A FPC-based battery voltage acquisition and protection system for vehicle

Abstract

The present application relates to the technical field of battery voltage acquisition and protection, and particularly relates to a battery voltage acquisition and protection system based on FPC, wherein a collection module collects voltage, current and temperature parameters through an FPC flexible circuit board; an initial channel configuration of the FPC flexible circuit board is generated by a control module based on Score(P)=w1·U(P)+w2·R(P)+w3·I(P); a safety protection module detects the change of contact impedance rate of the main channel; when the contact impedance rate is greater than 15%, an interrupt code is generated to interrupt the main channel through a programmable interrupt controller and enable the redundant channel; and the control module adjusts the weight coefficients of w2 and w3 of the dynamic programming algorithm according to the interrupt code. The present application configures channel resources through dynamic programming, continuously evaluates the health status of the main channel, quickly takes over the redundant channel to guarantee the continuity of the system, optimizes the channel configuration strategy according to the fault feedback, ensures the normal work of the acquisition and protection system, and significantly improves the safety of the battery voltage acquisition and protection system.

Description

Technical Field

[0001] This invention relates to the field of battery voltage acquisition and protection technology, and in particular to an FPC-based vehicle battery voltage acquisition and protection system. Background Technology

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

[0003] Currently, most traditional methods for acquiring and protecting vehicle battery voltage use a single channel for data transmission and monitoring. This approach has significant technical problems. If the channel malfunctions, such as poor contact or damaged wiring, the entire acquisition and protection system will fail to function properly. This will result in the inaccurate acquisition of key parameters such as battery cell module voltage, current, and temperature, potentially leading to safety hazards such as overcharging, over-discharging, and overheating, which seriously affect vehicle safety. Therefore, it is necessary to improve this approach. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing an FPC-based vehicle battery voltage acquisition and protection system. This system dynamically plans and configures channel resources, continuously assesses the health status of the primary channel, allows redundant channels to quickly take over to ensure system continuity, and optimizes channel configuration strategies based on fault feedback to ensure the normal operation of the acquisition and protection system, thereby 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 data acquisition module is connected to the battery cell module via contacts on the FPC flexible circuit board;

[0007] The FPC flexible circuit board has a primary channel and a redundant channel. The contact impedance of the primary channel is greater than that of the redundant channel.

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

[0009] Using dynamic programming algorithm Generate the initial channel configuration for the FPC flexible circuit board. Where U(P) is the channel utilization, R(P) is the channel reliability, and I(P) is the signal interference level;

[0010] Adjust the dynamic programming algorithm based on the interrupt code. as well as The weighting coefficients, ∈[0.4,0.8], ∈[0.1,0.4], ∈[0.05,0.2], and + + =1;

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

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

[0013] The FPC-based vehicle battery voltage acquisition and protection system also includes:

[0014] The data acquisition module collects voltage, current, and temperature parameters via an FPC flexible circuit board.

[0015] Control module based on Generate the initial channel configuration for the FPC flexible circuit board;

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

[0017] When the contact impedance ratio is greater than 15%, an interrupt code is generated, which interrupts the main channel and enables the redundant channel through the programmable interrupt controller.

[0018] The control module adjusts the dynamic programming algorithm based on the interrupt code. as well as The weighting coefficients.

[0019] The beneficial effects of this invention are as follows: This invention dynamically plans and configures channel resources, continuously evaluates the health status of the primary channel, enables redundant channels to quickly take over and ensure system continuity, optimizes channel configuration strategies 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. Attached Figure Description

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

[0021] Figure 2 This is a partial sectional view of the structure of the present invention.

[0022] Figure 3 This is a partial top view of the heat-conducting component of the present invention.

[0023] Figure 4 This is a partial top view of the mounting bracket of the present invention.

[0024] The reference numerals in the figures include:

[0025] 1. Data Acquisition Module;

[0026] 2. Flexible printed circuit board (FPC); 21. Insulating reinforcing plate; 211. Conductive part; 22. Solder pad;

[0027] 3. Control module;

[0028] 4. Data processing module;

[0029] 5. Safety protection module;

[0030] 6. Fixing bracket; 61. Fixing hole; 62. Connecting groove; 63. Aluminum bar; 631. Welding groove; 632. Welding operation port;

[0031] 7. Heat-conducting component; 71. Fixing groove; 72. Locking bar; 721. Deformation part; 7211. First arc-shaped elastic element; 7212. Second arc-shaped elastic element; 73. Locking cavity;

[0032] 8. Insulating components; 81. Inserts. Detailed Implementation

[0033] The present invention will now be described in detail with reference to the accompanying drawings.

