Dynamic management method for battery pack of electric vehicle

Abstract

The invention relates to the technical field of electric vehicle power supply systems, and discloses an electric vehicle battery pack dynamic management method, the system comprises: a frame, the frame comprises a main support tube and a plurality of side support groups; the mounting box body is arranged in a mounting position formed by the side bracket group; the plurality of battery packs are mounted in the mounting box body and are arranged in a shape like a Chinese character'tian '; and the multi-power-supply selective connecting device is mounted in the frame. The multi-power-supply selective connecting device comprises a plurality of sets of communicating contact heads, a mode adjusting mechanism, a scale deposition layer cleaning structure, an operation mounting disc and a transmission mechanism. The system further comprises a monitoring system and a power supply control system. The control method comprises a real-time monitoring step, an abnormity judging step, a mode switching step and a scale cleaning step. According to the system, the functions of real-time monitoring, dynamic switching and fault isolation of the battery pack are realized, and the problem of contact reliability in a traditional multi-battery switching system is solved.

Description

[0001] This application is a divisional application of the Chinese patent application filed on March 27, 2025, with application number 2025103730324 and invention name “Battery pack dynamic management and self-cleaning switching system and battery pack dynamic management method”. Technical Field

[0002] The present invention relates to the technical field of electric vehicle power management, and in particular to a battery pack dynamic management and self-cleaning switching system and a control method thereof, which is particularly suitable for two-wheeled electric vehicles powered by multiple battery packs. Background Art

[0003] Lead-acid batteries are the most common power source in two-wheeled electric vehicles, typically using four or five 12V batteries connected in series. In actual use, if a battery in a battery pack experiences a serious anomaly or poor contact, it will affect the operation of the entire series circuit. Even more dangerously, users often fail to detect this abnormality in time, and continued use can cause other batteries to operate abnormally for extended periods. This not only accelerates the degradation of the battery pack's performance but can also cause the vehicle to suddenly lose power while driving, causing significant distress to the user and, in severe cases, even posing a safety hazard.

[0004] To address these issues, a system is needed that can monitor the status of individual batteries and flexibly adjust battery connection methods. This system can not only promptly detect battery anomalies and take corrective action, but also charge batteries with significantly different performance individually or in groups, thereby balancing performance differences among individual batteries, effectively extending the battery pack's lifespan and reducing failure rates.

[0005] However, implementing this detection and flexible charging solution requires numerous electronic components, complex wiring, and multiple switches. Frequent switching of these switches and contacts can lead to oxidation and spark corrosion, resulting in uneven contact surfaces and impaired contact. This increases resistance, leading to heat generation and poor charging performance. Furthermore, the complex wiring system increases points of failure, making maintenance more difficult and costly.

[0006] To address these issues, the present invention proposes a solution that replaces electronic components with a mechanical structure to achieve circuit switching. This solution, through its unique mechanical design, not only enables battery status monitoring and flexible charging methods, but also promptly notifies the user to switch to a temporary reduced-voltage riding mode when a battery anomaly is detected, allowing the vehicle to safely reach a repair point and avoid the risk of road breakdowns. Furthermore, the contact design of this solution facilitates cleaning and maintenance, significantly improving the system's reliability and service life. Summary of the Invention

[0007] The object of the present invention is to solve the deficiencies of the prior art. The present invention provides a battery pack dynamic management and self-cleaning switching system for two-wheeled electric vehicles, which adopts a "field" - shaped battery layout and a fouling layer self-cleaning design, and realizes the functions of real-time monitoring, dynamic switching and fault isolation of the battery pack through an integrated multi-power selective connection device, effectively solving the contact reliability problem in the traditional multi-battery switching system, while improving the heat dissipation efficiency of the system and realizing the intelligent management and long-term stable operation of the battery pack.

