equalization circuit, the equalization current reaches a maximum of 5A, and the equalization response time is less than 10ms.

3. The integrated host high-voltage box control method according to claim 2, characterized in that Based on the real-time state of the cells collected by the two-way equalization module, the main control module dynamically generates an equalization control strategy, screens the target cells to be equalized through the priority queue algorithm and arranges the priority order, and sequentially generates independent equalization instructions for the target cells, and specifies the energy transfer path of the cells to the two-way equalization module; After receiving the equalization instruction, the two-way equalization module switches the passive equalization circuit and the active equalization circuit through the built-in H-bridge circuit to switch the equalization mode, and controls the equalization current by adjusting the PWM duty cycle.

4. The integrated host high-voltage box control method according to claim 3, characterized in that Multiple cells form a cell group; The equalization strategy includes: primary equalization: when the voltage difference between adjacent cells is greater than 10mV, the two-way equalization module independently starts the discharge or charge equalization of local cells without the intervention of the equalization control strategy of the main control module; Secondary equalization: when the difference in SOC estimation data between cell groups is greater than 3%, the main control module coordinates the two-way equalization module and the collection module, and connects multiple target cells or cell groups through relays to cooperate with charge equalization and perform energy transfer across cells or cell groups; Three - level balancing: In the tail stage of the charging or discharging cycle, the main control module initiates global balancing, performs energy transfer across cells or cell groups, and makes the voltage levels of the cells or cell groups in the battery pack consistent through charging balancing.

5. The integrated host high - voltage box control method according to claim 3, wherein The energy transfer paths include between cell - cell, between cell group - cell group, between cell - resistor or capacitor - cell, between cell group - resistor or capacitor - cell group, between cell - resistor or capacitor - cell group, and between cell group - resistor or capacitor - cell.

6. The integrated host high - voltage box control method according to claim 4, wherein The integrated host high - voltage box is provided with multiple layers, including a cell connection layer arranged from bottom to top. The cell connection layer is equipped with a collection module, and the collection module is provided with a collection wire harness interface; a wire harness connection port is arranged on the outer wall of the integrated host high - voltage box, and the collection wire harness interface is arranged at the corresponding position of the wire harness connection port, and the collection wire harness is inserted into the collection wire harness interface; The slave control layer, in which a two - way balancing module is installed. The two - way balancing module and the collection module are connected to the master - slave communication module through pins and sockets. The master control layer, in which a power management unit and a main control module are installed. The main control module is connected to the master - slave communication module through pins and sockets. The main control module and the power management unit are connected by a bus. The power management unit and the main control module conduct information exchange and independent power supply. The main control module conducts information interaction and independent power supply with the master - slave communication module and the two - way balancing module. The two - way balancing module conducts information interaction and independent power supply with the collection module. The power management unit is electrically connected to the input and output terminals of the battery pack. The power management unit regulates the input and output of the battery pack according to the estimated data of the global SOC or SOH of the battery pack fed back by the main control module.

7. The integrated host high - voltage box control method according to claim 6, wherein The collection wire harness is composed of an FPC circuit board and a connector. Connectors are connected to both ends of the FPC circuit board, and the two connectors are respectively connected to the cell and the collection wire harness interface.

8. The integrated host high - voltage box control method according to claim 7, wherein Each collection wire harness interface supports hot - plugging to disconnect or connect the collection wire harness; When hot - plugging the collection wire harness, the relay corresponding to the collection wire harness interface on the collection module automatically disconnects, synchronously disconnecting the connection path between the cell corresponding to the hot - plugged collection wire harness in the collection module and the two - way balancing module, giving the two - way balancing module the state information of the corresponding cell being offline. The two - way balancing module transmits the state information of the corresponding cell being offline to the main control module, and the main control module feeds it back to the power management unit, enabling the power management unit to adjust the power management data.

9. The integrated host high - voltage box control method according to claim 8, wherein Multiple two - way balancing modules are arranged in the slave control layer, and the multiple two - way balancing modules are electrically connected to the master - slave communication module; The main control module periodically scans the health status of the currently used bidirectional equalization module. When a fault is detected in the currently used bidirectional equalization module, it automatically switches to the standby bidirectional equalization module through the master-slave communication module, realizes the automatic replacement of the bidirectional equalization module, marks the position of the faulty bidirectional equalization module, and feeds back the fault information of the bidirectional equalization module to the power management unit; Redundant pin socket slots are reserved on the master-slave communication module, which supports expanding the bidirectional equalization module or the acquisition module, and isolating the faulty module.

10. The integrated host high-voltage box control method according to claim 9, wherein The main control module is software-compatible with the cell type through a built-in algorithm and automatically configures the equalization strategy algorithm for the connected cell type.

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