Thermal runaway early warning system and early warning method thereof

Abstract

The invention relates to the technical field of battery testing, and discloses a thermal runaway early warning system and an early warning method thereof.The thermal runaway early warning system comprises an acquisition unit, a heating control unit and a data processing unit; the acquisition unit is used for acquiring parameter information of the battery in real time; the heating control unit is used for heating the battery; and the data processing unit is in communication connection with the acquisition unit and the heating control unit, and is used for receiving the parameter information in real time, calculating the temperature rise rate, comparing the temperature rise rate with a preset threshold value, and triggering an alarm signal and controlling the heating control unit to stop heating when a comparison result meets a preset condition. The system can realize automatic monitoring and timely alarm of the battery, and is suitable for various scenes such as testing, use and storage of the battery.

Description

Technical Field

[0001] The present invention relates to the technical field of battery testing, and in particular to a thermal runaway early warning system and an early warning method thereof. Background Art

[0002] During the process of charging and discharging and changes in the external environment, the battery may experience thermal runaway, causing the battery temperature to rise sharply and triggering safety accidents. The current battery thermal runaway warning mainly uses manual monitoring, which has many problems. During the test process, a dedicated person is required to monitor the battery cell temperature and voltage waveform in real time, and another person is required to monitor the battery cell for dangerous conditions such as fire and explosion. A test requires at least two people to monitor simultaneously to complete, which has high labor costs and safety hazards. In addition, the existing warning method often disconnects the power supply of the heating plate in the battery cell thermal runaway test room, causing the temperature rise rate to far exceed the thermal runaway judgment condition of 3°C / s, making the battery cell data after thermal runaway meaningless and worthless. These problems seriously affect the accuracy and reliability of the test results, and also increase the safety risks during the test process.

[0003] Therefore, it is urgent to propose a thermal runaway early warning system and its early warning method to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a thermal runaway warning system and its warning method, which can realize automatic monitoring of batteries and timely alarm, and is suitable for various scenarios such as battery testing, use and storage.

[0005] In order to solve the above technical problems, the present invention provides a thermal runaway warning system, comprising a collection unit, a heating control unit and a data processing unit;

[0006] The acquisition unit is used to collect parameter information of the battery in real time;

[0007] The heating control unit is used to heat the battery;

[0008] The data processing unit is in communication with the acquisition unit and the heating control unit, and is used to receive the parameter information in real time, calculate the temperature rise rate, and compare the temperature rise rate with a preset threshold. When the comparison result meets the preset conditions, an alarm signal is triggered and the heating control unit is controlled to stop heating.

[0009] Furthermore, the acquisition unit includes a temperature sensor and a voltage sensor for being arranged on the battery.

[0010] Furthermore, the parameter information includes temperature data and voltage data.

[0011] Furthermore, the heating control unit includes a power supply, a heating plate and a switch; the switch is connected to the data processing unit for receiving a control signal from the data processing unit; one end of the switch is connected to the input end of the power supply, and the other end is connected to one end of the heating plate; the other end of the heating plate is connected to the output end of the power supply to form a closed loop.

[0012] Furthermore, the data processing unit includes a data storage module and a display module; the data storage module is used to store the parameter information according to a preset time interval; and the display module is used to display a change curve of the parameter information in real time.

[0013] In addition, the present invention also proposes a thermal runaway early warning method, which uses the thermal runaway early warning system as described above, specifically including the following:

[0014] Real-time collection of battery parameter information;

[0015] Calculating the temperature rise rate according to the parameter information;

[0016] The temperature rise rate is compared with a preset threshold value, and when the comparison result meets the preset condition, an alarm signal is triggered and heating is stopped.

[0017] Furthermore, the temperature rise rate calculation process includes: obtaining the temperature values of the temperature sensor at time t seconds and t+1 seconds; calculating the difference between the temperature value at t+1 seconds and the temperature value at t seconds to obtain the temperature rise rate.

[0018] Furthermore, the judgment of the comparison result includes: when the temperature rise rate is greater than or equal to a preset threshold, the count value is increased by 1, otherwise the count value is reset to zero; when the count value is greater than a preset number of times, an alarm signal is triggered.

[0019] Furthermore, the method further includes: exporting and storing the parameter information in a preset format and displaying a real-time change curve of the parameter information.

