High-voltage control box, high-voltage control system and energy storage system

Abstract

The invention provides a high-voltage control box, a high-voltage control system and an energy storage system.The high-voltage control box comprises a mounting box and at least two sets of battery control assemblies arranged in the mounting box, and each set of battery control assembly is electrically connected with one battery cluster and used for controlling the battery cluster to work; each set of battery control assembly comprises a battery management unit and a heating source, and the battery management unit is used for monitoring and managing a battery cluster electrically connected with the battery management unit; the battery management units of the at least two sets of battery control assemblies are stacked in the mounting box, and the stacking positions and the heating sources are arranged at intervals. According to the invention, a plurality of battery clusters can be efficiently controlled and managed; according to the high-voltage control box, the battery management units of the at least two sets of battery control assemblies are stacked in the mounting box, so that the space is effectively saved, the integrated design is realized in the high-voltage control box with limited space, the overall framework is simplified, and the cost for controlling a plurality of battery clusters is effectively reduced.

Description

Technical Field

[0001] This application relates to the technical field of high-voltage energy storage batteries, and more particularly, to a high-voltage control box, a high-voltage control system, and an energy storage system. Background Art

[0002] In the existing liquid-cooled energy storage battery system, the high-voltage control box, as a key component of the energy storage system, is a key component for managing and controlling high-voltage current in the energy storage system. It is mainly responsible for current distribution, monitoring, protection, and conversion between battery clusters to ensure the operation of the entire energy storage system under safe and efficient conditions; however, there are certain limitations in the functionality and design of the existing high-voltage control box.

[0003] The existing high-voltage control box can usually only control one cluster of battery packs. This design not only limits the scalability and versatility of the battery energy storage system containing multiple clusters of battery packs, but also increases the cost of the battery energy storage system; moreover, the layout and heat dissipation design inside the box of the existing high-voltage control box are often not satisfactory, resulting in too high a temperature rise inside the box, which may affect the safety and stability of the system.

[0004] In addition, in terms of the internal temperature monitoring of the high-voltage control box, the distribution and accuracy of the temperature sensors in the existing technology are not sufficient to accurately reflect the temperature conditions inside the box, thus affecting the thermal management of the system; the wiring and connection of the external wiring harness of the high-voltage control box are also often not reasonably designed, increasing the complexity of installation and maintenance.

[0005] Application Content

[0006] The main purpose of this application is to provide a high-voltage control box, a high-voltage control system, and an energy storage system to at least solve the problem that the existing high-voltage control box can only control one cluster of battery packs.

[0007] To achieve the above object, according to one aspect of this application, a high-voltage control box is provided, including: an installation box, and at least two sets of battery control components arranged in the installation box. Each set of battery control components is electrically connected to a battery cluster for controlling the operation of the battery cluster; each set of battery control components includes a battery management unit and a heat source. The battery management unit is used to monitor and manage the battery cluster electrically connected to it; the battery management units of at least two sets of battery control components are stacked in the installation box, and the stacking position is spaced from the heat source.

[0008] Further, the heat source includes a fuse, the fuse is located in the installation box, and the stacking position is spaced from the fuses of all battery control components.

[0009] Further, the battery control component further includes a fuse and at least one thermistor. The heat source includes the fuse. The thermistor and the fuse are respectively electrically connected to the battery management unit. The thermistor is used to detect the temperature.

[0010] Further, when there is one thermistor in a set of battery control components, the distance between the thermistor and the fuse in the same set of battery control components is within the range of 20-40 mm, so that the thermistor can measure the temperature of the fuse and the temperature inside the installation box simultaneously.

[0011] Further, when there are at least two thermistors in the battery control component, the distance between one of the thermistors and the fuse is less than 20 mm, so that the thermistor can only measure the temperature of the fuse; and / or, at least one thermistor is a negative temperature coefficient thermistor.

[0012] Further, the high-voltage control box further includes a master switch and a power supply. The power supply is respectively connected to each set of battery control components for supplying power to the battery control components. The master switch is connected to the power supply for simultaneously controlling the opening and closing of each set of battery control components.

[0013] Further, the power supply supplies direct current to the battery control component. The high-voltage control box further includes a diode. The diode is arranged on the direct current circuit where the power supply is connected to the battery control component for preventing current backflow; and / or, the power supply uses an AC-DC power supply for connecting to an external AC circuit and converting it into direct current to supply the battery control component; and / or, the power supply is arranged above the stacking position and is located inside the installation box.

[0014] Further, the internal space of the installation box is an installation cavity. The lines for connecting to the battery clusters in at least two sets of battery control components are respectively arranged in parallel and are spaced apart on the bottom wall of the installation cavity; and / or, the battery management units of at least two sets of battery control components are stacked on the bottom wall of the installation cavity, and the stacking position is located at a corner of the bottom wall.

[0015] Further, the high-voltage control box further includes a balancing component. The balancing component includes a balancing resistor, a balancing relay and a balancing circuit. The balancing circuit is respectively connected to at least two battery clusters. The balancing resistor and the balancing relay are respectively arranged on the balancing circuit. The balancing relay is connected to the battery management unit for controlling the on-off of the balancing circuit. Among them, through the balancing component, the voltage between at least two battery clusters is balanced.

[0016] Further, the high-voltage control box further includes a voltage detection component for detecting the voltage of each battery cluster; the voltage detection component is connected to the battery management unit; when the voltage difference between two battery clusters detected by the voltage detection component is greater than 5V and less than or equal to 20V, the battery management unit controls the equalization relay to turn on the equalization circuit so that the high-voltage battery cluster charges the low-voltage battery cluster until the voltage difference between the two battery clusters is not greater than 5V; when the voltage difference between two battery clusters detected by the voltage detection component is greater than 20V, the battery management unit determines that the low-voltage battery cluster is abnormal, suspends the charge and discharge operations of the low-voltage battery cluster, and issues an alarm message; and / or, the heat source includes an equalization resistor; when there are multiple equalization resistors, the stacking positions are spaced from all the equalization resistors.

[0017] Further, the high-voltage control box further includes a pre-charging component and an external connection component; the external connection component includes a main circuit and a main relay, the battery cluster is connected to the external high-voltage power grid through the main circuit, the main relay is arranged on the main circuit and is connected to the battery management unit, and the main relay is used to control the on-off of the main circuit; the pre-charging component includes a pre-charging circuit, a pre-charging resistor and a pre-charging relay, the pre-charging circuit is respectively connected to the battery cluster and the external high-voltage power grid, the pre-charging resistor and the pre-charging relay are respectively arranged on the pre-charging circuit, and the pre-charging relay is connected to the battery management unit and is used to control the on-off of the pre-charging circuit; wherein, when the battery cluster starts to charge, the battery management unit controls the pre-charging circuit to conduct, and the main circuit is disconnected to pre-charge the battery cluster. When the difference between the voltage of the battery cluster and the voltage of the external high-voltage power grid is less than the set value, the pre-charging process is completed, the battery management unit controls the pre-charging circuit to disconnect, the main circuit conducts, and the battery cluster is connected to the external high-voltage power grid through the main circuit to charge or discharge.

[0018] Further, the high-voltage control box further includes an external connection component; the external connection component includes a main circuit, and the battery cluster is connected to the external high-voltage power grid through the main circuit; the high-voltage control box further includes a main copper bar arranged on the main circuit for transmitting current and / or shunting to at least two battery clusters; wherein, the width of the main copper bar is not less than 30mm and the thickness is not less than 3mm; and / or, each set of battery control components includes a fuse and a secondary copper bar, and the fuse and the secondary copper bar are respectively arranged on the connection circuit between the battery control component and the battery cluster; wherein, the width of the secondary copper bar is not less than 30mm and the thickness is not less than 3mm; and / or, the circuit connected to the battery management unit and used for transmitting data is a communication wire harness; the circuit used for supplying power to the battery management unit is a power supply wire harness; the circuit respectively connected to the battery cluster and the external high-voltage power grid is a high-voltage wire harness; the wire harness respectively connected to at least two battery clusters and used for balancing the voltage between at least two battery clusters is an equalization wire harness; at least two of the communication wire harness, the power supply wire harness, the high-voltage wire harness and the equalization wire harness are insulated and spaced apart.