[0008] To solve the above problems, the present invention adopts the following scheme: A battery pack dynamic management and self-cleaning switching system, comprising: A frame, the frame includes a main support tube and multiple groups of side support groups connected to the main support tube, and the side support groups are arranged in a three-sided surrounding shape and form an installation position for placing batteries; <{ An installation box body disposed in the installation position, the installation box body has a drain hole and a ventilation structure; Multiple battery packs installed in the installation box body, the multiple battery packs are designed in a "field" - shaped layout, and there is a heat dissipation space between the multiple battery packs; A multi-power selective connection device installed in the frame, the multi-power selective connection device includes: Multiple groups of connecting contacts for electrically connecting with the multiple battery packs, and the surface of the connecting contacts is coated with a conductive elastic layer; A mode adjustment mechanism, the mode adjustment mechanism includes an adjustment disc, and both ends of the adjustment disc are evenly distributed with multiple contacts along the circumferential direction, and the multiple contacts form several groups of gear position contact combinations; a plurality of connection areas are provided on the outer peripheral wall of the adjustment disc, and a power-off friction area is provided between the connection areas; A fouling layer cleaning structure, the fouling layer cleaning structure is disposed between the adjustment disc and the connecting contacts for cleaning the fouling on the surfaces of the connecting contacts and the contacts; An operation installation disc for installing the adjustment disc and the fouling layer cleaning structure; and A transmission mechanism, the transmission mechanism includes an adjustment gear disposed at the edge of the end face of the adjustment disc, and a gear transmission rod meshing with the adjustment gear; A monitoring system, the monitoring system includes: a voltage monitoring unit for monitoring the battery pack voltage; a current monitoring unit for monitoring the battery pack charge and discharge current; a temperature monitoring unit for monitoring the battery pack temperature; an internal resistance monitoring unit for monitoring the battery pack internal resistance; and a control unit for controlling the mode adjustment mechanism to perform mode switching according to monitoring data; a power supply control system, the power supply control system includes: two groups of electrical connection devices arranged on the outer wall of the adjustment disk, each group of electrical connection devices including an electrical connection wire and an electrical contact block; a gold-plated compression spring arranged between the electrical contact block and the electrical connection wire; and a placement shell for accommodating the electrical connection wire, the placement shell forming a sealed fit with the operation mounting disk.

[0009] Beneficial effects: The "field"-shaped battery pack layout design and the set heat dissipation space can effectively improve the system's heat dissipation efficiency and extend the battery life; the three-sided enclosed frame design and the installation box with drainage and ventilation structures improve structural stability while protecting the battery pack from environmental influences; the integrated design of the multi-power selective connection device, combined with a comprehensive monitoring system and power supply control system, realizes real-time monitoring and dynamic switching functions of the battery pack; the setting of the fouling layer cleaning structure solves the contact reliability problem in the traditional system and ensures the long-term stable operation of the system.

[0010] Preferably, the side support group is made of hollow steel pipe, wherein the diameter of the main support pipe is 30-40 mm, and the diameter of the secondary support pipe is 20-25 mm; the spacing between the battery groups is 30-50 mm.

[0011] Beneficial effects: The hollow steel tube design reduces overall weight while ensuring strength. The optimized diameter parameters of the primary and secondary support tubes provide optimal support strength. At the same time, the reasonable setting of the battery pack spacing ensures sufficient heat dissipation space, thereby improving the heat dissipation efficiency and structural stability of the system.

[0012] Preferably, the conductive elastic layer has a thickness of 0.2-0.3 mm and is made of graphene composite material.

[0013] Beneficial effects: Through the precise control of the thickness of the conductive elastic layer and the application of graphene composite materials, good conductivity is ensured and the durability of the system is improved. The setting of the elastic layer provides stable contact pressure, thereby improving the reliability and service life of the overall connection.

[0014] Preferably, the fouling layer cleaning structure comprises: A contact friction arc section for cleaning dirt deposited on the communication contact; and a contact friction arc section for cleaning dirt deposited on the contact; Wherein, the contact friction arc segment and the contact point friction arc segment are symmetrically installed on two side surfaces of the operation installation plate.

[0015] Beneficial effects: The double-sided cleaning structure and symmetrical installation design not only improve the cleaning efficiency and ensure the uniformity and stability of cleaning, but also the realization of the automatic cleaning function extends the maintenance cycle of the system and reduces maintenance costs.

[0016] Preferably, the contact friction arc segment includes: a first friction surface for contacting the connecting contact head, the surface roughness Ra value of the first friction surface is 0.8-1.2μm; wherein, the contact friction arc segment is provided with a plurality of connecting holes, and the connecting holes correspond one-to-one to the connecting contact heads.

[0017] Beneficial effect: Through the precise control of surface roughness and the one-to-one correspondence design of the connection holes, combined with the design characteristics of the arc structure, it ensures the reliability of the cleaning effect and the stability of the electrical connection, while improving the uniformity of cleaning and overall work efficiency.