[0020] Furthermore, the triggering of the alarm signal includes displaying the temperature rise rate exceeding limit warning information on the display interface and starting a buzzer to sound an alarm.

[0021] Through the above technical solution, the present invention has the following beneficial effects:

[0022] Through the cooperation of the acquisition unit, heating control unit and data processing unit, automatic monitoring of the battery thermal runaway process is achieved. The system can calculate the temperature rise rate in real time and compare it with the preset threshold. When an abnormality is found, it automatically triggers an alarm signal and stops heating. There is no need for manual real-time monitoring, which improves test efficiency and safety.

[0023] In addition, by setting up temperature sensors and voltage sensors, combined with the preset temperature rise rate threshold and number of consecutive judgments, accurate identification of early signs of thermal runaway is achieved; the TCP / IP communication protocol is also used to ensure the real-time and reliability of data transmission; and through the cooperation of the data storage module and the display module, automatic recording and visual display of test data are achieved, making the test results more valuable for reference. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 2 is a block diagram of a thermal runaway warning system according to an embodiment of the present invention;

[0025] Figure 2 Schematic diagram of the structure of a heating control unit in a thermal runaway warning system according to an embodiment of the present invention;

[0026] Figure 3 This is a flow chart of a thermal runaway early warning method according to an embodiment of the present invention;

[0027] Figure 4 A schematic diagram of communication connection and parameter information setting in a thermal runaway warning method according to an embodiment of the present invention;

[0028] Figure 5 A temperature and temperature rise rate change curve diagram of the first temperature measuring point in one embodiment of the present invention;

[0029] Figure 6 A temperature and temperature rise rate change curve diagram of the second temperature measuring point in one embodiment of the present invention;

[0030] Figure 7 A temperature and temperature rise rate change curve diagram of the third temperature measuring point in one embodiment of the present invention;

[0031] Figure 8 A temperature and temperature rise rate change curve diagram of the fourth temperature measuring point in one embodiment of the present invention;

[0032] Figure 9 2 is a graph showing the temperature and temperature rise rate change curves of the fifth temperature measuring point in one embodiment of the present invention;

[0033] Figure 10 A temperature and temperature rise rate change curve diagram of the sixth temperature measuring point in one embodiment of the present invention;

[0034] Figure 11 2 is a temperature and temperature rise rate change curve diagram of the seventh temperature measuring point in one embodiment of the present invention;

[0035] Figure 12 2 is a graph showing the temperature and temperature rise rate change curves at the eighth temperature measuring point in one embodiment of the present invention;

[0036] Figure 132 is a temperature and temperature rise rate change curve diagram of the ninth temperature measuring point in one embodiment of the present invention;

[0037] Figure 14 Schematic diagram of an alarm pop-up box in a thermal runaway warning method according to an embodiment of the present invention. DETAILED DESCRIPTION

[0038] The following is a more detailed description of a thermal runaway warning system and its method according to the present invention, with reference to the accompanying drawings. Preferred embodiments of the present invention are shown, and it should be understood that those skilled in the art may modify the present invention described herein while still achieving the beneficial effects of the present invention. Therefore, the following description should be understood as a general guideline for those skilled in the art and is not intended to limit the present invention.

[0039] The following paragraphs describe the present invention in more detail by way of example with reference to the accompanying drawings. The advantages and features of the present invention will become more apparent from the following description. It should be noted that the drawings are greatly simplified and not to exact scale, and are provided solely for the purpose of assisting in the description of the embodiments of the present invention.

[0040] like Figure 1-Figure 2 As shown, an embodiment of the present invention provides a thermal runaway warning system, which includes a collection unit, a heating control unit and a data processing unit.

[0041] Specifically, the acquisition unit is configured to collect battery parameter information in real time; the heating control unit is configured to heat the battery; and the data processing unit is communicatively connected to the acquisition unit and the heating control unit to receive the parameter information in real time, calculate the temperature rise rate, and compare the temperature rise rate with a preset threshold. When the comparison result meets a preset condition, an alarm signal is triggered and the heating control unit is controlled to stop heating. This embodiment achieves automatic monitoring and alarming, improving testing efficiency.

