Industrial vehicle battery management system

Abstract

The invention provides an industrial vehicle battery management system, and relates to the technical field of industrial vehicle battery management. According to the industrial vehicle battery management system, by introducing the pulse generation unit, the discharge capacity can be calculated according to the use current amount and the temperature change of the battery, and the discharge resistance of different frequencies can be calculated, so that compared with a traditional battery management system (BMS) in the prior art, the error can be remarkably reduced according to the charge-discharge rate (C-rate) of discharge during the use of the battery, and the reliability of the battery management system is improved. The charging amount and the service life of the battery side can be more accurately diagnosed, predicted and managed, the battery replacement and the management of the service cycle of the battery are convenient to optimize, the situation of fire caused by battery aging (degradation) can be detected and prevented in advance, the stability and the efficiency of the battery in the aspects of use and management are improved, the charging amount (SOC) and the service life (SOH) of the battery are improved, and the service life of the battery is prolonged. The battery pack is suitable for industrial vehicles (agricultural equipment such as excavators, forklifts and tractors and electric vehicles) equipped with lead-acid or lithium batteries.

Description

Technical Field

[0001] The present invention relates to the technical field of battery management for industrial vehicles, and in particular to a battery management system for industrial vehicles. Background Art

[0002] Industrial vehicles are powered motor vehicles used to transport, push, tow, lift, stack, or place various types of cargo. These include agricultural equipment like excavators, forklifts, and tractors, as well as electric vehicles. They are typically powered by batteries and equipped with a battery management system (BMS).

[0003] The BMS battery management system is mainly used to intelligently manage and maintain each battery cell, monitor the battery status, prevent overcharging and over-discharging, and extend the battery life. Among them, traditional BMS technology mainly estimates the battery's state of charge (SOC) and life (SOH) through current integration and battery voltage correction. However, traditional methods have significant drawbacks: 1. Relying only on voltage and current integration, without considering battery loss caused by factors such as temperature and charge and discharge rate (C-rate), resulting in inaccurate SOC and SOH predictions; 2. Ignoring dynamic effects: The charge and discharge rate (C-rate) directly affects battery temperature and energy loss, but traditional BMS does not consider this factor. At the same time, under high temperature or high C-rate conditions, the battery's internal resistance increases and energy efficiency decreases, but traditional methods do not correct for such errors. 3. Significant safety hazards exist: the battery life cannot be accurately predicted, resulting in unclear replacement or maintenance timing, and battery degradation may cause fire or mechanical failure (such as swelling, leakage).

[0004] To this end, the present invention has developed a new industrial vehicle battery management system. Summary of the Invention

[0005] (1) Technical problems solved In response to the shortcomings of the existing technology, the present invention provides an industrial vehicle battery management system, which solves the problems that traditional BMS battery management systems rely only on voltage and current integration, do not consider battery loss caused by factors such as temperature and charge and discharge rate (C-rate), resulting in inaccurate SOC and SOH predictions, and do not consider the impact of charge and discharge rate (C-rate) directly on battery temperature and energy loss, resulting in significant safety hazards.

[0006] (2) Technical solution To achieve the above objectives, the present invention is implemented through the following technical solutions: an industrial vehicle battery management system for diagnosing and managing the charge and life status of lead or lithium batteries installed on the vehicle, comprising: An integrated controller (100), wherein the integrated controller (100) retains the current balancing function of a traditional BMS, and the integrated controller (100) includes a sensing unit (110) and a pulse generating unit (120), wherein the sensing unit (110) is used to detect the battery voltage, temperature, and current state in real time, and the pulse generating unit (120) is used to perform pulse discharge based on the battery frequency, and the pulse generating unit (120) is connected and installed in units of battery units or modules; A management control terminal (200) includes a wireless communication module (300), and the management control terminal (200) receives data from the integrated controller (100) via the wireless communication module (300) to achieve battery status management.

[0007] Through the above technical solution, the BMS uses sensors to monitor battery parameters such as voltage, current, and temperature in real time, ensuring that the battery operates within a safe range. This data helps the BMS calculate the battery voltage and lifespan, enabling precise battery management to prevent overcharging and overdischarging, and avoid damage from overheating or overloading. By balancing the charge and discharge process, the BMS can reduce variations between individual cells, maintain the consistency of the battery pack, and thus extend the life of the entire battery pack.

[0008] Preferably, the integrated controller (100) controls the battery to perform pulse discharge according to a frequency when in use through the pulse generating unit (120), and calculates the maximum impedance of the battery using the impedance generated when discharging at the maximum charge and discharge rate (C-rate) used by the battery.

[0009] Preferably, the integrated controller (100) measures the charge capacity (SOC) and life (SOH) of the battery by pulse discharge of the battery side frequency through the pulse generating unit (120), calculates the internal impedance (internal resistance value) according to the battery temperature change using the temperature data obtained by the sensing unit (110), and calculates the power loss (I 2 R).