[0019] Further, the high-voltage control box further includes a terminal resistor and a transmission circuit. The terminal resistor is replaceably disposed on the transmission circuit and is located outside the installation box. The transmission circuit is respectively connected to the battery management unit of each set of battery control components and is used for transmitting data to the outside; and / or, the battery control component further includes a cooling fan. The cooling fan is connected to the battery management unit. The cooling fan is disposed inside the installation box, and the cooling fan drives the air flow to circulate inside the installation box and flows through at least a part of the heat source; and / or, the installation box includes a box cover, a box body, and a sealing gasket. An installation cavity is provided inside the box body, and at least a part of at least two sets of battery control components is disposed in the installation cavity. The box cover is disposed on the box body, and the sealing gasket is disposed between the box cover and the box body. The box cover and the sealing gasket jointly seal the installation cavity to isolate the installation cavity from the outside; and / or, the high-voltage control box further includes a control component. The control component is connected to the battery control component, and the battery control component is controlled to work by controlling the control end of the control component. A part of the outer surface of the installation box is a control panel, and the control end is disposed on the control panel. The battery control component further has electrical interfaces for connecting to the outside. There are multiple electrical interfaces, and at least a part of the multiple electrical interfaces is disposed on the control panel.

[0020] The present application further provides a high-voltage control system. The high-voltage control system includes the above-mentioned high-voltage control box. The high-voltage control system further includes at least two battery clusters, and the at least two battery clusters are connected to at least two sets of battery control components in one-to-one correspondence.

[0021] The present application further provides an energy storage system. The energy storage system includes the above-mentioned high-voltage control system. The energy storage system further includes a liquid cooling component for cooling the high-voltage control box and / or the battery cluster.

[0022] In this solution, the present application provides a high-voltage control box, including: an installation box, and at least two sets of battery control components disposed in the installation box. Each set of battery control components is electrically connected to a battery cluster and is used for controlling the battery cluster to work. Each set of battery control components includes a battery management unit and a heat source. The battery management unit is used for monitoring and managing the battery cluster electrically connected thereto. The battery management units of at least two sets of battery control components are stacked in the installation box, and the stacking position is spaced from the heat source.

[0023] By providing at least two sets of battery control components inside the installation box in this application, the high-voltage control box can efficiently control and manage multiple battery clusters, and can achieve balanced charging and discharging of multiple battery clusters, significantly improving the control efficiency and control reliability for multiple battery clusters; by arranging the battery management units of at least two sets of battery control components in a stacked manner inside the installation box, space is effectively saved, and thus an integrated design is realized inside the high-voltage control box with limited space, which not only simplifies the overall architecture but also effectively reduces the cost of controlling multiple battery clusters; this application solves the problem that the existing high-voltage control box can only control one battery cluster; this application has a simple structure and low cost and is suitable for popularization and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings forming a part of this application are used to provide a further understanding of this application. The schematic embodiments of this application and their descriptions are used to explain this application and do not constitute an improper limitation to this application. In the drawings:

[0025] Figure 1 FIG. 9 shows a partial structural schematic diagram of the high-voltage control box provided by an embodiment of this application from a top view angle;

[0026] Figure 2 FIG. 13 shows a partial structural schematic diagram of the high-voltage control box provided by an embodiment of this application;

[0027] Figure 3 FIG. 17 shows an external structural schematic diagram of the high-voltage control box provided by an embodiment of this application;

[0028] Figure 4 FIG. 21 shows a control circuit schematic diagram of a battery control component of the high-voltage control box provided by an embodiment of this application;

[0029] Figure 5 FIG. 25 shows a wiring schematic diagram of the battery management unit provided by an embodiment of this application;

[0030] Figure 6 FIG. 29 shows a power supply circuit schematic diagram of the power supply provided by an embodiment of this application.

[0031] Among them, the above-mentioned drawings include the following reference numerals:

[0032] 10. Installation box; 11. Stacking position; 12. Installation cavity; 13. Box cover; 14. Box body; 15. Control panel;

[0033] 20. Battery control component; 21. Battery management unit; 22. Fuse; 23. Thermistor; 24. Cooling fan; 25. Electrical interface; 26. Hall sensor; 27. Shunt; 28. Disconnector;

[0034] 30. Power supply;

[0035] 40. Diode;

[0036] 50. Pre-charging component; 51. Pre-charging circuit; 52. Pre-charging resistor; 53. Pre-charging relay;

[0037] 60. Communication harness;

[0038] 70. Control component;

[0039] 80. External connection component; 81. Main relay. Detailed implementation manners

[0040] Next, the technical solutions in the embodiments of the present application will be clearly and completely described with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and shall in no way be construed as any limitation to the present application and its application or use. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0041] As Figures 1 to 6 shown, the present application provides a high-voltage control box, including: an installation box 10, and at least two sets of battery control components 20 arranged in the installation box 10. Each set of battery control components 20 is electrically connected to a battery cluster and used to control the operation of the battery cluster; each set of battery control components 20 includes a battery management unit 21 and a heat source. The battery management unit 21 is used to monitor and manage the battery cluster electrically connected thereto; the battery management units 21 of at least two sets of battery control components 20 are stacked in the installation box 10, and the stacking position 11 is spaced from the heat source.

[0042] By providing at least two sets of battery control components 20 in the installation box 10 in the present application, the high-voltage control box can efficiently control and manage multiple battery clusters, and can achieve balanced charging and discharging of multiple battery clusters, significantly improving the control efficiency and control reliability of multiple battery clusters; by arranging the battery management units 21 of at least two sets of battery control components 20 to be stacked in the installation box 10, the space is effectively saved, and thus an integrated design is realized in the high-voltage control box with limited space, which not only simplifies the overall architecture but also effectively reduces the cost of controlling multiple battery clusters; the present application solves the problem that the existing high-voltage control box can only control one battery cluster; the structure of the present application is simple and the cost is low, which is suitable for popularization and use.

[0043] In a specific embodiment of the present application, the battery management unit 21 adopts an existing BMS (Battery Management System) product. The battery management unit 21 in the present application is the core component for managing the state of the battery cluster. It monitors parameters such as the voltage, current, and temperature of the battery through a series of sensors, controls the charging and discharging of the battery based on this data, balances the performance between battery clusters, and performs fault diagnosis and safety protection; the battery management unit 21 includes a microprocessor, voltage and current sensors, temperature sensors, a battery protection circuit, and a communication interface with an external control device.

[0044] In a specific embodiment of the present application, the battery management unit 21 further includes multiple BMU products (Battery Management Unit, battery management unit body). The BMU products are installed inside the battery cluster and are directly connected to the battery cells, responsible for monitoring and managing the state and performance of individual battery cells. The functions and working principles of the BMU products are as follows:

[0045] Functions and features: 1. Monitoring of individual battery cells: The BMU products can monitor key parameters such as the voltage, current, and temperature of each battery cell in real time to ensure that the battery cells operate within the normal and safe range; 2. Balancing management: For the voltage and capacity differences between different battery cells in the battery cluster, the BMU products can perform active or passive balancing through the internal balancing circuit to reduce the inconsistency between cells and extend the overall life of the battery; 3. Fault detection and protection: The BMU products can detect abnormal conditions of the battery cells, such as overcharging, over-discharging, overheating, short circuits, etc., and immediately take measures when these problems are detected, such as disconnecting the connection between the battery cell and the system to prevent the expansion of the fault and protect the safety of the system; 4. Data communication: The BMU products send the monitored battery cell state information to the controller of the upper-layer battery management unit 21 through a communication interface (such as CAN bus, I2C, etc.) to achieve remote monitoring of the internal state of the battery cluster;

[0046] Working principle: 1. Voltage monitoring: The BMU products measure the voltage of each battery cell through a voltage sampling circuit. The voltage sampling circuit uses a high-precision voltage converter (ADC) and a voltage isolation circuit to ensure the accuracy and safety of the measurement; 2. Temperature monitoring: Multiple temperature sensors (such as NTC thermistors) are installed inside the BMU to monitor the temperature inside the battery cell or battery cluster; when the temperature exceeds the safe range, the BMU can start the cooling system or send an alarm to the controller of the battery management unit 21 to adjust the working state of the battery cluster; 3. Current monitoring: Through a current sensor (or such as Figure 1Among the Hall sensor 26 or shunt 27), the BMU product can measure the charging and discharging current of the battery cell, ensure that the current of the battery cell is within a safe range, and avoid overcharging or over-discharging; 4. Data transmission: The BMU exchanges data with the controller of the battery management unit 21 through the communication interface, sends the collected battery cell status information (voltage, current, temperature, etc.) to the controller, and at the same time receives the control instructions from the controller, such as charging, discharging, cooling start, etc.; 5. Fault protection: When the BMU detects abnormal voltage, current or temperature of the battery cell, it can respond quickly, such as disconnecting the connection between the battery cell and the external circuit through the relay to prevent the faulty cell from affecting the entire battery pack.

