Vehicle battery voltage acquisition and protection system based on FPC

Abstract

The invention relates to the technical field of battery voltage acquisition and protection, in particular to a vehicle battery voltage acquisition and protection system based on an FPC (Flexible Printed Circuit), which is characterized in that an acquisition module acquires voltage, current and temperature parameters through an FPC; the control module generates initial channel configuration of the FPC based on Score (P) = w1 * U (P) + w2 * R (P) + w3 * I (P); the safety protection module detects the change of the contact impedance rate of the main channel; when the contact impedance rate is greater than 15%, generating an interrupt code, interrupting a main channel through a programmable interrupt controller, and starting a redundant channel; and the control module adjusts weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interrupt code. According to the method, channel resources are dynamically planned and configured, the health state of the main channel is continuously evaluated, the continuity of the system is guaranteed by rapidly taking over redundant channels, the channel configuration strategy is optimized according to fault feedback, normal work of the acquisition and protection system is ensured, and the safety of the battery voltage acquisition and protection system is remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of battery voltage acquisition and protection, and in particular to an FPC-based vehicle battery voltage acquisition and protection system. Background Art

[0002] In the automotive battery voltage acquisition and protection system, the reliability and stability of the channel are crucial to the normal operation of the entire battery system.

[0003] At present, traditional automotive battery voltage collection and protection methods mostly use a single channel for data transmission and monitoring. This method has obvious technical problems. Once a channel fails, such as poor contact or line damage, the entire collection and protection system will not work properly, resulting in the inability to accurately collect key parameters such as the battery cell module voltage, current, and temperature. This may cause safety hazards such as battery overcharging, over-discharging, and overheating, seriously affecting the safety of the vehicle. Therefore, it is necessary to improve it. Summary of the Invention

[0004] The purpose of the present invention is to address the shortcomings of the existing technology and provide an FPC-based automotive battery voltage acquisition and protection system. By dynamically planning and configuring channel resources, the health status of the main channel is continuously evaluated, and the redundant channel quickly takes over to ensure system continuity, the channel configuration strategy is optimized according to fault feedback, ensuring the normal operation of the acquisition and protection system, and significantly improving the safety of the battery voltage acquisition and protection system.

[0005] To achieve the above objectives, the present invention provides an FPC-based vehicle battery voltage acquisition and protection system, comprising an acquisition module, an FPC flexible circuit board, a control module, a data processing module, and a safety protection module;

[0006] The acquisition module is connected to the battery module through the contacts of the FPC flexible circuit board;

[0007] The FPC flexible circuit board is provided with a main channel and a redundant channel, and the contact impedance rate of the main channel is greater than the contact impedance rate of the redundant channel;

[0008] The control module is used to perform the following functions:

[0009] The initial channel configuration of the FPC flexible circuit board is generated by the dynamic programming algorithm Score(P), Score(P) = w1·U(P)+w2·R(P)+w3·I(P), where U(P) is the channel utilization, R(P) is the channel reliability, and I(P) is the signal interference level.

[0010] Adjust the weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interrupt code, w1∈[0.4,0.8], w2∈[0.1,0.4], w3∈[0.05,0.2], and w1+w2+w3=1;

[0011] The data processing module is used to provide the channel reliability parameter R(P) of the FPC flexible circuit board;

[0012] The safety protection module is used to detect changes in the contact impedance rate of the main channel;

[0013] The method comprises:

[0014] The acquisition module collects voltage, current and temperature parameters through the FPC flexible circuit board;

[0015] The control module generates the initial channel configuration of the FPC flexible circuit board based on Score(P)=w1·U(P)+w2·R(P)+w3·I(P);

[0016] The safety protection module detects changes in the contact impedance rate of the main channel;

[0017] When the contact resistance rate is greater than 15%, an interrupt code is generated, the programmable interrupt controller interrupts the main channel and enables the redundant channel;

[0018] The control module adjusts the weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interrupt code.

[0019] Beneficial effects of the present invention: The present invention configures channel resources through dynamic planning, continuously evaluates the health status of the main channel, quickly takes over the redundant channel to ensure system continuity, optimizes the channel configuration strategy based on fault feedback, ensures the normal operation of the acquisition and protection system, and significantly improves the safety of the battery voltage acquisition and protection system. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a flowchart of the present invention.

[0021] Figure 2 It is a schematic diagram of a partial sectional side view of the present invention.

[0022] Figure 3 It is a schematic diagram of the partial structure of the heat conducting member of the present invention from a top view.