[0034] like Figure 1 As shown, the present invention provides an FPC-based vehicle battery voltage acquisition and protection system, which 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 data acquisition module 1 is connected to the battery cell 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. The contact impedance ratio ΔR of the main channel is greater than that of the redundant channel.

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

[0038] Using dynamic programming algorithm Generate the initial channel configuration for FPC flexible circuit board 2. Where U(P) is the channel utilization, R(P) is the channel reliability, and I(P) is the signal interference level;

[0039] Adjust the dynamic programming algorithm based on the interrupt code. , as well as The weighting coefficients, ∈[0.4,0.8], ∈[0.1,0.4], ∈[0.05,0.2], and + + =1;

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

[0041] Safety protection module 5 is used to detect changes in the contact impedance ΔR of the main channel;

[0042] An FPC-based vehicle battery voltage acquisition and protection system also includes:

[0043] Acquisition module 1 acquires voltage, current, and temperature parameters via FPC flexible circuit board 2;

[0044] Control module 3 is based on Generate the initial channel configuration for FPC flexible circuit board 2;

[0045] Safety protection module 5 detects changes in the contact impedance ΔR of the main channel;

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

[0047] Control module 3 adjusts the dynamic programming algorithm based on the interrupt code. as well as The weighting coefficients.

[0048] The FPC flexible circuit board 2 is equipped with a main channel and a redundant channel. When the impedance ratio ΔR of the main channel contact exceeds the threshold, the main channel can be quickly interrupted and the redundant channel can be enabled by the programmable interrupt controller. This ensures the continuous and stable operation of the battery voltage acquisition and protection function and avoids the failure of the entire system due to the failure of a single channel.

[0049] Control module 3 utilizes dynamic programming algorithm The initial channel configuration is generated by comprehensively considering three factors: channel utilization U(P), channel reliability R(P), and signal interference level I(P). This allows the system to find the optimal channel configuration scheme based on actual needs, thereby improving system performance and efficiency.

[0050] The control module 3 can dynamically adjust the weight coefficients of channel reliability and signal interference in the dynamic programming algorithm according to the interrupt 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] Safety protection module 5 monitors the change in contact impedance ΔR of the main channel in real time, which can promptly detect potential channel faults and take protective measures to prevent the fault from escalating and ensure the safety of the battery system.

[0052] Preferably, the gold plating thickness of the contacts in both the primary and redundant channels is ≥0.2μm. The gold plating improves contact conductivity and corrosion resistance, and reduces contact impedance during long-term use. The contact impedance ratio ΔR of the primary channel is ≤10mΩ, and that of the redundant channel is ≤8mΩ. The redundant channel uses an even lower impedance ratio to ensure 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 ratio ΔR of both the main channel and the redundant channel is greater than 15%, it generates an interrupt code, interrupts the main channel and the redundant channel through the programmable interrupt controller, activates the communication link of the emergency wireless communication module, and maintains a cell voltage sampling of ≥1Hz.

[0054] By setting up an emergency wireless communication module using FPC, an independent wireless communication link is established, creating a third-level fault-tolerant channel that maintains basic monitoring even when all physical connections fail.

[0055] When the impedance ratio of the primary channel and the redundant channel is greater than 15%, the emergency wireless communication module is activated to avoid monitoring blind spots caused by dual failures of the primary channel and the redundant channel, thus preventing battery runaway.

[0056] The dual-channel disconnection is executed by a programmable interrupt controller, and the channel isolation is achieved through hardware-level interrupt response, thereby eliminating electromagnetic interference (EMI) on the wireless signal from the faulty channel.

[0057] The emergency wireless communication module maintains a sampling frequency of ≥1Hz, and a minimum effective sampling frequency threshold is set to balance energy consumption and data continuity requirements in emergency mode.

[0058] Specifically, the FPC flexible circuit board 2 integrates a LoRa communication chip, which operates at a frequency of 433MHz and uses an SF7 spreading factor and a 125kHz bandwidth configuration.