[0018] Preferably, the communication area of the regulating disc is made of gold-plated copper alloy, the power-off friction area is made of tungsten carbide matrix material, and the surface of the power-off friction area is processed with fine grooves with a depth of 0.1 mm and a spacing of 0.5 mm.

[0019] Beneficial effects: Through the application of gold-plated copper alloy and the use of tungsten carbide matrix materials, combined with the special design of micro-grooves, the system's electrical conductivity and wear resistance are significantly improved, the cleaning effect is improved, and the service life of the entire system is effectively extended.

[0020] The present invention also provides a method for dynamic management of battery packs using the above-mentioned multi-power selective connection device, comprising the following steps: a real-time monitoring step, comprising: monitoring voltage parameters of multiple battery packs, wherein the monitoring range of the voltage parameters is 10.5-14.4V; monitoring current parameters of multiple battery packs, wherein the monitoring range of the current parameters is -50A to +50A; monitoring temperature parameters of multiple battery packs, wherein the monitoring range of the temperature parameters is -20°C to 60°C; monitoring internal resistance parameters of multiple battery packs, wherein the monitoring range of the internal resistance parameters is 5-15mΩ; Abnormal judgment steps include: judging whether the voltage is lower than 10.5V; judging whether the temperature exceeds 55°C; judging whether the discharge current exceeds 45A; judging whether the internal resistance mutation exceeds 30%; The mode switching step includes: when an abnormal parameter is detected, controlling the adjustment disk to rotate to switch the connection mode of the battery pack; controlling the rotation speed of the adjustment disk to be within the range of 60-120 rpm; and ensuring the positioning accuracy of the adjustment disk to be within the range of ±1°; The scale cleaning steps include: automatically performing scale cleaning when switching the battery pack connection mode; performing scale cleaning according to a preset maintenance plan; and performing cleaning at a pressure of 0.6-0.8 MPa.

[0021] Beneficial effects: Through comprehensive parameter monitoring range settings and specific abnormality judgment standards, combined with precise control parameters and cleaning pressure requirements, the safety, reliability and stability of system operation are comprehensively improved, effectively ensuring the efficient management and long-term stable operation of the battery pack; at the same time, through the integration of automatic fouling cleaning functions, the system maintenance cost is reduced and the operating efficiency is improved.

[0022] Preferably, the mode switching step includes: Manual control mode: operate the starting operating component on the front part of the vehicle; drive the installation disc to rotate by pulling the pull rope, and the stroke of the pull rope is 15-20mm; drive the adjustment disc to rotate by the adjustment operating component with an operating torque not exceeding 2N•m; or automatic control mode: drive the installation disc to rotate by the servo motor; drive the adjustment disc to rotate by the stepper motor or servo motor; the system response time does not exceed 200ms.

[0023] Beneficial Effects: The design of both manual and automatic control modes, combined with precise stroke control and rapid response, ensures both operational flexibility and reliability while improving switching efficiency. Furthermore, operating torque limitations and rapid response time requirements ensure operational safety and the system's real-time performance.

[0024] Preferably, the connection mode in the mode switching step includes: Standard operating mode: 48V mode: four batteries are connected in series for standard operating conditions; Emergency working mode: 36V mode: three batteries are connected in series, automatically skipping the faulty battery; 24V mode: two batteries are connected in series for emergency working conditions; Diagnostic working mode: Single battery mode: used for single battery performance evaluation.

[0025] Beneficial effects: Through the design of multiple voltage level working modes and the function of automatically skipping faulty batteries, the system can be flexibly applied under different working conditions, improving the reliability and adaptability of the system. At the same time, through the setting of the diagnostic mode, it is easy to detect and deal with battery failures in a timely manner, effectively ensuring the continuity and stability of power supply.