[0023] Figure 4 It is a schematic diagram of the partial structure of the fixing frame of the present invention from a top view.

[0024] Reference numerals include:

[0025] 1. Acquisition module;

[0026] 2. FPC flexible circuit board; 21. Insulation reinforcement plate; 211. Conductive part; 22. Solder pad;

[0027] 3. Control module;

[0028] 4. Data processing module;

[0029] 5. Security protection module;

[0030] 6. Fixing frame; 61. Fixing hole; 62. Connection slot; 63. Aluminum bar; 631. Welding slot; 632. Welding operation port;

[0031] 7. Heat conducting member; 71. Fixing groove; 72. Locking strip; 721. Deformation portion; 7211. First arc-shaped elastic member; 7212. Second arc-shaped elastic member; 73. Locking cavity;

[0032] 8. Insulation; 81. Inserts. DETAILED DESCRIPTION

[0033] The present invention is described in detail below with reference to the accompanying drawings.

[0034] like Figure 1 As shown, the FPC-based vehicle battery voltage acquisition and protection system of the present invention includes an acquisition module 1, an FPC flexible circuit board 2, a control module 3, a data processing module 4 and a safety protection module 5;

[0035] The acquisition module 1 is connected to the battery module through the contacts of the FPC flexible circuit board 2;

[0036] The FPC flexible circuit board 2 is provided with a main channel and a redundant channel, and the contact resistance ratio ΔR of the main channel is greater than the contact resistance ratio ΔR of the redundant channel;

[0037] The control module 3 is used to perform the following functions:

[0038] The initial channel configuration of the FPC flexible circuit board 2 is generated by the dynamic programming algorithm Score(P), Score(P) = w1·U(P)+w2·R(P)+w3·I(P), where U(P) is the channel utilization, R(P) is the channel reliability, and I(P) is the signal interference level;

[0039] Adjust the weight coefficients of w1, w2, and w3 of the dynamic programming algorithm according to the interrupt code, w1∈[0.4,0.8], w2∈[0.1,0.4], w3∈[0.05,0.2], and w1+w2+w3=1;

[0040] The data processing module 4 is used to provide the channel reliability parameter R(P) of the FPC flexible circuit board 2;

[0041] The safety protection module 5 is used to detect the change of the contact resistance ratio ΔR of the main channel;

[0042] Methods include:

[0043] The acquisition module 1 collects voltage, current and temperature parameters through the FPC flexible circuit board 2;

[0044] The control module 3 generates the initial channel configuration of the FPC flexible circuit board 2 based on Score(P)=w1·U(P)+w2·R(P)+w3·I(P);

[0045] The safety protection module 5 detects the change of the contact resistance ratio ΔR of the main channel;

[0046] When the contact resistance ratio ΔR>15%, an interrupt code is generated, the programmable interrupt controller interrupts the main channel and enables the redundant channel;

[0047] The control module 3 adjusts the weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interruption code.

[0048] A main channel and a redundant channel are provided through the FPC flexible circuit board 2. When the contact impedance ratio ΔR of the main channel changes beyond a threshold, the main channel can be quickly interrupted and the redundant channel can be enabled through the programmable interrupt controller, ensuring the continuous and stable operation of the battery voltage collection and protection functions, and avoiding failure of the entire system due to a single channel failure.

[0049] Control module 3 uses the dynamic programming algorithm Score(P) to generate the initial channel configuration, comprehensively considering three factors: channel utilization U(P), channel reliability R(P), and signal interference level I(P). It can find the optimal channel configuration solution based on actual needs and improve system performance and efficiency.

[0050] The control module 3 can dynamically adjust the weight coefficients of channel reliability and signal interference degree in the dynamic programming algorithm according to the interruption code, so that the channel configuration can adapt to different working conditions and environmental changes, further improving the flexibility and adaptability of the system.

[0051] The safety protection module 5 detects the change of the contact impedance rate ΔR of the main channel in real time, can promptly discover potential channel fault hazards, and quickly take protective measures to prevent the fault from expanding and ensure the safety of the battery system.

[0052] Ideally, the gold plating thickness of the contacts on the primary and redundant channels should be ≥ 0.2 μm. This gold plating improves contact conductivity and corrosion resistance, reducing contact resistance during long-term use. The contact impedance ratio ΔR of the primary channel should be ≤ 10 mΩ, while that of the redundant channel should be ≤ 8 mΩ. The lower impedance ratio of the redundant channel ensures signal quality after switching.