[0047] Through the above functions and principles, the BMU product in this application plays the role of a "guardian" of the battery cell in the battery pack, ensuring the healthy state of the battery cell and improving the safety and reliability of the entire battery pack; in the energy storage system of this application, multiple BMUs cooperate with the central controller in the battery management unit 21 to form a complete battery management system.

[0048] Such as Figure 1 、 Figure 2 and Figure 4 As shown, the heat source includes the fuse 22, the fuse 22 is located in the installation box 10, and the stacking position 11 is spaced from the fuses 22 of all the battery control components 20.

[0049] The fuse 22 will generate heat under over-current conditions. By setting it at a distance from the stacked battery management unit 21, it can avoid the adverse impact of the heat generated by the fuse 22 on the battery management unit 21 and ensure the normal operation of the battery management unit 21; this setting improves the safety and stability of the electrical components inside the high-voltage control box and reduces the system failure rate.

[0050] In a specific embodiment of this application, when the battery cluster current exceeds the set value, the fuse 22 will automatically disconnect and cut off the current. Since the fuse 22 is spaced from the battery management unit 21, the heat generated by the fuse 22 will not affect the battery management unit 21, ensuring the safety of the battery cluster and the high-voltage control box.

[0051] Such as Figure 1 and Figure 2 As shown, the battery control component 20 further includes a fuse 22 and at least one thermistor 23. The heat source includes the fuse 22, and the thermistor 23 and the fuse 22 are respectively electrically connected to the battery management unit 21; the thermistor 23 is used to detect the temperature.

[0052] The thermistor 23 can adjust its resistance value according to the temperature change, thereby generating a measurable voltage change in the circuit. The battery management unit 21 obtains the temperature information by monitoring these voltage changes. The above design improves the temperature monitoring accuracy of the high-voltage control box, helps to detect and handle overheating problems in a timely manner, and protects the battery cluster and electrical components.

[0053] In an embodiment of the present application, the thermistor 23 continuously monitors the temperatures of the battery control assembly 20 and the mounting box 10. Once an abnormal temperature is detected, the battery management unit 21 will immediately take measures, such as starting the heat dissipation system or adjusting the charge and discharge power of the battery cluster, to prevent overheating.

[0054] Specifically, as Figure 1 and Figure 2 shown, when there is one thermistor 23 in a set of battery control assemblies 20, the distance between the thermistor 23 and the fuse 22 in the same set of battery control assemblies 20 is in the range of 20 - 40 mm, so that the thermistor 23 can measure the temperature of the fuse 22 and the temperature inside the mounting box 10 at the same time.

[0055] By reasonably setting the distance between the thermistor 23 and the fuse 22, it is ensured that the thermistor 23 can not only monitor the temperature of the fuse 22, but also reflect the overall temperature condition inside the mounting box 10 (that is, the thermistor 23 reflects the data of the higher temperature among the fuse 22 and the internal environment of the mounting box 10). Thus, a single thermistor 23 realizes the dual temperature monitoring of the fuse 22 and the internal environment of the mounting box 10. With such a setting, the temperature monitoring ability of the high-voltage control box is improved with a simple structure, which helps to detect the overheating of the fuse 22 and the abnormal temperature inside the mounting box 10 in a timely manner, and ensures the overall safety.

[0056] During the actual use process, the thermistor 23 simultaneously monitors the temperatures of the fuse 22 and the inside of the mounting box 10 within the set distance range. Once an abnormal temperature is detected, it immediately sends a signal to the battery management unit 21 and takes corresponding measures.

[0057] It should be noted that: the distance between a thermistor 23 and a fuse 22 defined above in this application refers to the thermistor 23 and the fuse 22 in the same set of battery control components 20; for two adjacent sets of battery control components 20, there is no direct circuit connection relationship between the thermistor 23 in one set of battery control components 20 and the fuse 22 in another set of battery control components 20, and the two are usually set at a relatively far distance. For example: the distance between the thermistor 23 in one set of battery control components 20 and the fuse 22 in another set of battery control components 20 is much greater than 40 mm (usually the distance exceeds 100 mm and can be even larger according to the size of the installation box 10). Therefore, for two adjacent sets of battery control components 20, it is usually not necessary to directly define the distance relationship between the thermistor 23 in one set of battery control components 20 and the fuse 22 in another set of battery control components 20; of course, it should also be noted that if the distance between the thermistor 23 in one set of battery control components 20 and the fuse 22 in another set of battery control components 20 is less than 40 mm, in order to avoid the adverse effect of this fuse 22 as a heat source on the thermistor 23 that is not in the same set of battery control components 20, it is also necessary to limit the distance between the thermistor 23 in one set of battery control components 20 and the fuse 22 in another set of battery control components 20, and at least ensure that the distance interval between the two exceeds 40 mm to ensure the accuracy of the detection result of the thermistor 23.

[0058] Optionally, when there are at least two thermistors 23 in the battery control components 20, the distance between one of the thermistors 23 and the fuse 22 is less than 20 mm, so that this thermistor 23 only measures the temperature of the fuse 22; and / or, at least one thermistor 23 is a negative temperature coefficient thermistor 23.

[0059] By setting multiple thermistors 23, precise temperature monitoring of the fuse 22 and extensive monitoring of the temperatures at different positions inside the installation box 10 can be achieved; the resistance value of the negative temperature coefficient thermistor 23 decreases when the temperature rises, and it can more sensitively reflect the temperature change; the above design improves the temperature monitoring accuracy and response speed of the high-voltage control box, helps to detect and handle overheating problems in a timely manner, and ensures the safe and stable operation of the system.

[0060] In actual use, the application scenarios include energy storage systems that require precise temperature monitoring and rapid response; the usage process is that multiple thermistors 23 respectively monitor the temperatures of the fuse 22 and inside the installation box 10. Once an abnormality is detected, it immediately reports to the battery management unit 21 and takes measures such as starting the cooling system or adjusting the working state of the battery cluster to prevent overheating.

[0061] Such as Figure 1 、 Figure 2 andFigure 6 As shown, the high-voltage control box further includes a main control switch and a power supply 30. The power supply 30 is connected to each set of battery control components 20 respectively for supplying power to the battery control components 20. The main control switch is connected to the power supply 30 for simultaneously controlling the opening and closing of each set of battery control components 20.

[0062] The stable power is provided to the battery control components 20 by the power supply 30, and the main control switch realizes the centralized control of all the battery control components 20, simplifying the system operation. Such a setting improves the power management ability and operation convenience of the high-voltage control box and reduces the system failure rate.

[0063] In actual use, the power supply 30 continuously supplies power to the battery control components 20. The main control switch closes when the system starts, and all the battery control components 20 start to work. When the system is shut down or under maintenance, the main control switch disconnects, simultaneously cutting off the power supply of all the battery control components 20 to ensure operation safety.

[0064] As Figure 1 , Figure 2 and Figure 6 shown, the power supply 30 supplies direct current to the battery control components 20. The high-voltage control box further includes a diode 40. The diode 40 is arranged on the direct current circuit where the power supply 30 is connected to the battery control components 20 for preventing current backflow; and / or, the power supply 30 adopts an AC-to-DC power supply for connecting to an external AC circuit and converting it into direct current to supply the battery control components 20; and / or, the power supply 30 is arranged above the stacking position 11 and is located inside the installation box 10.

[0065] By setting the power supply 30 to provide stable direct current, the diode 40 prevents current backflow, protecting the battery control components 20. The AC-to-DC power supply adapts to a wider power environment, improving system compatibility. The layout design of the power supply 30 optimizes heat dissipation and space utilization. The above designs improve the power stability and system compatibility of the high-voltage control box, reduce the failure rate, and optimize the internal layout.

[0066] In the actual use process, the power supply 30 converts alternating current into direct current, protects the circuit through the diode 40 to avoid backflow, supplies power to the battery control components 20, and ensures the normal operation of the system.