[0042] Preferably, the acquisition unit includes a voltage sensor and a temperature sensor for being installed on the battery. The number of temperature sensors can be set to one, two, or three, for example, depending on actual needs. The number of voltage sensors can also be set based on actual needs.

[0043] Specifically, the temperature sensor can use a K-type thermocouple, for example, with a measurement range of -200°C to 1300°C and an accuracy of ±0.5°C. Eight temperature measurement points are evenly distributed across the battery surface—four on the front and four on the back—to ensure comprehensive monitoring of the battery surface temperature distribution. The voltage sensor uses a high-precision voltage acquisition module with a range of 0-5V, a resolution of 0.1mV, and a sampling frequency of up to 1kHz. Multi-point temperature acquisition improves the accuracy and reliability of temperature data.

[0044] In one embodiment, the parameter information includes temperature data and voltage data. Temperature data reflects real-time temperature changes at various points in the battery, while voltage data is used to monitor battery status. A sudden drop in voltage may indicate that the battery has entered a dangerous state. Those skilled in the art will appreciate that other parameters, such as current and air pressure, can also be collected based on actual needs.

[0045] Preferably, the data processing unit transmits data to the acquisition unit via the TCP / IP communication protocol. The TCP / IP protocol utilizes the Ethernet physical layer, with a transmission rate of 100 Mbps, offering excellent real-time performance and reliability, enhancing the stability of data transmission. The system employs a master-slave architecture, with the data processing unit acting as the master and the acquisition unit as the slave. A heartbeat packet mechanism ensures the reliability of the communication connection.

[0046] In this embodiment, the data processing unit includes a data storage module and a display module. Specifically, the data storage module can employ, for example, an SQLite database, for storing parameter information at preset time intervals and exporting the data in CSV format for subsequent analysis. The display module can employ, for example, a 10.1-inch capacitive touch screen with a resolution of 1920×1200, for displaying real-time curves of temperature and voltage parameter information, supporting curve scaling and data tagging. This embodiment improves the convenience of data management through these settings.

[0047] In one specific example, the heating control unit includes a power supply 1, a heating plate 2, and a switch 3. The switch 3 is connected to the data processing unit and is configured to receive control signals from the data processing unit. One end of the switch 3 is connected to the input of the power supply 1, and the other end is connected to one end of the heating plate 2. The other end of the heating plate 2 is connected to the output of the power supply 1, forming a closed loop. When the temperature rise rate exceeds a preset threshold for a predetermined number of consecutive times, the data processing unit sends a control signal to the switch 3 (i.e., triggers an alarm signal based on the comparison result and sends a control signal to the switch 3 to cause the heating control unit to stop heating), automatically shutting off the power supply 1, thereby achieving timely control of the thermal runaway process. This automatic control mechanism avoids manual operation delays and improves system response speed and safety. In addition to being remotely controlled by the data processing unit, the switch 3 also has a manual operation function. When necessary, the power supply 1 can be quickly shut off manually, achieving a dual protection mechanism.

[0048] In this embodiment, when the power supply 1 is an AC power supply, one end of the switch 3 is connected to the live wire end of the power supply, and the other end is connected to one end of the heating plate 2; the other end of the heating plate 2 is connected to the neutral wire end of the power supply 1 to form a closed loop; when the power supply 1 is a DC power supply, one end of the switch is connected to the positive terminal of the power supply 1, and the other end is connected to one end of the heating plate 2; the other end of the heating plate 2 is connected to the negative terminal of the power supply 1 to form a closed loop.

[0049] The switch 3 includes a heating control switch and an emergency stop switch. In this embodiment, the live wire of the power supply 1 (e.g., a 220V AC power supply) is first connected to the input of the heating control switch. The output of the heating control switch is connected to the input of the emergency stop switch. The output of the emergency stop switch is connected to one end of the heating plate 2. The other end of the heating plate 2 is connected back to the neutral wire of the power supply 1, forming a complete power supply circuit. This connection method ensures that the power supply 1 is effectively disconnected when either switch is disconnected, improving the safety and reliability of the system.

[0050] In addition, if Figure 3 As shown, this embodiment also proposes a thermal runaway warning method, which uses the thermal runaway warning system as described above and specifically includes the following steps:

[0051] S1. Real-time collection of battery parameter information;

[0052] S2. Calculating the temperature rise rate according to the parameter information; and

[0053] S3. Compare the temperature rise rate with a preset threshold value, and when the comparison result meets the preset condition, trigger an alarm signal and stop heating.