[0010] Preferably, the integrated controller (100) and the wireless communication module (300) communicate using SPI (Serial Peripheral Interface), and the wireless communication module (300) and the management control terminal (200) communicate using WiFi or Zigbee.

[0011] Preferably, the type of the management control terminal (200) can be a desktop computer, a laptop computer, a tablet computer or a smart phone equipped with a management application.

[0012] (3) Beneficial effects The present invention provides a battery management system for industrial vehicles. It has the following beneficial effects: This industrial vehicle battery management system, by introducing a pulse generation unit, can calculate the discharge capacity based on the battery's current usage and temperature changes. It can also calculate the discharge resistance at different frequencies, thereby being able to calculate the charge and discharge rate (C-rate) of the battery during use. Compared with existing traditional battery management systems (BMS), it significantly reduces errors and can more accurately diagnose, predict and manage the battery's charge capacity and lifespan, facilitating optimized battery replacement and life cycle management. It can also pre-detect and prevent fires caused by battery aging (deterioration), improving battery stability and efficiency in use and management, and increasing the battery's state of charge (SOC) and lifespan (SOH). At the same time, through improvements to the structure and method, it can be installed on industrial vehicles using lead or lithium batteries. It is suitable for industrial vehicles equipped with lead-acid or lithium batteries (such as excavators, forklifts, tractors and other agricultural equipment and electric vehicles). By improving the structure and diagnostic method, accurate diagnosis and management of battery life and charging status can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a diagram of the overall system architecture of the present invention; Figure 2 This is the SPI communication timing diagram of the present invention.

[0014] Legend: 100, integrated controller; 110, sensing unit; 120, pulse generating unit; 200, management and control terminal; 300, wireless communication module. DETAILED DESCRIPTION

[0015] like Figure 1-Figure 2 As shown, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0016] Example: The term "industrial vehicle" used in this invention is for descriptive convenience and has a broad meaning, including agricultural equipment such as excavators, forklifts, tractors, and electric vehicles.

[0017] An industrial vehicle battery management system for diagnosing and managing the charge and life status of lead or lithium batteries installed on the vehicle, including: The integrated controller 100 retains the current balancing function of a traditional BMS and includes a sensing unit 110 and a pulse generating unit 120. The sensing unit 110 is used to detect the battery voltage, temperature, and current status in real time. The pulse generating unit 120 is used to perform pulse discharge based on the battery frequency. The pulse generating unit 120 is connected and installed in units of battery cells or modules. The management and control terminal 200 includes a wireless communication module 300. The management and control terminal 200 receives data from the integrated controller 100 through the wireless communication module 300 to implement battery status management; The management control terminal 200 may be a desktop computer, a laptop computer, a tablet computer, or a smart phone equipped with a management application.

[0018] According to the working mode, the integrated controller 100 controls the battery to perform pulse discharge according to the frequency when in use through the pulse generating unit 120, and calculates the maximum impedance of the battery when discharging at the maximum charge and discharge rate (C-rate) used by the battery.

[0019] Since maximum current discharge tests cannot be frequently performed in practice (to avoid accelerated battery aging), the present invention innovatively uses frequency sweep technology to establish a charge-discharge rate-impedance mapping function, while also taking into account energy loss caused by temperature changes, to accurately determine the state of charge (SOC) and lifespan (SOH). Specifically, the industrial vehicle battery management system of this application is characterized by calculating the battery's impedance based on the frequency of pulse discharge to determine the battery's charge capacity (SOC) and lifespan (SOH).

[0020] Specifically, the integrated controller 100 measures the state of charge (SOC) and life (SOH) of the battery by pulse discharge at the battery side frequency through the pulse generating unit 120, further calculates the internal impedance (internal resistance value) according to the battery temperature change using the temperature data obtained by the sensing unit 110, and calculates the power loss (I 2 R).

[0021] Taking this battery status diagnosis as an example, when discharging at 3 times the charge and discharge rate (C-rate) (when the battery capacity is 200Ah, 3 times the capacity is 600A), if the impedance is 100mΩ when the battery is discharged at 1A at a frequency of 3kHz, then the impedance when discharging at 600A can be calculated.

[0022] Using this method, we performed a step-by-step frequency sweep starting at 300Hz and then quantified the impedance change corresponding to different discharge rates. (At 300Hz, the battery impedance is 10mΩ, and at 600Hz, the battery impedance is 20mΩ) At this time, 300 Hz corresponds to the internal resistance value of the battery when the battery is discharged at 0.3 times the charge and discharge rate (C-rate) capacity, and as the discharge frequency increases, the impedance generated at a higher discharge capacity can be calculated.

[0023] The internal resistance of the battery changes according to the battery life (SOH), and the battery charging capacity is determined according to the battery life (SOH).