[0059] The collected data is encapsulated into a 12-byte short frame, which includes a 4-byte cell ID, a 4-byte voltage value, and a differential code 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 computing unit and a data storage unit. The computing unit is integrated into the MCU, and the data storage unit 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, using a four-wire Kelvin detection method, applying a 1mA test current with a constant current source (such as LM334). The programmable interrupt (such as an ARM Cortex-M series NVIC controller or a RISC-V architecture PLIC controller) has a response time ≤100ns. The programmable interrupt controls the main channel via a MOSFET switch and the redundant channel via a relay.

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

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

[0065] The signal conditioning circuit is used to filter, amplify, and suppress interference in the acquired 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, the success rate of acquiring weak signals (such as millivolt-level single-unit voltages) is improved, and misjudgments caused by signal distortion are avoided. The multi-channel acquisition chip is model TIBQ76952.

[0066] In this embodiment, the channel utilization rate U(P) is calculated as: (actual sampling time / total cycle time) × 100%. By quantifying the proportion of time that the channel actually performs data acquisition, the effectiveness of channel resources is measured, avoiding resource waste or performance bottlenecks caused by channel idleness or overload. This achieves 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 under balanced 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 impedance ratio ΔR; the failure events caused by poor contact, line open circuit, etc. during the operation cycle of the channel are statistically analyzed to quantify the risk of frequent failures.

[0068] Contact impedance ratio ΔR stability is assessed by monitoring the fluctuation range of contact impedance ratio ΔR in real time (e.g., standard deviation ≤ 2mΩ) to evaluate the electrical stability of the channel during long-term operation.

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

[0070] The specific formula for calculating the channel reliability R(P) is as follows:

[0071] 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 coefficient between R1 and R2, real-time impedance changes are given priority (85% weighting), while historical data is also taken into account (15%).

[0072] It exhibits high gradient characteristics in the threshold range (R(P)=0.4~0.6), enabling the system to respond quickly to critical states.

[0073] The vague concept of "reliability" is transformed into a measurable numerical indicator to meet the quantitative requirements of the ISO 26262 standard for functional safety.

[0074] The signal interference level I(P) is obtained by analyzing the power proportion of the >1kHz component in the acquired signal using Fast Fourier Transform (FFT). Specifically, the time-domain signal is converted into a frequency-domain distribution using FFT, and the proportion of high-frequency noise (>1kHz) energy in the total signal power is calculated to quantify the impact of electromagnetic interference, switching noise, etc. on the data.

[0075] The interference location accuracy reaches ±0.5kHz, and it can distinguish different interference sources such as motor harmonics (2-10kHz) and inverter spikes (100kHz level).

[0076] When dynamically adjusting the weights of the dynamic programming algorithm, the channel switching response speed is improved by 40% in high-interference environments (I(P)>15%), avoiding SOC estimation errors of >5% caused by sampling data jumps.

[0077] This embodiment The calculation formula is: Where R0 is the initial nominal impedance of the contact, and Rcurrent is the real-time detected contact impedance ratio ΔR. By comparing the difference between the real-time impedance Rcurrent and the initial impedance R0, the influence of inherent parameters such as contact material and size is eliminated, and the degree of impedance degradation is reflected.

[0078] By comparing the rate of impedance change with a preset threshold (e.g., 15%) rather than absolute values, this method is suitable for assessing the health status of contacts of different specifications. This allows for earlier identification of latent faults such as contact oxidation and mechanical fatigue, preventing poor contact caused by a gradual increase in impedance.

[0079] By calculating the relative change rate, the influence of ambient temperature fluctuations (within ±10℃) on the absolute value of impedance is eliminated, and the false alarm rate is ≤0.3%.

[0080] When the rate of change is greater than 15%, a switchover is triggered, and the success rate of redundant channel takeover is 100%, avoiding data jumps caused by impedance degradation of the primary channel.

[0081] In this embodiment, the programmable interrupt controller interrupts the primary channel and enables the redundant channel as follows:

[0082] Trigger the highest-level interrupt via the programmable interrupt controller to complete the following operations within <5ms:

[0083] a) Turn off the MOSFET switch of the main channel;

[0084] b) Activate the power relays of the redundant channels.

[0085] Specifically, by configuring the programmable interrupt controller vector table, channel switching instructions are set 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 delay, ensuring that the interrupt response time after fault detection is ≤50ns.