[0053] Furthermore, the FPC flexible circuit board 2 also includes an emergency wireless communication module. When the safety protection module 5 detects that the contact impedance rate ΔR of the main channel and the redundant channel is greater than 15%, an interrupt code is generated, and the main channel and the redundant channel are interrupted through the programmable interrupt controller, and the communication link of the emergency wireless communication module is activated to maintain the battery cell voltage sampling of ≥1Hz.

[0054] By setting up an emergency wireless communication module through FPC, a wireless communication link independent of wired transmission is established, building a third-level fault-tolerant channel, and maintaining basic monitoring when all physical connections fail.

[0055] When the channel impedance ratio of the main channel and the redundant channel is greater than 15%, the emergency wireless communication module is activated to avoid the monitoring blind area caused by the double failure of the main channel and the redundant channel and prevent the battery from losing control.

[0056] Dual-channel disconnection is performed through a programmable interrupt controller, and hardware-level interrupt response is used to implement channel isolation, eliminating electromagnetic interference (EMI) from faulty channels on wireless signals.

[0057] Maintain ≥1Hz sampling through wireless communication of the emergency wireless communication module, set the minimum effective sampling frequency threshold, and balance the energy consumption and data continuity requirements in emergency mode.

[0058] Specifically, the FPC flexible circuit board 2 integrates a LoRa communication chip, has an operating frequency band of 433 MHz, and adopts an SF7 spreading factor and a 125 kHz bandwidth configuration.

[0059] The collected data is encapsulated into a 12-byte short frame, including a 4-byte cell ID, a 4-byte voltage value, and a differential encoding check bit.

[0060] Specifically, the control module 3 includes a main control chip, which is a 32-bit MCU (such as STM32H743), with an operating frequency of ≥400MHz and a built-in FPU unit;

[0061] The data processing module 4 includes a calculation unit and data storage. The calculation unit is integrated into the MCU. The data storage is used to cache real-time data (SRAM) and store historical fault records (EEPROM, such as AT24C256).

[0062] Safety protection module 5 is a contact impedance detection circuit that uses a four-wire Kelvin test method, applying a 1mA test current with a constant current source (such as an LM334). The programmable interrupter (such as an ARM Cortex-M series NVIC controller or a RISC-V architecture PLIC controller) has a response time of ≤100ns. The programmable interrupter controls the primary channel via a MOSFET switch and the redundant channel via a relay.

[0063] The acquisition module 1 of this embodiment includes at least one multi-channel acquisition chip and at least one signal conditioning circuit;

[0064] The multi-channel acquisition chip is used to monitor the voltage, current, and temperature parameters of the battery cells in the battery module. Specifically, the multi-channel acquisition chip integrates multiple analog-to-digital conversion (ADC) channels to simultaneously monitor the voltage, current, and temperature signals of multiple cells in the battery module, avoiding the signal delays and error accumulation caused by traditional single-channel time-sharing acquisition. Signal acquisition parallelism is increased by ≥3 times, and the battery cell status monitoring response time is shortened to ≤5ms, achieving millisecond-level synchronous acquisition of battery cell parameters across the entire module, eliminating status deviations caused by time-sharing scanning.

[0065] The signal conditioning circuit is used to filter, amplify, and perform anti-interference processing on the collected signals to ensure the accuracy of the working data. Specifically, a low-pass filter is used to suppress high-frequency noise (such as switching power supply ripple and electromagnetic radiation), and a programmable gain amplifier (PGA) is used to compensate for weak signal attenuation, ensuring that the signal amplitude matches the ADC input range. The signal-to-noise ratio (SNR) is improved by ≥20dB, increasing the success rate of weak signal acquisition (such as millivolt-level single-cell voltage) and avoiding misjudgments due to signal distortion. The multi-channel acquisition chip model is TIBQ76952.

[0066] In this embodiment, channel utilization U(P) is calculated as: (actual sampling time / total cycle time) × 100%. By quantifying the proportion of time a channel actually performs data acquisition, the effective utilization of channel resources is measured, avoiding resource waste or performance bottlenecks caused by idle or overloaded channels. This enables dynamic allocation of channel resources, improves channel utilization, avoids overheating or sampling distortion caused by high load on a single channel, and improves system throughput by balancing load across multiple channels.

[0067] The channel reliability R(P) value is calculated based on the number of historical failures and the stability of the contact resistance ratio ΔR. Failure events caused by poor contact, line breaks, etc. during the channel's operating cycle are counted to quantify the risk of frequent failures.