[0024] In addition, based on the internal impedance loss of the battery due to temperature changes, the power loss (I 2 R).

[0025] In summary, this invention integrates the real-time battery operating current and energy loss caused by temperature fluctuations to accurately calculate the battery's actual available capacity and remaining lifespan, thereby enabling precise prediction of battery replacement cycles. Compared to previous technologies, this technology significantly improves efficiency, reliability, and stability.

[0026] The integrated controller 100 and the wireless communication module 300 communicate using SPI (Serial Peripheral Interface), and the wireless communication module 300 and the management control terminal 200 communicate using WiFi or Zigbee.

[0027] SPI (Serial Peripheral Interface) communication is full-duplex, enabling bidirectional communication and simultaneous transmission and reception. It offers complete protocol flexibility for transmitted bits, allowing for arbitrary length adjustments up to 16 bits. It eliminates the need for a transceiver or transmitter, making the hardware interface straightforward. The maximum clock speed is unlimited, so there's no speed limit. Push-pull outputs (rather than open-drain outputs) use the same voltage, ensuring signal consistency and high speed, while also offering low power consumption.

[0028] In the above SPI communication, if Figure 2 As shown, four lines are required for sending and receiving: MOSI (Master Out Slave In), MISO (Master In Slave Out), clock (SCLK) and SS (Slave Select).

[0029] The Master Out Slave In (MOSI) line outputs data from the master to the master, the Master In Slave Out (MISO) line sends data from the master to the master, and the Clock (SCLK) line is used for synchronization signals. The Slave Select (SS) line is used by the master to select a communication line when communicating with multiple caches and determines where data is sent.

[0030] Compared with existing battery management systems (BMS), the industrial vehicle battery management system of the present invention, implemented using the above structure as an example, has the advantages of improving battery life (SOH) and state of charge (SOC), facilitating diagnosis and management, and reducing errors by installing the system on lead or lithium battery vehicles.

[0031] The industrial vehicle battery management system described in this invention is suitable for industrial vehicles such as excavators, forklifts, and tractors powered by lead-acid or lithium batteries. It is also suitable for the health management of battery modules in ESS systems in the battery or battery pack industry, or may be applicable to battery packs in electric vehicles, involving life prediction and maintenance planning for power battery packs.

[0032] This invention relates to an industrial vehicle battery management system. Installed on industrial vehicles powered by lead or rechargeable lithium batteries, it provides accurate and convenient diagnosis and management of the battery's charge / discharge status and lifespan. The system comprises an integrated controller that includes a sensor unit and a pulse generator. The sensor unit senses the battery's voltage, temperature, and current, while the pulse generator generates pulse discharges based on the battery's frequency. The pulse generator is preferably connected to a battery unit or battery pack.

[0033] By improving the structure and method, the battery life and charge status can be easily diagnosed and managed compared to the existing battery management system (BMS); errors can be reduced, and high safety and management efficiency can be achieved.

[0034] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An industrial vehicle battery management system for diagnosing and managing the charge and life status of lead or lithium batteries installed on the vehicle, characterized in that include: An integrated controller (100), wherein the integrated controller (100) retains the current balancing function of a traditional BMS, and the integrated controller (100) includes a sensing unit (110) and a pulse generating unit (120), wherein the sensing unit (110) is used to detect the battery voltage, temperature, and current state in real time, and the pulse generating unit (120) is used to perform pulse discharge based on the battery frequency, and the pulse generating unit (120) is connected and installed in units of battery units or modules; A management control terminal (200) includes a wireless communication module (300), and the management control terminal (200) receives data from the integrated controller (100) via the wireless communication module (300) to achieve battery status management.

2. The industrial vehicle battery management system according to claim 1, characterized in that: The integrated controller (100) controls the battery to perform pulse discharge according to a frequency when in use through a pulse generating unit (120), and calculates the maximum impedance of the battery using the impedance generated when discharging at the maximum charge and discharge rate (C-rate) used by the battery.

3. The industrial vehicle battery management system according to claim 2, characterized in that: The integrated controller (100) measures the state of charge (SOC) and life (SOH) of the battery by pulse discharge at the battery side frequency through the pulse generating unit (120), calculates the internal impedance (internal resistance value) according to the battery temperature change using the temperature data obtained by the sensing unit (110), and calculates the amount of power lost (I 2 R).

4. The industrial vehicle battery management system according to claim 1, characterized in that: SPI (Serial Peripheral Interface) is used for communication between the integrated controller (100) and the wireless communication module (300), and WiFi or Zigbee is used for communication between the wireless communication module (300) and the management control terminal (200).

5. The industrial vehicle battery management system according to claim 1, characterized in that: The type of the management control terminal (200) can be a desktop computer, a laptop computer, a tablet computer, or a smart phone equipped with a management application.

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