[0086] Compared to traditional software polling schemes (response time > 10ms), the interrupt response speed is improved by ≥200 times, avoiding the risk of transient overvoltage / overcurrent caused by sudden changes in the primary channel impedance (such as contact failure). Even when strong electromagnetic interference causes abnormal data sampling, it can still guarantee 100% interrupt triggering, improving system robustness.

[0087] MOSFETs (such as AON7407, turn-off time ≤0.8ms or IPB180N04S4, turn-off delay ≤100ns) cut off the main channel current path, preventing fault propagation to redundant channels, with residual contact current <10mA. When the contact impedance ΔR >15% (e.g., oxidation causing R=20mΩ), turning off the MOSFET can prevent local overheating of the contacts (e.g., >150℃ causing insulation layer carbonization).

[0088] Select a solid-state relay (such as AQV252G, pull-in time ≤2ms) or a magnetic latching relay (such as G6K-2F, operating time ≤3ms), and provide drive current through the PIC's PWM output pin. Connect an RC buffer circuit (R=10Ω, C=1μF) in parallel with the relay contacts to absorb the surge current (such as ≤5A) during the transient charging of the load capacitor and prevent the contacts from welding.

[0089] The total time from primary channel shutdown to redundant channel activation is ≤4.8ms, voltage sampling data continuity is maintained at ≥99.99%, and SOC estimation error is avoided to the extent that it exceeds 1%. The relay lifespan reaches 10 years. 7 It can be used more than once, meeting the automotive-grade 15-year usage requirements, with a redundancy switchover success rate of >99.999%.

[0090] In this embodiment, after each channel switch, the control module 3 dynamically adjusts the dynamic programming algorithm according to the fault type. The specific method for determining the weighting coefficients is as follows:

[0091] Switching due to R(P) exceeding the limit: =min( ×1.3, 0.5);

[0092] Switching due to I(P) exceeding the limit: =min( ×1.5, 0.4).

[0093] Specifically, when switching due to R(P) exceeding the limit, the channel utilization weight is increased when reliability deteriorates, forcing the algorithm to prioritize high-utilization channels and reduce the probability of reusing faulty channels.

[0094] When switching due to excessive I(P), the anti-interference weight is strengthened when signal interference is severe, the selection of high-frequency interference channels is suppressed, and the signal-to-noise ratio of signal acquisition is improved.

[0095] By constraining the upper limit of the weight coefficient and setting a threshold for weight growth, we can prevent a single parameter from becoming too dominant and maintain the balance of multi-objective optimization in the dynamic programming algorithm.

[0096] Control module 3 uses a fault type adaptive weight adjustment mechanism to enable the channel switching strategy to accurately match the failure cause. For example, if the reliability decreases, the focus is on utilization; if the interference increases, the focus is on immunity, thus improving the switching effectiveness in scenarios with contact failure and electromagnetic interference.

[0097] like Figure 2 As shown, this embodiment includes a fixing frame 6, a heat-conducting component 7, and an insulating component 8. The acquisition module 1 and the FPC flexible circuit board 2 are both fixed to the fixing frame 6. The heat-conducting component 7 is disposed at the bottom of the fixing frame 6, and the insulating component 8 is disposed at the top of the fixing frame 6.

[0098] Specifically, the heat-conducting component 7 is connected to the battery's temperature control system for heat conduction. The heat-conducting component 7 uses a 6061 aluminum alloy substrate (thermal conductivity 167W / m·K) and is directly attached to the bottom of the mounting bracket 6 through a thermally conductive silicone pad (thermal conductivity 3W / m·K), forming a sandwich structure of "collection module 1-mounting bracket 6-heat-conducting component 7".

[0099] At an ambient temperature of 40℃, the junction temperature of the chip in the acquisition module 1 drops from 110℃ to 85℃, extending the device lifespan by 3 times (estimated by the Arrhenius model). When the module temperature is >90℃, the heat-conducting component 7 can quickly dissipate heat, avoiding carbonization of the insulation layer caused by local overheating (breakdown voltage drop >50%).

[0100] Insulator 8 is made of PC + 30% glass fiber composite material (CTI≥600V), with a thickness of 1.5mm, and the surface is coated with a ceramicized silicone rubber coating (volume resistivity>10). 5 Ω·cm), covering the top of the mounting bracket 6 and the exposed area of ​​the FPC circuit board.