[0068] Contact resistance ratio ΔR stability: By real-time monitoring of the contact resistance ratio ΔR fluctuation range (such as standard deviation ≤ 2mΩ), the long-term electrical stability of the channel is evaluated.

[0069] By combining the two, a numerical reliability model is constructed to improve the accuracy of fault prediction and identify potential hazards such as contact oxidation and mechanical fatigue in advance. The switching timing of redundant channels is optimized to avoid performance jitter caused by incorrect switching, and the system's mean time between failures is extended to 2.5 times that of traditional solutions.

[0070] The specific calculation formula for the channel reliability R(P) value is:

[0071]

[0072] Where Nf is the number of historical faults, R1 = 0.5, R1 is the historical fault impact coefficient (exponential decay factor); R2 = 3, R2 is the impedance stability sensitivity coefficient (linear amplification factor); based on the difference between R1 and R2, real-time impedance changes are prioritized (85% weight), while historical data (15% weight) is also taken into account.

[0073] In the threshold range (R(P)=0.4-0.6), it exhibits a high gradient characteristic, which enables the system to respond quickly to critical states.

[0074] Transform the vague concept of "reliability" into measurable numerical indicators to meet the quantitative requirements of ISO 26262 standard for functional safety.

[0075] The signal interference level, I(P), is determined by analyzing the power ratio of components greater than 1kHz in the acquired signal using a Fast Fourier Transform (FFT). Specifically, the FFT transform is used to convert the time-domain signal into a frequency-domain distribution. The ratio of high-frequency noise (greater than 1kHz) to the total signal power is calculated, quantifying the impact of electromagnetic interference, switching noise, and other factors on the data.

[0076] Interference positioning accuracy reaches ±0.5kHz, and can distinguish different interference sources such as motor harmonics (2-10kHz) and inverter spikes (100kHz level);

[0077] When the dynamic programming algorithm weights are dynamically adjusted, the channel switching response speed is improved by 40% in a high-interference environment (I(P)>15%), avoiding SOC estimation errors greater than 5% caused by sampling data jumps.

[0078] The calculation formula of the contact resistance ratio ΔR in this embodiment is:

[0079]

[0080] Where R0 is the initial nominal impedance of the contact, and Rcurrent is the real-time measured contact impedance ratio ΔR. The difference between the real-time impedance Rcurrent and the initial impedance R0 eliminates the influence of inherent differences in contact parameters such as material and size, and reflects the degree of impedance degradation.

[0081] Comparing the impedance change rate to a preset threshold (e.g., 15%), rather than the absolute value, allows for adaptable health assessment of contacts of varying specifications. This allows for early identification of hidden faults such as contact oxidation and mechanical fatigue, preventing poor contact caused by a gradual increase in impedance.

[0082] By calculating the relative rate of change, the influence of ambient temperature fluctuation (within ±10°C) on the absolute value of impedance is eliminated, and the fault false alarm rate is ≤0.3%.

[0083] When the change rate is greater than 15%, switching is triggered, and the redundant channel takeover success rate reaches 100%, avoiding data jumps caused by impedance degradation of the main channel.

[0084] The programmable interrupt controller of this embodiment interrupts the main channel and enables the redundant channel specifically as follows:

[0085] The highest level interrupt is triggered by the programmable interrupt controller, and the following operations are completed in less than 5ms:

[0086] a) Turn off the MOSFET switch of the main channel;

[0087] b) Activate the power relay of the redundant channel.

[0088] Specifically, the programmable interrupt controller vector table is configured to set the channel switching instruction to the highest priority (e.g., NVIC interrupt group level 0), ensuring that fault signals are responded to before other tasks (e.g., CAN communication, data logging). This eliminates software polling delays, and the interrupt response time after fault detection is ≤ 50ns.

[0089] Compared to traditional software polling solutions (response time > 10ms), interrupt response speed is increased by ≥200 times, eliminating the risk of transient overvoltage / overcurrent caused by sudden changes in the main channel impedance (such as contact failure). Even when strong electromagnetic interference causes data sampling anomalies, interrupt triggering is guaranteed to be 100%, improving system robustness.

[0090] A MOSFET (such as the AON7407, with a turn-off time ≤ 0.8ms or the IPB180N04S4, with a turn-off delay ≤ 100ns) cuts off the current path in the primary channel, preventing fault propagation to the redundant channel. The residual current in the contact is less than 10mA. When the contact resistance ΔR exceeds 15% (e.g., oxidation results in R = 20mΩ), turning off the MOSFET prevents local overheating of the contact (e.g., >150°C, which can cause carbonization of the insulation layer).