[0054] In one embodiment, the temperature rise rate calculation process includes: obtaining the temperature values of the temperature sensor at time t seconds and t+1 seconds; calculating the difference between the temperature value at t+1 seconds and the temperature value at t seconds to obtain the temperature rise rate.

[0055] In one embodiment, the specific calculation formula of the temperature rise rate is: Temperature rise rate = (T t+1 -T t ) / Δt, where T t+1 is the temperature value at t+1 second, T t is the temperature value at t seconds, and Δt is the sampling interval. For example, if the temperature is 50°C at t = 10 seconds and 53.2°C at t = 11 seconds, the temperature rise rate at that moment is (53.2 - 50) / 1 = 3.2°C / s. The system calculates the temperature rise rate for each of the eight temperature measurement points, and an alarm is triggered if any point exceeds the preset threshold.

[0056] In this embodiment, the alarm trigger uses a continuous judgment mechanism: the preset temperature rise rate threshold is 3°C / s, and the preset number of judgments is three. The specific judgment process is: when the temperature rise rate at a certain temperature measurement point is greater than or equal to 3°C / s, the counter value at that point is incremented by 1; if the temperature rise rate is less than 3°C / s, the counter value is reset to zero. When the count value at any temperature measurement point reaches three times, the system triggers an alarm and automatically cuts off the heating power supply 1. This continuous judgment mechanism effectively avoids false alarms caused by instantaneous temperature fluctuations.

[0057] The data export module saves test parameter information in CSV format for subsequent data analysis. This file contains information such as the timestamp, temperature and voltage values at eight measurement points, and the calculated rate of temperature rise. The system defaults to a sampling interval of 1 second and a sampling period of 2 hours, meaning a single test can record 7,200 sets of data. Operators can adjust these parameters to meet specific needs. The sampling interval can be set from 0.1 to 2 seconds, and the sampling period can be set from 0.5 to 4 hours.

[0058] Preferably, the comparison result includes: when the temperature rise rate is greater than or equal to a preset threshold, the count value is incremented by 1; otherwise, the count value is reset to zero; and when the count value exceeds a preset number of times, an alarm signal is triggered. This continuous judgment mechanism effectively avoids false alarms caused by temperature fluctuations and improves system reliability.

[0059] In addition, this embodiment further includes exporting and storing the parameter information in a preset format and displaying a real-time curve of the parameter information. In one specific example, the display interface is divided into four areas: a temperature curve area, a voltage curve area, a status information area, and a control button area. The temperature curve uses different colors (or other formats) to distinguish eight temperature measurement points, the voltage curve displays real-time voltage values, and the status information area displays system operating status and alarm information. The curve display intuitively reflects the test process.

[0060] Preferably, the triggering alarm signal includes displaying a temperature rise rate exceeding limit warning message on a display interface and simultaneously activating a buzzer to sound an alarm. The warning message includes the location of the exceeding temperature measurement point and the specific temperature rise rate value. The buzzer can be designed with adjustable decibels. The sound and light alarm of this embodiment can improve the reliability of the alarm.

[0061] In one embodiment, the preset threshold is 3°C / s, and the preset number of times is 3. Those skilled in the art will appreciate that the preset threshold can be adjusted within the range of 1-5°C / s, and the preset number of times can be adjusted within the range of 2-5. Specific parameters can be set based on battery type and test requirements.

[0062] Preferably, the sampling interval of the parameter information is 1 second, and the sampling period is 2 hours. It is known to those skilled in the art that the sampling interval can be set according to actual test requirements, for example, it can be adjusted within the range of 0.1-2 seconds; the sampling period can be set according to actual test requirements, for example, it can be set within the range of 0.5-4 hours.

[0063] In one embodiment, the battery may include a lithium battery, a lithium ion battery, an alkali metal ion secondary battery, a secondary battery (or a rechargeable battery), and the like.