[0067] In a specific embodiment of the present application, the power supply 30 is an ACDC power supply (i.e., an AC / DC converter, AC to DC Converter, an AC-to-DC power supply). The main function of the ACDC is to provide a stable and reliable DC power supply for the electronic components inside the high-voltage control box, such as the battery management unit 21 (BMS), the display module, the control circuit, etc. The following details its functions: 1. Power conversion: The ACDC converter converts the alternating current input from the external power grid into direct current to supply power to the electronic devices inside the high-voltage control box. This is because most electronic devices, especially microprocessors and control circuits, require a stable DC power supply to operate. 2. Voltage conversion: The ACDC converter can convert the input AC voltage into the DC voltage required for the internal electronic devices to work. For example, the high-voltage control box may require DC power supplies of different voltage levels to drive different electronic components, and the ACDC converter can provide this voltage conversion function. 3. Isolation protection: The ACDC converter also provides electrical isolation to prevent voltage fluctuations or faults in the external power grid from affecting the sensitive electronic components inside the high-voltage control box. This isolation protection is crucial for ensuring system stability and safety. 4. Current limiting: The ACDC converter has an overcurrent protection function, which can limit the output current to prevent the internal electronic devices from being damaged due to excessive current. This is very important for protecting the normal operation of the battery management unit 21 (BMS) and the control circuit. 5. Cooperating with the BMS: The ACDC converter in the high-voltage control box works closely with the BMS. The BMS can control the on / off of the ACDC converter to achieve the low-voltage power control of the entire system. For example, when the system needs to be powered off emergently or maintained, the BMS can control the ACDC converter to power off to ensure safety. 6. Improving system efficiency: The design and optimization of the ACDC converter can improve the overall energy conversion efficiency of the system and reduce energy loss, which is of great significance for improving the energy efficiency of the liquid-cooled energy storage system. 7. Cooperating with the diode 40: The ACDC converter is configured with a diode 40 on the output side to prevent reverse current from flowing back to the power supply. This design can not only protect the ACDC converter but also ensure the stable operation of the system in the case of multiple circuit parallel connections and prevent abnormal current flow between power supplies.

[0068] Therefore, the ACDC converter in the above embodiment plays key roles such as power conversion, voltage adjustment, electrical isolation, and current protection in the high-voltage control box and is an important part to ensure the normal operation and safety of the system. By working together with the BMS, the ACDC converter can achieve efficient and safe control of the energy storage system.

[0069] Such as Figure 1 and Figure 2As shown in the figure, the internal space of the installation box 10 is an installation cavity 12. The lines used to connect to the battery clusters in at least two sets of battery control components 20 are arranged in parallel respectively and are spaced apart on the bottom wall of the installation cavity 12; and / or, the battery management units 21 of at least two sets of battery control components 20 are stacked on the bottom wall of the installation cavity 12, and the stacking position 11 is located at a corner of the bottom wall.

[0070] By arranging the lines in parallel and spacing the circuits, the current distribution and heat dissipation are optimized, improving the system efficiency and stability; stacking the battery management units 21 saves space, and the choice of the stacking position 11 avoids direct interference from heat sources; the above design improves the rationality of the internal layout of the high-voltage control box and the heat dissipation efficiency, reducing the system failure rate.

[0071] Specifically, the high-voltage control box further includes a balancing component. The balancing component includes a balancing resistor, a balancing relay, and a balancing circuit; the balancing circuit is connected to at least two battery clusters respectively; the balancing resistor and the balancing relay are respectively arranged on the balancing circuit, and the balancing relay is connected to the battery management unit 21 for controlling the on / off of the balancing circuit; wherein, through the balancing component, the voltage between at least two battery clusters is balanced.

[0072] Through the balancing resistor and the balancing relay in the balancing circuit, the voltage balance between the battery clusters is achieved, avoiding the decline in battery performance and the shortening of battery life caused by voltage differences; such a setting improves the utilization rate of the battery clusters and the efficiency of the entire energy storage system, and extends the battery life.

[0073] In a specific embodiment of the present application, the battery management unit 21 monitors the voltage of the battery cluster. When a voltage difference is detected, by controlling the balancing relay, the balancing circuit is turned on, and the current flows between the battery clusters through the balancing resistor until the voltage reaches balance, thereby optimizing the charge and discharge process of the battery cluster and improving the overall performance of the system.

[0074] Specifically, the high-voltage control box further includes a voltage detection component for detecting the voltage of each battery cluster; the voltage detection component is connected to the battery management unit 21; when the voltage difference between two battery clusters detected by the voltage detection component is in the range greater than 5V and less than or equal to 20V, the battery management unit 21 controls the balancing relay to turn on the balancing circuit so that the high-voltage battery cluster charges the low-voltage battery cluster until the voltage difference between the two battery clusters is not greater than 5V; when the voltage difference between two battery clusters detected by the voltage detection component is greater than 20V, the battery management unit 21 determines that the low-voltage battery cluster is abnormal, suspends the charge and discharge operation of the low-voltage battery cluster, and issues an alarm message; and / or, the heat source includes the balancing resistor; when there are multiple balancing resistors, the stacking position 11 is spaced apart from all the balancing resistors.

[0075] The voltage of the battery cluster is monitored in real time by a voltage detection component. The battery management unit 21 controls the on / off of the balancing circuit according to the voltage difference to achieve active voltage balancing. At the same time, when the voltage difference is too large, abnormal battery clusters can be detected in time to avoid system failures. Such a setting improves the voltage balancing ability and fault detection ability of the high-voltage control box, ensures the safe and stable operation of the system, and extends the battery life.

[0076] In actual use, the voltage detection component continuously monitors the voltage of the battery cluster. When the voltage difference is within the set range, the battery management unit 21 controls the balancing circuit to conduct to perform voltage balancing. When the voltage difference exceeds the range, it is determined that the battery cluster is abnormal, the charge and discharge operations are suspended, and an alarm message is sent to ensure the safe operation of the system.

[0077] As Figure 1 、 Figure 2 and Figure 4 shown, the high-voltage control box further includes a pre-charging component 50 and an external connection component 80. The external connection component 80 includes a main circuit and a main relay 81. The battery cluster is connected to the external high-voltage power grid through the main circuit. The main relay 81 is arranged on the main circuit and is connected to the battery management unit 21. The main relay 81 is used to control the on / off of the main circuit. The pre-charging component 50 includes a pre-charging circuit 51, a pre-charging resistor 52, and a pre-charging relay 53. The pre-charging circuit 51 is respectively connected to the battery cluster and the external high-voltage power grid. The pre-charging resistor 52 and the pre-charging relay 53 are respectively arranged on the pre-charging circuit 51. The pre-charging relay 53 is connected to the battery management unit 21 and is used to control the on / off of the pre-charging circuit 51. Among them, when the battery cluster starts to charge, the battery management unit 21 controls the pre-charging circuit 51 to conduct and the main circuit to be disconnected to pre-charge the battery cluster. When the difference between the voltage of the battery cluster and the voltage of the external high-voltage power grid is less than the set value, the pre-charging process is completed. The battery management unit 21 controls the pre-charging circuit 51 to be disconnected and the main circuit to conduct. The battery cluster is connected to the external high-voltage power grid through the main circuit to perform charging or discharging.

[0078] The principle of this design is to realize the pre-charging of the battery cluster through the pre-charging component 50, avoiding the current impact when directly connecting to the high-voltage power grid, and protecting the battery cluster and the high-voltage control box. The external connection component 80 realizes the stable connection and control between the battery cluster and the high-voltage power grid. The above design improves the charging safety and system stability of the high-voltage control box and reduces the damage risk of the battery cluster.

[0079] The actual use process is as follows: Before the battery cluster is connected to the power grid, the battery management unit 21 controls the pre-charging relay 53 to close, and pre-charges the battery cluster through the pre-charging resistor 52 until the voltage of the battery cluster is close to the grid voltage. The pre-charging relay 53 is disconnected and the main relay 81 is closed. The battery cluster is connected to the grid to perform normal charge and discharge operations, ensuring the safe start and operation of the system.

[0080] Specifically, as Figure 1 and Figure 4 shown, the high-voltage control box further includes an external connection component 80; the external connection component 80 includes a main circuit, and the battery cluster is connected to the external high-voltage power grid through the main circuit; the high-voltage control box further includes a main copper bar, and the main copper bar is arranged on the main circuit for transmitting current and / or shunting to at least two battery clusters; wherein, the width of the main copper bar is not less than 30 mm, and the thickness is not less than 3 mm; and / or, each set of battery control components 20 includes a fuse 22 and a secondary copper bar, and the fuse 22 and the secondary copper bar are respectively arranged on the connection circuit between the battery control component 20 and the battery cluster; wherein, the width of the secondary copper bar is not less than 30 mm, and the thickness is not less than 3 mm; and / or, the circuit connected to the battery management unit 21 and used for transmitting data is a communication wire harness 60; the circuit used for supplying power to the battery management unit 21 is a power supply wire harness; the circuits respectively connected to the battery cluster and the external high-voltage power grid are high-voltage wire harnesses; the wire harness respectively connected to at least two battery clusters and used for balancing the voltage between at least two battery clusters is an equalizing wire harness; at least two of the communication wire harness 60, the power supply wire harness, the high-voltage wire harness, and the equalizing wire harness are arranged at an insulating interval.