[0101] In an 800V high-voltage system, insulator 8 can withstand a 10kV power frequency withstand voltage test (1 minute without breakdown), and the creepage distance meets Class III standards (≥8mm). During the electrolyte splash test (IP69K), the surface impedance of insulator 8 remains >10. 12 Ω, to avoid the risk of short circuits caused by the deposition of conductive ions.

[0102] The acquisition module 1 connects to the FPC circuit board via a ZIF connector. The mounting bracket 6 has a U-shaped slot at the corresponding position, allowing the FPC to bend flexibly within a range of ±5°, releasing assembly tolerances and thermal expansion stress. The ground copper foil of the FPC circuit board and the mounting bracket 6 are grounded through conductive foam (surface resistance <0.1Ω), forming a Faraday cage structure that shields interference in the 150kHz-1GHz frequency band >40dB.

[0103] like Figure 2 and Figure 3 As shown, in this embodiment, the insulating component 8 is provided with an insert 81, the fixing bracket 6 is provided with a fixing hole 61, and the heat-conducting component 7 is provided with a fixing groove 71. The insert 81 is inserted into the fixing groove 71 through the fixing hole 61. The lower part of the insert 81 is provided with a through hole. The fixing groove 71 is provided with a locking bar 72 and a locking cavity 73. The end of the locking bar 72 is provided with a deformable part 721, and the locking cavity 73 is provided on one side of the fixing groove 71 and communicates with the fixing groove 71.

[0104] The end of the locking bar 72 is inserted into the locking cavity 73 through a through hole, and the deformable portion 721 at the end of the locking bar 72 abuts against the locking cavity 73. As the end of the locking bar 72 passes through the through hole, the deformable portion 721 at the end of the locking bar 72 is elastically bent by the pressure of the side wall of the through hole. After entering the locking cavity 73, the deformable portion 721 at the end of the locking bar 72 recovers its deformation and locks itself in the locking cavity 73, achieving self-locking of the locking bar 72. Under external force, the locking bar 72 and the locking cavity 73 remain locked. The elastic deformation of the deformable portion 721 at the end of the locking bar 72 generates continuous contact pressure, forming a dynamic compensating contact that adapts to material deformation caused by temperature changes.

[0105] Preferably, the deformable portion 721 at the end of the locking bar 72 includes a first arc-shaped elastic element 7211 and a second arc-shaped elastic element 7212, which are spaced apart to provide space for deformation displacement of the first arc-shaped elastic element 7211 and the second arc-shaped elastic element 7212. When compressed, the first arc-shaped elastic element 7211 and the second arc-shaped elastic element 7212 move closer to each other, and the outer contour of the deformable portion 721 at the end of the locking bar 72 shrinks, making it easier to pass through the through hole. When not compressed, the first arc-shaped elastic element 7211 and the second arc-shaped elastic element 7212 move away from each other and return to their original position, so that the deformable portion 721 at the end of the locking bar 72 abuts against the locking cavity 73.

[0106] Furthermore, the contact impedance ratio ΔR detection includes a lifetime prediction algorithm, specifically:

[0107] A) Construct a state equation based on a Kalman filter, inputting the frame vibration acceleration VIBK and the real-time contact impedance RK; the output is the predicted contact impedance RKY. Where TS = 100ms;

[0108] B) When the predicted contact impedance RKY > 14%, the programmable interrupt controller is triggered in advance to switch channels. The numerical formula for channel reliability R(P) is: Where Nf is the number of historical faults, ΔR is the contact impedance rate detected in real time, and VIBrms is the effective value of vibration.

[0109] A state equation is constructed using a Kalman filter, dynamically fusing vibration acceleration and real-time impedance data to improve the accuracy of contact life prediction. An optimal state update cycle of TS=100ms is set to balance prediction real-time performance with computational resource consumption. Switching is triggered when the predicted impedance RKY > 14%, achieving a dual threshold effect for channel switching and proactively mitigating the risk of progressive contact failure. The R(P) formula incorporates the VIBrms parameter, quantifying the cumulative effect of mechanical shock with the effective vibration value, and the reliability assessment covers both physical wear and electrical degradation. Through a vibration-impedance coupled prediction model and dynamic reliability assessment, channel switching is completed before physical contact damage reaches the critical threshold, reducing the risk of system collapse due to contact failure.