[0064] In this embodiment, continue to refer to Figure 4-Figure 14 As shown, Figure 5-Figure 13 In the middle, TempSeries (temperature series): represents the real-time temperature value of the temperature measurement point; DiffTempSeries (temperature difference series): represents the temperature rise rate of the temperature measurement point. The horizontal axis (Time) represents time in seconds (s); the vertical axis on the left represents the temperature value in degrees Celsius (℃); the vertical axis on the right represents the temperature rise rate in degrees Celsius per second (℃ / s). The working process of the thermal runaway warning system is as follows:

[0065] Power-on self-test: After the system is powered on, it first performs a self-test to check the communication status of each module and ensure that the connection between the acquisition unit, heating control unit, and data processing unit is normal. If any communication anomaly is found, the system will display an error message on the display interface and suspend the test process.

[0066] Parameter setting: The operator sets the test parameters through the touch screen, including: Temperature rise rate threshold: The default setting is 3℃ / s, which can be adjusted within the range of 1-5℃ / s according to actual needs. Preset number of times: The default setting is 3 times, which means that an alarm is triggered when the temperature rise rate exceeds the threshold for 3 consecutive times. Sampling interval: The default setting is 1 second, which means that temperature data and voltage data are collected every 1 second. Sampling period: The default setting is 2 hours, which means that the test duration is 2 hours. Heating control: After starting the test, the heating control unit controls the heating plate 2 to heat the battery at a rate of 2℃ / min. The power and heating rate of the heating plate 2 can be adjusted according to the battery type and test requirements.

[0067] Data Acquisition: The acquisition unit collects real-time temperature and voltage data from eight battery measurement points. The temperature sensor uses a K-type thermocouple with a measurement range of -200°C to 1300°C and an accuracy of ±0.5°C. The voltage sensor uses a high-precision voltage acquisition module with a range of 0-5V, a resolution of 0.1mV, and a sampling frequency of 1kHz.

[0068] Temperature rise rate calculation: The data processing unit receives the temperature and voltage data sent by the acquisition unit through the TCP / IP protocol and calculates the temperature rise rate of each temperature measurement point. The calculation formula for temperature rise rate is: Temperature rise rate = = (T t+1 -T t ) / Δt, where T t+1 is the temperature value at t+1 second, T t is the temperature value at t seconds, and Δt is the sampling time interval (usually 1 second).

[0069] Alarm trigger: The system monitors the temperature rise rate of each temperature measuring point in real time. When the temperature rise rate of a temperature measuring point exceeds the preset threshold (3℃ / s) for three consecutive times, the system automatically triggers the alarm signal, and an alarm prompt box will pop up to display specific alarm information, such as Figure 14 The alarm signals include: Display interface pop-up window: Displays the location of the over-limit temperature measurement point and the specific temperature rise rate value. Buzzer alarm: Activates the buzzer to sound an alarm, reminding the operator to deal with it in time.

[0070] Cut off heating power supply 1: The system automatically cuts off the power supply to heating plate 2 and stops heating.

[0071] Data Export: After the test is completed, the system saves the complete test data as a CSV file. The data file is named in the following format: Filename = Test Time + Battery Number + Test Type Filename = Test Time + Battery Number + Test Type. For example, 20231001_Battery001_HeatRun.csv. The data file contains the following fields: Timestamp: Recorded every 1 second. Temperature data: Temperature values of 8 measurement points or Figure 5-Figure 13 9 temperature measurement points (can be set according to actual needs). Voltage data: real-time voltage value of the battery. Temperature rise rate: the temperature rise rate of each temperature measurement point.

[0072] Data Display: The system displays real-time temperature, voltage, and temperature rise rate curves on the display interface. The temperature curves differentiate eight temperature measurement points in different ways, the voltage curves display real-time voltage values, and the temperature rise rate curves show the temperature rise rate changes at each measurement point. The operator can zoom in and out of the curves and mark data using the touchscreen for easy analysis.

[0073] Abnormal handling: During the test process, if the temperature data is detected to be abnormal (such as the temperature value is outside the measurement range or the temperature fluctuation is too large), the system will automatically filter the data and record the abnormality log. If the abnormality persists, the system will prompt the operator to check.

[0074] System scalability: This system adopts a modular design, and data is transmitted between modules using standard communication protocols (such as TCP / IP), which facilitates subsequent function expansion and maintenance. For example, current sensors and air pressure sensors can be added to collect more parameter information.