[0091] Select a solid-state relay (such as the AQV252G, with a pull-in time ≤2ms) or a latching relay (such as the G6K-2F, with actuation time ≤3ms) and provide the drive current through the PIC's PWM output pin. Connect an RC snubber circuit (R = 10Ω, C = 1μF) in parallel with the relay contacts to absorb the transient inrush current (e.g., ≤5A) caused by charging the load capacitor and prevent contact welding.

[0092] The total time from the main channel closing to the redundant channel activation is ≤4.8ms, the voltage sampling data continuity is maintained ≥99.99%, and the SOC estimation error is avoided>1%. The relay life is up to 10 7 More than times, meeting the 15-year automotive grade use requirement, and the redundancy switching success rate is >99.999%.

[0093] In this embodiment, after each channel switching, the control module 3 dynamically adjusts the weight coefficient of the dynamic programming algorithm Score (P) according to the fault type in the following specific method:

[0094] Switching due to R(P) exceeding the standard: w2=min(w2×1.3,0.5);

[0095] Switching due to I(P) exceeding the standard: w3=min(w3×1.5,0.4).

[0096] Specifically, when switching due to R(P) exceeding the standard, the channel utilization weight is increased when reliability degrades, forcing the algorithm to give priority to high-utilization channels and reduce the probability of faulty channel reuse.

[0097] When switching due to I(P) exceeding the standard, the anti-interference weight is strengthened when the signal interference is serious, the selection of high-frequency interference channels is suppressed, and the signal-to-noise ratio of signal acquisition is improved.

[0098] By constraining the upper limit of the weight coefficient and setting the weight growth threshold, we can prevent a single parameter from being too dominant and maintain the balance of multi-objective optimization of the dynamic programming algorithm.

[0099] Control module 3 uses a weight adjustment mechanism that adapts to the fault type to accurately match the channel switching strategy to the failure cause. For example, when reliability decreases, the focus is on utilization; when interference increases, the focus is on anti-interference performance, thereby improving the switching effectiveness in scenarios such as contact failure and electromagnetic interference.

[0100] like Figure 2 As shown, this embodiment includes a fixing frame 6, a heat conductor 7, and an insulating member 8. The acquisition module 1 and the FPC flexible circuit board 2 are both fixed to the fixing frame 6, the heat conductor 7 is arranged at the bottom of the fixing frame 6, and the insulating member 8 is arranged at the top of the fixing frame 6.

[0101] Specifically, the heat conductor 7 is connected to the temperature control system of the battery for heat conduction. The heat conductor 7 adopts a 6061 aluminum alloy substrate (thermal conductivity coefficient 167W / m·K) and is directly bonded to the bottom of the fixing frame 6 through a thermal conductive silicone pad (thermal conductivity coefficient 3W / m·K), forming a sandwich structure of "acquisition module 1-fixing frame 6-heat conductor 7".

[0102] At an ambient temperature of 40°C, the junction temperature of the acquisition module 1 chip drops from 110°C to 85°C, extending the device life by three times (estimated using the Arrhenius model). When the module temperature exceeds 90°C, the thermal conductor 7 quickly dissipates heat, preventing carbonization of the insulation layer caused by local overheating (a >50% drop in breakdown voltage).

[0103] The insulating member 8 is made of PC+30% glass fiber composite material (CTI≥600V), with a thickness of 1.5mm and a ceramic silicone rubber coating (volume resistivity>105 Ω·cm), covering the top of the fixing frame 6 and the exposed area of the FPC circuit board.

[0104] In an 800V high voltage system, the insulation component 8 can withstand a 10kV power frequency withstand voltage test (1 minute without breakdown), and the creepage distance meets the Class III level (≥8mm). In the electrolyte splash test (IP69K), the surface impedance of the insulation component 8 remains >10 12 Ω, avoiding the risk of short circuit caused by conductive ion deposition.

[0105] The acquisition module 1 connects to the FPC via a ZIF connector. A U-shaped slot is designed in the corresponding position of the mounting bracket 6, allowing the FPC to flex within a ±5° range, relieving assembly tolerances and thermal expansion stress. The FPC's copper grounding foil and mounting bracket 6 are grounded via conductive foam (surface resistance <0.1Ω), forming a Faraday cage structure that shields >40dB of interference in the 150kHz-1GHz frequency band.