[0081] By reasonably arranging the copper bars and wire harnesses, the current transmission and voltage equalization are optimized. At the same time, through the insulating interval setting, the electromagnetic interference is reduced, and the system safety is improved; the above design improves the current transmission efficiency and voltage equalization ability of the high-voltage control box, reduces the system failure rate, and improves the system safety.

[0082] In a specific embodiment of the present application, the high-voltage wire harness introduces the high-voltage current of the external power grid, the main copper bar and the secondary copper bar are responsible for the transmission and distribution of the current, the communication wire harness 60 transmits the control signal of the battery management unit 21, and the equalizing wire harness realizes the voltage equalization between the battery clusters. All the wire harnesses are arranged at an insulating interval, reducing the electromagnetic interference between each other and ensuring the overall efficient and stable operation.

[0083] It should be noted that: In a specific embodiment of the present application, a busbar is an important electrical connection component, and its main function is to efficiently and safely transmit and distribute current. The busbar is designed as a flat conductor with a large cross-sectional area and is used to connect components such as battery clusters, power electronic devices, relays, and circuit breakers. The functions of the busbar in the present application are summarized as follows: 1. Current transmission; the busbar has good electrical conductivity and can carry high currents, so it is used to connect battery clusters to power electronic devices such as inverters and converters, as well as to connect to other electrical components; the efficient current transmission ability ensures the high-power output and energy conversion efficiency of the energy storage system; 2. Current distribution; in the energy storage system of the present application, the busbar can distribute current from a central point to multiple battery clusters or devices; by designing a complex busbar layout, uniform current distribution can be achieved to ensure the stable operation of the system under high loads; 3. Electrical connection and support: The busbar not only serves as a current transmission channel but also as the basis for electrical connections, supporting the layout of battery clusters, modules, and components; in some structures of the present application, the busbar can be directly welded or bolted to other modules to provide both mechanical support and electrical connection functions; 4. Reduction of connection components; compared with wires, the busbar can significantly reduce the number of connection components such as connectors and screws, thereby reducing the complexity and cost of the system and improving reliability; in addition, the direct physical connection of the busbar reduces contact resistance and heat loss, extending the service life of the system; 5. Easy maintenance and expansion; the modular design of the busbar layout makes the system easy to maintain and expand on-site; when it is necessary to replace or maintain battery modules, the busbar connection can be directly disconnected without the need for complex wire disassembly and reconnection processes; 6. Heat dissipation; the large cross-sectional area of the busbar helps with heat dissipation, especially in high-current applications. Copper is a good thermal conductor and can conduct heat from battery clusters or other electrical components to radiators or cooling systems, thereby reducing the temperature of the components and improving system efficiency and safety; 7. Reduction of electromagnetic interference; the large cross-sectional area of the busbar reduces the skin effect of high-frequency currents and reduces electromagnetic interference, which is very important for sensitive electronic devices and communication lines in the energy storage system; 8. Protection of the circuit; during design, the layout and material selection of the busbar can provide short-circuit protection; for example, if a short circuit occurs, the fuse 22 or circuit breaker on the busbar can play a protective role and quickly cut off the circuit to prevent system damage.

[0084] It is also worth noting that: In the energy storage system of the present application, the design and layout of the busbar need to consider multiple aspects such as electrical performance, mechanical strength, heat dissipation, electromagnetic compatibility (EMC), and system safety to ensure the efficient, reliable, and safe operation of the system; the busbar is usually designed to meet specific current-carrying capabilities while considering the overall layout and maintenance requirements of the system.

[0085] In a specific embodiment of the present application, the dimensions of the copper busbar can be a width of 30 mm, a thickness of 3 mm, a length of 500 mm, and a cross-sectional area of 90 mm 2 , with a tin plating treatment on the surface, a thickness of 0.02 mm, and two M8 mounting holes at each end for bolt fixation. The designed maximum current-carrying capacity is 600 A, and the voltage rating is 1000 V DC, meeting the UL standard and being used for the electrical connection between the battery cluster and the inverter.

[0086] As Figure 1 , Figure 2 and Figure 3 shown, the high-voltage control box further includes a terminal resistor and a transmission circuit. The terminal resistor is replaceably disposed on the transmission circuit and is located outside the mounting box 10; the transmission circuit is respectively connected to the battery management unit 21 of each set of battery control components 20 for transmitting data to the outside; and / or, the battery control component 20 further includes a cooling fan 24, and the cooling fan 24 is connected to the battery management unit 21; the cooling fan 24 is disposed inside the mounting box 10, and the cooling fan 24 drives the air flow to circulate inside the mounting box 10 and flows through at least a part of the heat source; and / or, the mounting box 10 includes a box cover 13, a box body 14, and a gasket; an installation cavity 12 is provided inside the box body 14, and at least a part of at least two sets of battery control components 20 is disposed in the installation cavity 12; the box cover 13 is disposed on the box body 14, the gasket is disposed between the box cover 13 and the box body 14, and the box cover 13 and the gasket jointly seal the installation cavity 12 to isolate the installation cavity 12 from the outside; and / or, the high-voltage control box further includes a control component 70, and the control component 70 is connected to the battery control component 20, and the battery control component 20 is controlled to work by operating the control end of the control component 70; a part of the outer surface of the mounting box 10 is a control panel 15, and the control end is disposed on the control panel 15; the battery control component 20 further has electrical interfaces 25 for connecting to the outside, and there are multiple electrical interfaces 25, and at least a part of the multiple electrical interfaces 25 is disposed on the control panel 15.

[0087] By setting a replaceable terminal resistor and a transmission circuit, stable data transmission and flexible system maintenance are achieved; the setting of the cooling fan 24 optimizes heat dissipation and extends the life of electrical components; the sealing design ensures the protection level of the high-voltage control box and improves the system's ability to adapt to harsh environments; the layout design of the control component 70 and the electrical interfaces 25 improves the operation convenience and maintenance efficiency of the system.

[0088] The above design improves the data transmission stability, heat dissipation efficiency, protection level and operation convenience of the high-voltage control box, reduces the maintenance cost and improves the overall system performance. In actual use, the terminal resistor ensures the stability of data transmission. The cooling fan 24 starts in a timely manner according to the control of the battery management unit 21 to optimize heat dissipation. The sealed design ensures the protection level of the high-voltage control box. The layout design of the control component 70 and the electrical interface 25 makes the system operation and maintenance more convenient, realizing the efficient and stable operation of the system.

[0089] In a specific embodiment of the present application, the terminal resistor (Terminal Resistor) is used in the communication and diagnostic circuits of the battery management system (BMS), and its main functions are as follows: 1. Matching and stability of the communication circuit; in a system using the CAN bus or other communication protocols, the terminal resistor is used to match the impedance of the communication line to ensure signal integrity and communication stability; in the CAN bus, the terminal resistor is set at both ends of the bus, and the resistance value is generally 120 ohms. This can prevent signals from reflecting at the end of the transmission line, generating echoes, resulting in signal distortion and communication errors. By connecting terminal resistors at both ends of the bus, a matching impedance network can be formed, enabling signals to be transmitted smoothly along the bus, improving the reliability and efficiency of communication; 2. Preventing communication interference; the terminal resistor helps to reduce electromagnetic interference (EMI) on the communication line, ensuring that the communication between the BMS and other control systems is not interfered. In the energy storage system of the present application, the high-voltage circuit and electronic devices may generate a large amount of electromagnetic interference. The correct configuration of the terminal resistor can effectively filter out these interferences, ensuring the clarity and stability of communication signals; 3. Diagnosis and fault detection; in the present application, the terminal resistor is also used for auxiliary diagnosis and fault detection; for example, if the terminal resistor is not correctly configured on the bus, the BMS can detect communication faults or anomalies, thereby quickly locating the problem and taking measures to avoid system failures or damages; 4. Protecting the circuit; the terminal resistor can also provide a certain degree of circuit protection in some cases. For example, when the communication line is short-circuited or open-circuited, the terminal resistor can limit the current or help detect the fault, preventing damage to the BMS or other electronic devices; 5. Eliminating signal reflection; in a multi-node communication network, signal reflection may occur on the communication line between nodes, resulting in signal attenuation and communication errors. The terminal resistor can reduce this signal reflection and improve the communication quality by matching the characteristic impedance of the communication line.