[0110] like Figure 4 As shown, the fixing frame 6 in this embodiment is provided with a connecting groove 62 and an aluminum bar 63. The aluminum bar 63 is fixed on both sides of the connecting groove 62 and is used to connect with the battery cell module. The aluminum bar 63 is cut open from the side to form a welding groove 631. The top of the aluminum bar 63 is provided with a welding operation port 632 that communicates with the welding groove 631.

[0111] Insulating reinforcing plates 21 are provided on both sides of the FPC flexible circuit board 2, and a solder pad 22 is provided at the end of the FPC flexible circuit board 2 that is connected to the battery cell module.

[0112] A conductive part 211 is provided at one end of the insulating reinforcing plate 21 that is connected to the pad 22, and the conductive part 211 is connected to the bottom of the pad 22;

[0113] The FPC flexible circuit board 2 is inserted into the fixing frame 6 along the connecting groove 62. At the same time, the conductive part 211 and the pad 22 of the reinforcing plate are inserted into the welding groove 631. An external welding device welds the conductive part 211 and the pad 22 of the reinforcing plate to the aluminum bar 63 through the welding operation port 632. This allows the FPC flexible circuit board 2 to be welded to the aluminum bar 63 through the conductive part 211 and the pad 22. The welding point between the conductive part 211 and the pad 22 and the aluminum bar 63 is protected within the welding groove 631, making it less susceptible to external influences and ensuring the stability of the welding between the FPC flexible circuit board 2 and the aluminum bar 63 through the conductive part 211 and the pad 22.

[0114] On the other hand, by inserting the conductive part 211 of the insulating reinforcing plate 21 and the solder pad 22 together into the welding groove 631, the solder pad 22 is precisely positioned on the aluminum bar 63. At the same time, the insulating reinforcing plate 21 can also support the solder pad 22, making it less prone to deformation and keeping it flat. This facilitates the external welding device to weld the conductive part 211 of the insulating reinforcing plate 21 and the solder pad 22 together to the aluminum bar 63 through the welding operation port 632.

[0115] 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 piezoelectric material layer has an energy storage capacitor with a capacity of ≥100μF to power the ADC circuit of the acquisition module 1.

[0116] By utilizing the piezoelectric effect of the piezoelectric material layer, the mechanical vibration energy of the battery module is converted into electrical energy to achieve energy self-sufficiency and eliminate data acquisition interruptions caused by external power supply line failures.

[0117] By integrating a piezoelectric layer with a ≥100μF energy storage capacitor, 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.

[0118] The piezoelectric power supply system is directly connected to the ADC circuit, and the closed-loop construction of the vibration energy-electric energy-signal acquisition link ensures the continuous operation of the key acquisition module 1 under extreme working conditions.

[0119] Furthermore, the energy storage capacitor integrated in the piezoelectric layer has been increased to 220μF, providing intermittent power supply with a duty cycle of ≤0.1% for the LoRa communication chip (operating cycle: 10ms activation / 9.99s sleep).

[0120] The above description is only a preferred embodiment of the present invention. For those skilled in the art, there will be changes in the specific implementation and application scope based on the ideas of the present invention. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. A FPC-based battery voltage acquisition and protection system for vehicles, characterized in that, It comprises a collection module (1), an FPC flexible circuit board (2), a control module (3), a data processing module (4) and a safety protection module (5); The collection module (1) is connected with the battery cell module through the contacts of the FPC flexible circuit board (2); The FPC flexible circuit board (2) is provided with a main channel and a redundant channel, the contact impedance ratio of the main channel is greater than the contact impedance ratio of the redundant channel ; the contact impedance ratio of the main channel is greater than the contact impedance ratio of the redundant channel . The control module (3) is used for performing the following functions: by a dynamic programming algorithm generating an initial channel configuration for an FPC flexible circuit board (2), where U(P) is the channel utilization, R(P) is the channel reliability and I(P) is the signal interference level; Dynamic programming algorithm adjusted according to an interruption code and a weight coefficient of ∈ [0.4, 0.8], ∈ [0.1, 0.4], ∈ [0.05, 0.2], and + + = 1. The data processing module (4) is used for providing the channel reliability R(P) of the FPC flexible circuit board (2); The security protection module (5) is configured to detect a change in the contact impedance of the primary channel ; The FPC-based battery voltage collection and protection system for vehicles further comprises: The collection module (1) collects voltage, current and temperature parameters through the FPC flexible circuit board (2); The control module (3) is based on generating an initial channel configuration of the FPC flexible printed circuit board (2); The security protection module (5) detects changes in the contact impedance of the primary channel ; When the contact impedance ratio > 15%, an interrupt code is generated, the primary channel is interrupted by the programmable interrupt controller and the redundant channel is enabled; The control module (3) adjusts the weight coefficients of the dynamic programming algorithm according to the interrupt code. and of the dynamic programming algorithm.

2. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 1, characterized in that, The collection module (1) comprises at least one multi-channel collection chip and at least one signal conditioning circuit; The multi-channel collection chip is used for monitoring the voltage, current and temperature parameters of the battery cell in the battery cell module; The signal conditioning circuit is used for filtering, amplifying and anti-interference processing of the collected signals to ensure the accuracy of the working data.

3. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 1, characterized in that, The calculation method of the channel utilization rate U(P) is: (actual sampling time / total cycle time) × 100%; The value of the channel reliability R(P) is calculated according to the historical fault times and the contact impedance rate stability; The value of the signal interference degree I(P) is obtained by analyzing the power ratio of >1kHz components in the collected signal through fast Fourier transform.

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

5. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 1, characterized in that, The programmable interrupt controller interrupts the main channel and enables the redundant channel, specifically: Trigger the highest level interrupt through the programmable interrupt controller, and complete the following operations within <5ms: a) Close the MOSFET switch of the main channel; b) Activate the power relay of the redundant channel.

6. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 1, wherein the control module (3) dynamically adjusts the weight coefficients of the dynamic programming algorithm according to the fault type after each channel switching. The specific method for dynamically adjusting the weight coefficients of the dynamic programming algorithm according to the fault type after each channel switching is as follows: Switching due to R(P) exceeding: = min( × 1.3, 0.5); Switching due to I (P) exceeding: = min( x 1.5, 0.4).

7. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 1, characterized in that, It comprises a fixed frame (6), a heat conducting part (7) and an insulating part (8), the collection module (1) and the FPC flexible circuit board (2) are fixed on the fixed frame (6), the heat conducting part (7) is arranged at the bottom of the fixed frame (6), and the insulating part (8) is arranged at the top of the fixed frame (6).

8. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 7, characterized in that, The insulating part (8) is provided with an insertion strip (81), the fixed frame (6) is provided with a fixing hole (61), the heat conducting part (7) is provided with a fixing groove (71), the insertion strip (81) is inserted into the fixing groove (71) through the fixing hole (61), the lower part of the insertion strip (81) is provided with a through hole, the fixing groove (71) is provided with a locking strip (72) and a locking cavity (73), the end of the locking strip (72) is provided with a deformation part (721), and the locking cavity (73) is arranged on one side of the fixing groove (71) and communicates with the fixing groove (71), The end of the locking strip (72) is inserted into the locking cavity (73) through the through hole, and the deformation part (721) at the end of the locking strip (72) abuts against the locking cavity (73).

9. The FPC-based battery voltage acquisition and protection system for vehicles according to claim 7, characterized in that, The fixed frame (6) is provided with a connecting groove (62) and an aluminum bar (63), the aluminum bar (63) is fixed on both sides of the connecting groove (62) and is used for being connected with the battery cell module, the aluminum bar (63) is formed into a welding groove (631) by being cut from the side, and the top of the aluminum bar (63) is provided with a welding operation opening (632) which communicates with the welding groove (631). Both of the FPC flexible circuit board (2) are provided with an insulating reinforcing plate (21), one end of the FPC flexible circuit board (2) connected with the battery cell module is provided with a solder pad (22); One end of the insulating reinforcing plate (21) connected with the solder pad (22) is provided with a conductive part (211), the conductive part (211) is connected to the bottom of the solder pad (22); The FPC flexible circuit board (2) is inserted into the fixing frame (6) along the connecting groove (62), and the conductive part (211) of the reinforcing plate and the solder pad (22) are inserted into the welding groove (631) together, and an external welding device welds the conductive part (211) of the reinforcing plate and the solder pad (22) to the aluminum bar (63) through the welding operation opening (632).

10. The FPC-based battery voltage acquisition and protection system for vehicles 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, and the capacity of the piezoelectric material layer is ≥100μF energy storage capacitor, which supplies power to the ADC circuit of the acquisition module (1).

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