[0106] like Figure 2 and Figure 3 As shown, the insulating member 8 of this embodiment is provided with an inserting strip 81, the fixing frame 6 is provided with a fixing hole 61, the heat conducting member 7 is provided with a fixing groove 71, the inserting strip 81 is inserted into the fixing groove 71 through the fixing hole 61, a through hole is provided at the lower portion of the inserting strip 81, the fixing groove 71 is provided with a locking strip 72 and a locking cavity 73, the end portion of the locking strip 72 is provided with a deformation portion 721, the locking cavity 73 is provided on one side of the fixing groove 71 and is communicated with the fixing groove 71,

[0107] The end of the locking bar 72 is inserted into the locking cavity 73 through the through-hole, and the deformed portion 721 at the end of the locking bar 72 contacts the locking cavity 73. As the end of the locking bar 72 penetrates the through-hole, the deformed portion 721 at the end of the locking bar 72 is squeezed by the sidewall of the through-hole and elastically bends. After entering the locking cavity 73, the deformed portion 721 at the end of the locking bar 72 recovers its deformation and becomes firmly fixed to the locking cavity 73, achieving self-locking of the locking bar 72. Under the action of external forces, the locking bar 72 and the locking cavity 73 remain locked. The elastic deformation of the deformed portion 721 at the end of the locking bar 72 generates continuous contact pressure, forming dynamic compensating contact, which adapts to material deformation caused by temperature changes.

[0108] Preferably, the deformable portion 721 at the end of the lock bar 72 includes a first curved elastic member 7211 and a second curved elastic member 7212. The first curved elastic member 7211 and the second curved elastic member 7212 are spaced apart to provide space for deformation and displacement of the first curved elastic member 7211 and the second curved elastic member 7212. When under pressure, the first curved elastic member 7211 and the second curved elastic member 7212 move closer to each other, reducing the outer profile of the deformable portion 721 at the end of the lock bar 72 to facilitate passage through the through hole. When not under pressure, the first curved elastic member 7211 and the second curved elastic member 7212 move away from each other and return to their original position, causing the deformable portion 721 at the end of the lock bar 72 to abut against the locking cavity 73.

[0109] Furthermore, the contact resistance ratio ΔR detection includes a life prediction algorithm, specifically:

[0110] A) A state equation is constructed based on a Kalman filter, with the input parameters of the fixed frame vibration acceleration VIBK and the real-time contact impedance RK. The output is the contact predicted impedance RKY, which is RKY = RK + 0.03·VIBK·TS, where TS = 100ms.

[0111] B) When the contact predicted impedance RKY>14%, the programmable interrupt controller is triggered in advance to switch channels. The numerical calculation formula of channel reliability R(P) is:

[0112]

[0113] , where Nf is the number of historical faults, ΔR is the contact impedance ratio detected in real time, and VIBrms is the effective value of vibration.

[0114] By constructing a state equation through a Kalman filter, the vibration acceleration and real-time impedance data are dynamically integrated to improve the accuracy of contact life prediction. The time interval TS = 100ms sets the optimal state update cycle to balance the real-time prediction and computing resource consumption. The predicted impedance RKY>14% triggers the switch, achieving the effect of setting a dual threshold for channel switching and avoiding the risk of progressive contact failure in advance. The R(P) formula introduces the VIBrms parameter, and the effective value of vibration quantifies the cumulative effect of mechanical shock. The reliability assessment covers the dual factors of physical wear and electrical degradation. Through the vibration and impedance coupling prediction model and dynamic reliability assessment, channel switching is completed before the physical damage of the contact reaches the critical threshold, which will reduce the risk of system crash due to contact failure.

[0115] like Figure 4 As shown, the fixing frame 6 of this embodiment is provided with a connection groove 62 and an aluminum bar 63. The aluminum bar 63 is fixed on both sides of the connection groove 62 and is used to connect to the battery module. The aluminum bar 63 is cut from the side to form a welding groove 631. The top of the aluminum bar 63 is penetrated by a welding operation port 632 that communicates with the welding groove 631.