[0090] In addition, it is worth noting that in an energy storage system, correct terminal resistance configuration is crucial for ensuring accurate data transmission, stable system operation, and long-term reliability. The resistance value and installation position of the terminal resistance in this application need to be determined based on factors such as communication protocol, line length, number of nodes, and system layout to ensure optimal communication performance and fault protection capabilities. The terminal resistance in this application is externally connected to facilitate system maintenance and fault troubleshooting, and at the same time ensure that all high-voltage control boxes at the battery cluster level can be used compatibly without distinction, improving the versatility and maintenance convenience of the system.

[0091] Specifically, this application also provides a high-voltage control system. The high-voltage control system includes the above-mentioned high-voltage control box. The high-voltage control system further includes at least two battery clusters, and the at least two battery clusters are respectively connected to at least two sets of battery control components 20 in one-to-one correspondence.

[0092] By integrating and managing multiple battery clusters through the high-voltage control box, efficient charge and discharge and balanced management of the battery system are achieved, improving the overall performance and reliability of the system. The high-voltage control system provided by this application can stably control and manage multiple battery clusters, improving the efficiency and safety of the battery system. Application scenarios include energy storage systems that require efficient management and control of multiple battery clusters, such as grid energy storage systems, etc.

[0093] In a specific embodiment of this application, when the system starts up, the high-voltage control box controls the battery clusters connected to it to perform pre-charging, and then performs normal charge and discharge operations. At the same time, through balanced management, the voltage balance between the battery clusters is ensured, improving the overall performance of the system.

[0094] Specifically, this application also provides an energy storage system. The energy storage system includes the above-mentioned high-voltage control system. The energy storage system further includes a liquid cooling component, and the liquid cooling component is used to cool the high-voltage control box and / or the battery clusters.

[0095] Through liquid circulation, effective heat dissipation is achieved, reducing the temperature of the high-voltage control box and the battery clusters, improving the system efficiency and safety. The energy storage system proposed in this application optimizes heat dissipation through the liquid cooling component, improving the overall performance and reliability of the system and reducing the maintenance cost. Application scenarios include energy storage systems that require efficient heat dissipation and high power density. During actual use, when the system is running, the liquid cooling component effectively dissipates heat through liquid circulation, reducing the temperature of the high-voltage control box and the battery clusters, ensuring the stable operation of the system, and improving the battery life and system efficiency.

[0096] In another specific embodiment of the present application, a battery cluster is a modular structure in an energy storage system. It is composed of multiple battery cells connected in series and / or in parallel, aiming to provide a higher voltage or a larger capacity. The battery cluster can be regarded as an intermediate level in the energy storage system, located between individual battery cells and the entire battery energy storage system. The following is a detailed description of the battery cluster in the present application: 1. The battery cluster is composed of multiple battery cells, which can be different types of batteries such as lithium-ion batteries, lead-acid batteries, nickel-cadmium batteries, etc. The battery cells are connected within the cluster in the following two main ways: Series connection: Connecting battery cells in series can increase the total voltage of the battery cluster. Parallel connection: Connecting battery cells in parallel can increase the total capacity of the battery cluster, but the voltage remains unchanged. This method can increase the energy storage capacity of the system. 2. The main functions of the battery cluster in the energy storage system are as follows: Energy storage: Through the combination of multiple battery cells, the battery cluster can store a large amount of electrical energy to meet high-power or long-term energy requirements. Modular design: The modularity of the battery cluster enables the scale of the energy storage system to be flexibly adjusted according to needs. By increasing or decreasing the number of battery clusters, the capacity of the system can be easily expanded or reduced. Balanced management: Each battery cluster is also equipped with a balancing circuit to regulate the voltage difference between the battery cells within the cluster, ensuring that all battery cells operate in the best state and extending the system life. Fault isolation: The battery cluster design helps with fault isolation. If a battery cluster fails, the system can automatically or manually isolate it without affecting the normal operation of other clusters. Safety management: The battery cluster is equipped with current and temperature monitoring devices, as well as overcurrent protection and overheat protection mechanisms, ensuring that the system can respond quickly in abnormal situations and prevent safety accidents such as fires and explosions. 3. The management of the battery cluster is executed by the corresponding battery management unit 21 (BMS). The BMS monitors parameters such as the voltage, current, and temperature of the battery cluster, controls the charge and discharge process, and performs fault diagnosis to ensure that the battery cluster operates in a safe and efficient state. In summary, the battery cluster is a basic building block in the energy storage system of the present application. Through the combination of series and parallel battery cells, it provides the required voltage and capacity, and at the same time, through mechanisms such as balanced management and fault isolation, it ensures the stability and safety of the system.

[0097] In a specific embodiment of the present application, as Figure 1 shown, the battery control assembly 20 further includes a disconnector 28, and its main functions and working principles are as follows:

[0098] Main functions: 1. Electrical isolation: The disconnect switch 28 can provide a visible disconnection point between the battery cluster and the power grid or other electrical equipment, ensuring that during maintenance, inspection, or replacement of the battery cluster, operators can be safely isolated from the high-voltage circuit and avoid the risk of electric shock; 2. System protection: In case of system faults or abnormalities (such as short circuits, overloads), the disconnect switch 28 can quickly cut off the circuit to prevent the expansion of the fault and protect the battery cluster and other power electronic devices from damage; 3. Control: The disconnect switch 28 allows controlling the on / off of the circuit during the charging and discharging processes of the battery cluster, which is crucial for the startup, shutdown, and switching of the operating state of the system; 4. Signal confirmation: The disconnect switch 28 is equipped with auxiliary contacts for sending signals of the switch state to the battery management unit 21 or other control systems, facilitating system monitoring and fault diagnosis.

[0099] Working principle: 1. Manual operation: The disconnect switch 28 can be designed for manual operation. The operator rotates it through a handle or key to disconnect or close the moving contact and the static contact; in the disconnected state, there is a sufficient gap (usually greater than several millimeters) between the contacts to ensure the safety distance for electrical isolation; 2. Motor drive: In systems with a higher degree of automation, the disconnect switch 28 can also be driven by a motor. By controlling the forward and reverse rotation of the motor, the closing and opening of the contacts can be achieved. This design enables remote control and automated operation, improving the operation convenience and safety of the system; 3. Contact design: The contacts are usually made of metal materials such as copper, silver, or copper alloys to ensure good electrical conductivity. In the disconnected state, the contacts are isolated by air or other insulating media, forming a high-impedance disconnection point; 4. Auxiliary contacts and signal feedback: The auxiliary contacts in the disconnect switch 28 provide signal feedback when the main contacts are closed or opened, usually used to indicate the state of the disconnect switch 28 (such as on / off state); these signals are fed back to the battery management unit 21 or other control systems for monitoring and controlling the operating state of the system; 5. Mechanical interlock: To prevent misoperation, the disconnect switch 28 can also be designed to include a mechanical interlock mechanism to ensure that the disconnect switch 28 can only be operated after the door of the high-voltage control box is closed and locked, and vice versa. This can prevent operators from opening the control box door when the high-voltage circuit is not fully disconnected, reducing the risk of electric shock; Therefore, the disconnect switch 28 in the high-voltage control box of the energy storage system is an important part for achieving electrical safety and system protection; by physically disconnecting the circuit and providing visible electrical isolation, the disconnect switch 28 ensures the safety of the system during maintenance, faults, or abnormal operating conditions; at the same time, its signal feedback function also enables the system to monitor the state of the high-voltage circuit in real time and take necessary protection measures in a timely manner.

[0100] In a specific embodiment of the present application, such as Figure 1As shown, the battery control component 20 further includes a Hall sensor 26 and a shunt 27; both can be used to monitor the working current of the battery cluster. The Hall sensor 26 works based on the Hall effect and can measure the current in a non-contact manner; the main functions of the Hall sensor 26 are: 1. Current detection: It can detect the current between the battery cluster and the external power grid in real time. Whether it is the charging or discharging process, the Hall sensor 26 can provide accurate current data; 2. Safety protection: By monitoring the current, it can quickly detect overcurrent situations, such as short circuits or abnormal current fluctuations in the battery cluster, which helps to promptly activate protection mechanisms, such as disconnecting the main relay 81, to prevent system damage or safety risks; 3. System monitoring: The Hall sensor 26 feeds back the current data to the battery management unit 21, enabling the BMS to monitor the charge and discharge status of the battery cluster in real time, optimize the charge and discharge strategies, and improve the service life and system efficiency of the battery; The shunt 27 is a resistor used for high-precision current detection. It is placed in the current loop. When current flows through the shunt, a small voltage drop will be generated across the shunt, and this voltage drop is proportional to the flowing current. In the battery control component 20, the main functions of the shunt 27 are: 1. Current measurement: It provides high-precision current measurement, especially suitable for occasions that require extremely high accuracy, such as the equalization management and fault diagnosis of the battery cluster; 2. Data transmission: It converts the current information into a voltage signal for easy reception and processing by the battery management unit 21, so that the charge and discharge process of the battery cluster can be controlled more accurately; Therefore, the above-mentioned Hall sensor 26 and shunt 27 jointly are responsible for the accurate detection and monitoring of the current in the battery control component 20 of the present application, and are key components to ensure the safe and efficient operation of the battery cluster and the entire energy storage system. Their use not only improves the system's perception ability of the current state but also provides accurate data for the battery management unit 21 to optimize the management and control strategies of the battery cluster.