[0075] Therefore, this embodiment improves test efficiency and safety through automatic monitoring and alarm mechanisms, eliminating the need for manual real-time monitoring; improves the accuracy of thermal runaway warning through multi-point temperature collection and continuous judgment mechanisms; enhances the traceability and analytical value of test data through automatic data storage and curve display functions; in addition, this embodiment adopts modular design and standard communication protocols, which can improve the scalability and maintenance convenience of the system.

[0076] In summary, the thermal runaway warning system and method proposed in the present invention have the following advantages:

[0077] Through the cooperation of the acquisition unit, heating control unit and data processing unit, automatic monitoring of the battery thermal runaway process is achieved. The system can calculate the temperature rise rate in real time and compare it with the preset threshold. When an abnormality is found, it automatically triggers an alarm signal and stops heating. There is no need for manual real-time monitoring, which improves test efficiency and safety.

[0078] In addition, by setting up multiple temperature sensors and voltage sensors, combined with the preset temperature rise rate threshold and the number of consecutive judgments, accurate identification of early signs of thermal runaway is achieved; the TCP / IP communication protocol is also used to ensure the real-time and reliability of data transmission; and through the cooperation of the data storage module and the display module, automatic recording and visual display of test data are achieved, making the test results more valuable for reference.

[0079] Obviously, those skilled in the art may make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if such changes and modifications fall within the scope of the claims and their equivalents, the present invention is intended to include such changes and modifications.

Claims

1. A thermal runaway warning system, characterized in that: It includes an acquisition unit, a heating control unit and a data processing unit; The acquisition unit is used to collect parameter information of the battery in real time; The heating control unit is used to heat the battery; The data processing unit is in communication with the acquisition unit and the heating control unit, and is used to receive the parameter information in real time, calculate the temperature rise rate, and compare the temperature rise rate with a preset threshold. When the comparison result meets the preset conditions, an alarm signal is triggered and the heating control unit is controlled to stop heating.

2. The thermal runaway warning system according to claim 1, characterized in that: The acquisition unit includes a temperature sensor and a voltage sensor for being arranged on the battery.

3. The thermal runaway warning system according to claim 1, wherein: The parameter information includes temperature data and voltage data.

4. The thermal runaway warning system according to claim 1, wherein: The heating control unit includes a power supply, a heating plate and a switch; the switch is connected to the data processing unit and is used to receive a control signal from the data processing unit; one end of the switch is connected to the input end of the power supply, and the other end is connected to one end of the heating plate; the other end of the heating plate is connected to the output end of the power supply to form a closed loop.

5. The thermal runaway warning system according to claim 1, wherein: The data processing unit includes a data storage module, a display module, an alarm module and a data export module; the data storage module is used to store the parameter information according to a preset time interval; the display module is used to display the change curve of the parameter information in real time; the alarm module is used to trigger an alarm signal when the temperature rise rate exceeds a preset threshold; the data export module is used to export and store the parameter information in a preset format.

6. A thermal runaway warning method, using the thermal runaway warning system according to any one of claims 1 to 5, characterized in that: The details include: Real-time collection of battery parameter information; Calculating the temperature rise rate according to the parameter information; The temperature rise rate is compared with a preset threshold value, and when the comparison result meets the preset condition, an alarm signal is triggered and heating is stopped.

7. The thermal runaway early warning method according to claim 6, characterized in that: The temperature rise rate calculation process includes: obtaining the temperature values of the temperature sensor at time t seconds and t+1 seconds; calculating the difference between the temperature value at t+1 seconds and the temperature value at t seconds to obtain the temperature rise rate.

8. The thermal runaway early warning method according to claim 6, characterized in that: The judgment of the comparison result includes: when the temperature rise rate is greater than or equal to a preset threshold, the count value is increased by 1, otherwise the count value is reset to zero; when the count value is greater than a preset number of times, an alarm signal is triggered.

9. The thermal runaway early warning method according to claim 6, characterized in that: Also includes: The parameter information is exported and stored in a preset format and a real-time change curve of the parameter information is displayed.

10. The thermal runaway early warning method according to claim 6, characterized in that: The triggering of the alarm signal includes displaying the temperature rise rate exceeding limit warning information on the display interface and starting the buzzer to sound an alarm.

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