[0116] Both sides of the FPC flexible circuit board 2 are provided with an insulating reinforcement plate 21, and the end of the FPC flexible circuit board 2 connected to the battery module is provided with a soldering pad 22;

[0117] One end of the insulating reinforcing plate 21 connected to the pad 22 is provided with a conductive portion 211, and the conductive portion 211 is connected to the bottom of the pad 22;

[0118] The FPC 2 is inserted into the fixing frame 6 along the connection slot 62. Simultaneously, the conductive portion 211 and the solder pad 22 of the reinforcing plate are inserted into the soldering slot 631. An external soldering device solders the conductive portion 211 and the solder pad 22 of the reinforcing plate to the aluminum bar 63 through the soldering operation port 632. This ensures that the FPC 2 is soldered to the aluminum bar 63 via the conductive portion 211 and the solder pad 22. Furthermore, the soldering point between the conductive portion 211 and the solder pad 22 and the aluminum bar 63 is protected within the soldering slot 631 and is less susceptible to external influences, ensuring the stability of the soldering between the conductive portion 211 and the solder pad 22 and the aluminum bar 63.

[0119] On the other hand, by inserting the conductive portion 211 of the insulating reinforcement plate 21 and the solder pad 22 together into the soldering groove 631, the solder pad 22 is precisely positioned on the aluminum bar 63. Simultaneously, the insulating reinforcement plate 21 supports the solder pad 22, preventing deformation and maintaining a straight position. This facilitates external soldering equipment to solder the conductive portion 211 of the insulating reinforcement plate 21 and the solder pad 22 together to the aluminum bar 63 through the soldering operation port 632.

[0120] The characteristic of this embodiment is that the FPC flexible circuit board 2 is provided with a piezoelectric material layer, which converts mechanical vibration into electrical energy. The energy storage capacitor of the piezoelectric material layer has a capacity ≥100μF and supplies power to the ADC circuit of the acquisition module 1.

[0121] The piezoelectric effect of the piezoelectric material layer is used to convert the mechanical vibration energy of the battery module into electrical energy to achieve self-supply of energy and eliminate the collection interruption caused by external power supply line failure.

[0122] By integrating ≥100μF energy storage capacitors in the piezoelectric layer, the large-capacity energy storage element buffers the charging and discharging process, stabilizes the operating voltage of the ADC circuit, and prevents power supply fluctuations during vibration intervals.

[0123] The piezoelectric power supply system is directly connected to the ADC circuit, and a closed-loop vibration energy-electric energy-signal acquisition link is constructed to ensure the continuous operation of the key acquisition module 1 under extreme working conditions.

[0124] Furthermore, the energy storage capacitor capacity integrated in the piezoelectric layer is increased to 220μF, providing intermittent power supply with a duty cycle of ≤0.1% for the LoRa communication chip (working cycle: 10ms activation / 9.99s sleep).

[0125] The above contents are only preferred embodiments of the present invention. For ordinary technicians in this field, according to the concept of the present invention, there may be changes in the specific implementation methods and application scopes. The contents of this specification should not be understood as limiting the present invention.

Claims

1. A vehicle battery voltage acquisition and protection system based on FPC, characterized in that: It comprises an acquisition module (1), an FPC flexible circuit board (2), a control module (3), a data processing module (4) and a safety protection module (5); The acquisition module (1) is connected to the battery module via contacts of the FPC flexible circuit board (2); The FPC flexible circuit board (2) is provided with a main channel and a redundant channel, and the contact resistance ratio ΔR of the main channel is greater than the contact resistance ratio ΔR of the redundant channel; The control module (3) is used to perform the following functions: The initial channel configuration of the FPC flexible circuit board (2) is generated by the dynamic programming algorithm Score(P), Score(P) = w1·U(P)+w2·R(P)+w3·I(P), where U(P) is the channel utilization, R(P) is the channel reliability, and I(P) is the signal interference degree; Adjust the weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interrupt code, w1∈[0.4,0.8], w2∈[0.1,0.4], w3∈[0.05,0.2], and w1+w2+w3=1; The data processing module (4) is used to provide a channel reliability parameter R(P) of the FPC flexible circuit board (2); The safety protection module (5) is used to detect the change of the contact impedance ratio ΔR of the main channel; The method comprises: The acquisition module (1) acquires voltage, current and temperature parameters via an FPC flexible circuit board (2); The control module (3) generates an initial channel configuration of the FPC flexible circuit board (2) based on Score(P)=w1·U(P)+w2·R(P)+w3·I(P); The safety protection module (5) detects the change of the contact impedance ratio ΔR of the main channel; When the contact resistance ratio ΔR>15%, an interrupt code is generated, the programmable interrupt controller interrupts the main channel and enables the redundant channel; The control module (3) adjusts the weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interruption code.