[0101] In another specific embodiment of the present application, as Figure 3 and 4 shown, the control panel 15 integrates devices such as a high-voltage connector, a main circuit breaker, a push-button switch, a display module, a low-voltage communication port, a power supply interface, and a diagnostic port; the control panel 15 has interfaces such as P-, P+, B+, and B-. Among them, the P- and P+ interfaces are located in the middle of the control panel 15, and the B+ and B- interfaces are located on both sides of the control panel 15. The P- and P+ interfaces are used to connect to external loads, and the B+ and B- interfaces are used to connect to the battery cluster; The control panel 15 also integrates an installation handle to facilitate the operation and installation of the installation box 10; the cross-sectional area of the main copper bar is 90 mm 2 , and the cross-sectional area of the secondary copper bar connected to the fuse 22 is 90 mm 2 , to increase the heat dissipation area; as Figure 4As shown, the main negative circuit starts from the B- terminal and sequentially includes a shunt resistor, a fuse, and a relay, and then reaches the circuit breaker. The distance between the thermistor 23 and the fuse 22 is 30 mm. The main positive circuit starts from the B+ terminal and sequentially includes a fuse, a relay, and then reaches the circuit breaker; the equalizing circuit in the equalizing component is connected in parallel with the main positive relay; as Figure 1 As shown, the high-voltage control box includes two sets of battery control components 20. The circuits of the two sets of battery control components 20 are arranged symmetrically left and right, share a power supply 30, and are configured with diodes 40 on the output side to prevent reverse current; the cooling fan 24 evenly distributes the heat of the heat source throughout the installation cavity 12. The entire installation box 10 is hermetically set to ensure the overall IP protection level; reinforcing ribs are welded on the bottom wall and the lid 13 of the installation cavity 12 to improve the strength; the circuits in each set of battery control components 20 are equipped with 2 fuses and relays to achieve full-domain short-circuit current protection.

[0102] Now, the specific working process and principle of an embodiment of the present application will be described in detail as follows:

[0103] The high-voltage control box contains voltage and current sensors for real-time monitoring of the voltage and current of the battery cluster; these sensors send the detected data to the battery management unit 21, and the battery management unit 21 judges the battery state according to the data, such as the state of charge (SOC), state of health (SOH), and temperature of the battery; the high-voltage control box contains multiple relays, and these relays are used to control the connection between the battery cluster and the external power grid; the closing and opening of the relays are controlled by the battery management unit 21 to achieve the charging or discharging of the battery cluster. The pre-charge relay 53 is used to perform pre-charging before the battery cluster is connected to the power grid to reduce the inrush current and protect the battery and the system; the fuse 22 is an important protection component in the high-voltage control box, and its function is to quickly cut off the circuit when the current in the circuit is too large, prevent the battery cluster from overloading or short-circuiting, and protect the battery and the entire system from damage; the high-voltage control box also contains a temperature sensor for monitoring the temperature of the battery cluster. Excessive temperature will affect the battery performance and safety, and the battery management unit 21 will take corresponding heat dissipation or shutdown measures according to the temperature monitoring results; to solve the problem of voltage imbalance between battery clusters, an equalizing circuit is provided in the high-voltage control box. Through the control of the equalizing resistor and the relay, energy transfer can be carried out between clusters to reduce the voltage difference and extend the battery life.

[0104] The specific working process is as follows: 1. Pre-power-on detection: Before the energy storage system is powered on, multiple battery management units 21 of the high-voltage control box will respectively detect the voltage, current, and temperature status of the corresponding connected battery clusters. If any abnormality is detected, such as a too large voltage difference, the system will not be powered on to prevent potential safety problems; 2. Pre-charging process: After confirming the normal system status, the battery management unit 21 will control the pre-charge relay 53 to close, and at the same time ensure that the main relay 81 is open to achieve pre-charging of the battery cluster; after pre-charging is completed, the pre-charge relay 53 is disconnected, and the main relay 81 is closed, and the battery cluster is connected to the power grid to start charging and discharging operations; 3. Charge and discharge control: During the charge and discharge process, the battery management unit 21 controls the on and off of the high-voltage relay by monitoring the voltage, current, and temperature of the battery cluster, and adjusts the charge and discharge power to ensure that the battery cluster operates within a safe range; 4. Fault detection and protection: The high-voltage control box also has a fault detection function. Once overvoltage, overcurrent, or temperature abnormality is detected, the battery management unit 21 will immediately disconnect the relevant relay or fuse 22 to cut off the circuit and protect the system; 5. Equalization between battery clusters: During the charge and discharge process, the battery management unit 21 will continuously monitor the voltage difference between battery clusters. If the difference exceeds the set range, the battery management unit 21 will activate the equalization circuit, and through the control of the equalization relay, transfer energy from the battery cluster with a higher voltage to the battery cluster with a lower voltage until the voltage difference is within a safe range.

[0105] In summary, the present application provides a high-voltage control box, a high-voltage control system, and an energy storage system; by providing at least two sets of battery control components 20 inside the installation box 10 in the present application, the high-voltage control box can efficiently control and manage multiple battery clusters, and can achieve balanced charging and discharging of multiple battery clusters, significantly improving the control efficiency and control reliability of multiple battery clusters; by stacking the battery management units 21 of at least two sets of battery control components 20 inside the installation box 10, space is effectively saved, and thus an integrated design is achieved inside the high-voltage control box with limited space, which not only simplifies the overall architecture but also effectively reduces the cost of controlling multiple battery clusters; the present application solves the problem that the existing high-voltage control box can only control one battery cluster; the structure of the present application is simple and the cost is low, which is suitable for popularization and use.

[0106] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0107] Unless otherwise specifically stated, the relative arrangements, numerical expressions, and numerical values of the components and steps set forth in these embodiments do not limit the scope of the present application. At the same time, it should be understood that, for the sake of convenience in description, the dimensions of the various parts shown in the drawings are not drawn in actual proportional relationships. Technologies, methods, and devices known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the said technologies, methods, and devices should be regarded as part of the authorization specification. In all the examples shown and discussed here, any specific value should be construed as merely exemplary and not as a limitation. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that like reference numerals and letters denote like items in the following drawings, and thus, once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0108] In the description of the present application, it should be understood that the orientation or positional relationships indicated by orientation words such as "front, rear, upper, lower, left, right", "lateral, vertical, perpendicular, horizontal", and "top, bottom", etc. are generally based on the orientation or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description. Without contrary statements, these orientation words do not indicate and imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and thus should not be construed as limiting the protection scope of the present application; the orientation words "inside, outside" refer to the inside and outside relative to the contour of each component itself.

[0109] For the convenience of description, spatial relative terms such as "above...", "over...", "on the upper surface of...", "above" can be used here to describe the spatial positional relationship of one device or feature to other devices or features as shown in the drawings. It should be understood that the spatial relative terms are intended to include different orientations in use or operation in addition to the orientation described in the drawings for the device. For example, if the device in the drawing is inverted, the device described as "above other devices or structures" or "over other devices or structures" will then be positioned "below other devices or structures" or "under other devices or structures". Thus, the exemplary term "above" can include both the orientations of "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and corresponding interpretations should be made for the spatial relative descriptions used here.

[0110] In addition, it should be noted that the use of words such as "first", "second", etc. to limit components is only for the convenience of distinguishing the corresponding components. Without otherwise stating, the above words have no special meanings, and thus should not be construed as limiting the protection scope of the present application.

[0111] The above are only the preferred embodiments of the present application and are not intended to limit the present application. For those skilled in the art, various changes and modifications can be made to the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included within the protection scope of the present application.

Claims

1. A high-voltage control box, characterized in that, Comprising: An installation box (10), and at least two sets of battery control components (20) arranged in the installation box (10). Each set of the battery control components (20) is electrically connected to a battery cluster and is used to control the operation of the battery cluster; each set of the battery control components (20) includes a battery management unit (21) and a heat source. The battery management unit (21) is used to monitor and manage the battery cluster electrically connected thereto; the battery management units (21) of at least two sets of the battery control components (20) are stacked in the installation box (10), and the stacking position (11) is spaced from the heat source.