2. The FPC-based vehicle battery voltage acquisition and protection system according to claim 1, characterized in that: The acquisition module (1) comprises at least one multi-channel acquisition chip and at least one signal conditioning circuit; The multi-channel acquisition chip is used to monitor the voltage, current and temperature parameter signals of the battery cells in the battery cell module; The signal conditioning circuit is used to filter, amplify and perform anti-interference processing on the collected signals to ensure the accuracy of the working data.

3. The FPC-based vehicle battery voltage acquisition and protection system according to claim 1, characterized in that: The channel utilization U(P) is calculated as follows: (actual sampling time / total cycle time)×100%; The value of the channel reliability R(P) is calculated based on the number of historical failures and the stability of the contact impedance ratio; The value of the signal interference level I(P) is obtained by analyzing the power ratio of the component >1kHz in the collected signal through fast Fourier transform.

4. The FPC-based vehicle battery voltage acquisition and protection system according to claim 1, characterized in that: The calculation formula of contact resistance ΔR is: Where R0 is the initial nominal impedance of the contact, and Rcurrent is the contact impedance ratio detected in real time.

5. The FPC-based vehicle battery voltage acquisition and protection system according to claim 1, characterized in that: The programmable interrupt controller interrupts the main channel and enables the redundant channel specifically: The highest-level interrupt is triggered by the programmable interrupt controller, and the following operations are completed in less than 5ms: a) Turn off the MOSFET switch of the main channel; b) Activate the power relay of the redundant channel.

6. According to the FPC-based vehicle battery voltage acquisition and protection system of claim 1, after each channel switching, the control module (3) dynamically adjusts the weight coefficient of the dynamic programming algorithm Score (P) according to the fault type in the specific method as follows: Switching due to R(P) exceeding the standard: w2=min(w2×1.3,0.5); Switching due to I(P) exceeding the standard: w3=min(w3×1.5,0.4).

7. The FPC-based vehicle battery voltage acquisition and protection system according to claim 1, characterized in that: The device comprises a fixing frame (6), a heat conducting member (7), and an insulating member (8); the acquisition module (1) and the FPC flexible circuit board (2) are both fixed to the fixing frame (6); the heat conducting member (7) is arranged at the bottom of the fixing frame (6); and the insulating member (8) is arranged at the top of the fixing frame (6).

8. The FPC-based vehicle battery voltage acquisition and protection system according to claim 7, characterized in that: The insulating member (8) is provided with an inserting strip (81), the fixing frame (6) is provided with a fixing hole (61), the heat conducting member (7) is provided with a fixing groove (71), the inserting strip (81) is inserted into the fixing groove (71) through the fixing hole (61), a through hole is provided at the lower portion of the inserting strip (81), the fixing groove (71) is provided with a locking strip (72) and a locking cavity (73), the end portion of the locking strip (72) is provided with a deformation portion (721), the locking cavity (73) is provided on one side of the fixing groove (71) and is communicated with the fixing groove (71), The end of the locking bar (72) is inserted into the locking cavity (73) through the through hole, and the deformed portion (721) at the end of the locking bar (72) contacts the locking cavity (73).

9. The FPC-based vehicle battery voltage acquisition and protection system according to claim 7, characterized in that: The fixing frame (6) is provided with a connection groove (62) and an aluminum bar (63), the aluminum bar (63) is fixed to both sides of the connection groove (62) and is used to connect with the battery module, the aluminum bar (63) is cut from the side to form a welding groove (631), and the top of the aluminum bar (63) is penetrated by a welding operation port (632) that is in communication with the welding groove (631); Both ends of the FPC flexible circuit board (2) are provided with insulating reinforcement plates (21), and one end of the FPC flexible circuit board (2) connected to the battery module is provided with a soldering pad (22); One end of the insulating reinforcing plate (21) connected to the soldering pad (22) is provided with a conductive portion (211), and the conductive portion (211) is connected to the bottom of the soldering pad (22); The FPC flexible circuit board (2) is inserted into the fixing frame (6) along the connecting groove (62), and the conductive portion (211) and the soldering pad (22) of the reinforcing plate are simultaneously inserted into the soldering groove (631). An external soldering device solders the conductive portion (211) and the soldering pad (22) of the reinforcing plate to the aluminum bar (63) through the soldering operation port (632).

10. The FPC-based vehicle battery voltage acquisition and protection system according to claim 1, characterized in that: The FPC flexible circuit board (2) is provided with a piezoelectric material layer, which converts mechanical vibration into electrical energy. The energy storage capacitor of the piezoelectric material layer, with a capacity of ≥100 μF, supplies power to the ADC circuit of the acquisition module (1).

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