2. The high-voltage control box according to claim 1, characterized in that, The heat source includes a fuse (22). The fuse (22) is located in the installation box (10), and the stacking position (11) is spaced from the fuses (22) of all the battery control components (20).

3. The high-voltage control box according to claim 1, wherein The battery control component (20) further includes a fuse (22) and at least one thermistor (23). The heat source includes the fuse (22). The thermistor (23) and the fuse (22) are respectively electrically connected to the battery management unit (21); the thermistor (23) is used to detect temperature.

4. The high-voltage control box according to claim 3, characterized in that, When there is one thermistor (23) in a set of the battery control components (20), the distance between the thermistor (23) and the fuse (22) in the same set of the battery control components (20) is within the range of 20 - 40 mm, so that the thermistor (23) can measure the temperature of the fuse (22) and the temperature inside the installation box (10) simultaneously.

5. The high-voltage control box according to claim 3, characterized in that, When there are at least two thermistors (23) in the battery control component (20), the distance between one of the thermistors (23) and the fuse (22) is less than 20 mm, so that this thermistor (23) only measures the temperature of the fuse (22); and / or, at least one of the thermistors (23) is a negative temperature coefficient thermistor (23).

6. The high-voltage control box according to claim 1, characterized in that The high - voltage control box further includes a main control switch and a power supply (30). The power supply (30) is respectively connected to each set of the battery control components (20) and is used to supply power to the battery control components (20); the main control switch is connected to the power supply (30) and is used to control the opening and closing of each set of the battery control components (20) simultaneously.

7. The high - voltage control box according to claim 6, wherein The power supply (30) supplies direct current to the battery control component (20). The high - voltage control box further includes a diode (40). The diode (40) is arranged on the direct - current circuit where the power supply (30) is connected to the battery control component (20) and is used to prevent current backflow; and / or, the power supply (30) is an AC - to - DC power supply, which is used to connect to an external AC circuit and convert it into direct current to supply the battery control component (20); and / or, the power supply (30) is arranged above the stacking position (11) and is located inside the installation box (10).

8. The high-voltage control box according to claim 1, wherein the internal space of the installation box (10) is an installation cavity (12), and the lines for connecting to the battery cluster in at least two sets of the battery control assemblies (20) are arranged in parallel respectively and are spaced on the bottom wall of the installation cavity (12); and / or, the battery management units (21) of at least two sets of the battery control assemblies (20) are stacked on the bottom wall of the installation cavity (12), and the stacking position (11) is located at a corner of the bottom wall.

9. The high-voltage control box according to claim 1, wherein The high-voltage control box further includes a balancing assembly, the balancing assembly includes a balancing resistor, a balancing relay and a balancing circuit; the balancing circuit is respectively connected to at least two of the battery clusters; the balancing resistor and the balancing relay are respectively arranged on the balancing circuit, and the balancing relay is connected to the battery management unit (21) for controlling the on-off of the balancing circuit; wherein, through the balancing assembly, the voltage between at least two of the battery clusters is balanced.

10. The high-voltage control box according to claim 9, wherein the high-voltage control box further includes a voltage detection assembly for detecting the voltage of each of the battery clusters; the voltage detection assembly is connected to the battery management unit (21); when the voltage difference between two of the battery clusters detected by the voltage detection assembly is in the range of greater than 5V and less than or equal to 20V, the battery management unit (21) controls the balancing relay to turn on the balancing circuit so that the battery cluster with a higher voltage charges the battery cluster with a lower voltage until the voltage difference between the two battery clusters is not greater than 5V; when the voltage difference between two of the battery clusters detected by the voltage detection assembly is greater than 20V, the battery management unit (21) determines that the battery cluster with a lower voltage is abnormal, suspends the charge and discharge operation of the battery cluster with a lower voltage, and issues an alarm message; and / or, the heat source includes the balancing resistor; when there are multiple balancing resistors, the stacking position (11) is spaced from all of the balancing resistors.

11. The high-voltage control box according to claim 1, characterized in that, The high-voltage control box further includes a pre-charging component (50) and an external connection component (80); the external connection component (80) includes a main circuit and a main relay (81), the battery cluster is connected to an external high-voltage power grid through the main circuit, the main relay (81) is arranged on the main circuit and connected to the battery management unit (21), and the main relay (81) is used to control the on-off of the main circuit; the pre-charging component (50) includes a pre-charging circuit (51), a pre-charging resistor (52) and a pre-charging relay (53), the pre-charging circuit (51) is respectively connected to the battery cluster and the external high-voltage power grid, the pre-charging resistor (52) and the pre-charging relay (53) are respectively arranged on the pre-charging circuit (51), and the pre-charging relay (53) is connected to the battery management unit (21) and is used to control the on-off of the pre-charging circuit (51); wherein, when the battery cluster starts to charge, the battery management unit (21) controls the pre-charging circuit (51) to conduct, and the main circuit is disconnected to pre-charge the battery cluster. When the difference between the voltage of the battery cluster and the voltage of the external high-voltage power grid is less than a set value, the pre-charging process is completed, the battery management unit (21) controls the pre-charging circuit (51) to disconnect, the main circuit conducts, and the battery cluster is connected to the external high-voltage power grid through the main circuit to charge or discharge.

12. The high-voltage control box according to claim 1, wherein the high-voltage control box further includes an external connection component (80); the external connection component (80) includes a main circuit, and the battery cluster is connected to an external high-voltage power grid through the main circuit; the high-voltage control box further includes a main copper bar, and the main copper bar is arranged on the main circuit and is used to transmit current and / or shunt to at least two of the battery clusters; wherein, the width of the main copper bar is not less than 30 mm and the thickness is not less than 3 mm; and / or, each set of the battery control components (20) includes a fuse (22) and a secondary copper bar, and the fuse (22) and the secondary copper bar are respectively arranged on the connection circuit between the battery control component (20) and the battery cluster; wherein, the width of the secondary copper bar is not less than 30 mm and the thickness is not less than 3 mm; and / or, the circuit connected to the battery management unit (21) and used to transmit data is a communication wire harness (60); the circuit used to supply power to the battery management unit (21) is a power supply wire harness; the circuit respectively connected to the battery cluster and the external high-voltage power grid is a high-voltage wire harness; the wire harness respectively connected to at least two of the battery clusters and used to balance the voltage between at least two of the battery clusters is an equalizing wire harness; at least two of the communication wire harness (60), the power supply wire harness, the high-voltage wire harness and the equalizing wire harness are insulated and spaced apart.

13. The high-voltage control box according to claim 1, wherein The high-voltage control box further includes a termination resistor and a transmission circuit. The termination resistor is replaceably disposed on the transmission circuit and is located outside the mounting box (10). The transmission circuit is respectively connected to the battery management unit (21) of each set of the battery control assemblies (20) and is used for transmitting data to the outside. And / or, the battery control assembly (20) further includes a cooling fan (24). The cooling fan (24) is connected to the battery management unit (21). The cooling fan (24) is disposed inside the mounting box (10). The cooling fan (24) drives air to circulate inside the mounting box (10) and flows through at least a part of the heat source. And / or, the mounting box (10) includes a box cover (13), a box body (14) and a gasket. An installation cavity (12) is formed inside the box body (14). At least a part of at least two sets of the battery control assemblies (20) is disposed inside the installation cavity (12). The box cover (13) is disposed on the box body (14). The gasket is disposed between the box cover (13) and the box body (14). The box cover (13) and the gasket jointly seal the installation cavity (12) to isolate the installation cavity (12) from the outside. And / or, the high-voltage control box further includes a control component (70). The control component (70) is connected to the battery control assembly (20). The battery control assembly (20) is controlled to work by operating the control end of the control component (70). A part of the outer surface of the mounting box (10) is a control panel (15). The control end is disposed on the control panel (15). The battery control assembly (20) further has electrical interfaces (25) for connecting to the outside. There are a plurality of the electrical interfaces (25), and at least a part of the plurality of electrical interfaces (25) is disposed on the control panel (15).

14. A high-voltage control system, characterized in that, The high-voltage control system includes the high-voltage control box according to any one of claims 1 to 13. The high-voltage control system further includes at least two battery clusters. At least two of the battery clusters are connected to at least two sets of the battery control assemblies (20) in one-to-one correspondence.

15. An energy storage system, characterized in that, The energy storage system includes the high-voltage control system according to claim 14. The energy storage system further includes a liquid cooling component for cooling the high-voltage control box and / or the battery clusters.

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