[0026] Compared with the prior art, the technical solution of the present invention has the following advantages: Through innovative structural design and intelligent control methods, the present invention achieves the following overall beneficial effects: (1) Adopting a "field" - shaped battery layout and a frame design surrounded by three sides, combined with an installation box body for drainage and ventilation, not only improves the structural stability and heat dissipation efficiency but also facilitates installation and maintenance; (2) The multi - power selective connection device set, combined with a comprehensive monitoring system and a power supply control system, realizes the real - time monitoring and dynamic switching functions of the battery pack, ensuring the safe and reliable operation of the system; (3) The unique fouling layer cleaning structure and precise parameter control solve the contact reliability problem in traditional systems, extend the service life of the system, and improve the power transmission efficiency; (4) The design of multiple working modes and fault protection mechanisms enhances the adaptability and stability of the system, realizing the intelligent management and long - term stable operation of the battery pack. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings described below are only some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0028] Figure 1 It is the overall flow block diagram of the system of the present invention; Figure 2 It is the flow block diagram of the cleaning part of the system of the present invention; Figure 3 It is the flow block diagram of the mode switching part of the system of the present invention; Figure 4 It is the flow block diagram of the monitoring part of the system of the present invention; [[ID=二十]] Figure 5 It is the structural schematic diagram of the present invention when applied to an electric vehicle frame; Figure 6 It is the internal structural schematic diagram of the switching device and the battery pack in cooperation of the present invention; Figure 7 For Figure 6 The partial enlarged view at position I in Figure 8 It is the structural schematic diagram of the mode adjustment mechanism of the present invention; [[ID=三十三]] Figure 9 It is the structural schematic diagram of the fouling layer cleaning structure of the present invention installed on the operation installation part; Figure 10 It is the structural schematic diagram of the fouling layer cleaning structure of the present invention; Figure 11 It is the structural schematic diagram of the adjustment disc and the electrical contact block connection of the present invention. ]

[0029] Reference numerals: vehicle frame 10, main support tube 11, side bracket assembly 12, mounting position 121, mounting box 13, steering support frame 18, battery pack 21, external connection line 22, connecting frame 30, multi-power selective connection device 40, connection contact head 41, mode adjustment mechanism 42, fouling layer cleaning structure 43, operation mounting plate 44, adjustment disc 421, gear contact assembly 422, contact 4221, contact friction arc segment 431, first friction surface 4311, connection hole 431 2. Contact friction arc segment 432, second friction surface 4321, mounting disc 441, connecting through-hole 4411, arcuate groove 4412, mounting space 442, protruding connecting block 443, pulling rope 444, protective baffle 45, adjusting gear 51, gear transmission rod 52, clearance gap 53, electrical connection line 61, electrical contact block 62, elastic member 63, connecting area 71, power-off friction area 72, third friction surface 721, mounting housing 80, arcuate gap 81, electrical conductive line 90. DETAILED DESCRIPTION

[0030] The following will be combined Figure 1-Figure 7 The preferred embodiments of the present invention are described in detail. It should be noted that the following description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will appreciate that various modifications and variations may be made to the present invention without departing from the spirit and scope of the present invention. The scope of protection of the present invention shall be determined by the appended claims.

[0031] Example 1: refer to Figure 1-Figure 5 This embodiment provides a battery pack dynamic management and self-cleaning switching system, primarily for use in electric vehicles, particularly two-wheeled electric vehicles powered by multiple battery packs. The system utilizes an innovative multi-power selective connection device 40 to achieve real-time monitoring, dynamic switching, and fault isolation of the battery packs. It also incorporates a unique contact self-cleaning mechanism, effectively addressing contact reliability issues in traditional multi-battery switching systems. The system utilizes a modular design and can be flexibly installed beneath the main support tube of the vehicle frame, ensuring a compact overall structure while facilitating maintenance and operation.

[0032] The multi - power selective connection device 40 is installed in the frame 10 of the two - wheel electric vehicle. The frame 10 is connected to the steering support frame 18. The frame 10 includes a main support pipe 11 connected to the steering support frame 18. On both sides of the main support pipe 11 along the width direction of the electric vehicle, a plurality of symmetric side bracket groups 12 are connected. Among them, the side bracket group 12 is made of hollow steel pipes. The diameter of the main support pipe is 30 - 40 mm, and the diameter of the secondary support pipe is 20 - 25 mm. Each bracket group is fixedly connected by welding, and stiffening plates are added at key nodes. The plurality of side bracket groups 12 are arranged in a three - side surrounding shape and form an installation position 121 for placing the battery. An installation box body 13 with a waterproof design is arranged in the installation position 121. The installation box body 13 has drainage holes and a ventilation structure, and a shock - proof pad is arranged inside. The battery is installed in the installation box body 13.

[0033] The power supply architecture of this system adopts a "field" - shaped layout design, configuring four 12V battery units, and dividing them into left and right two battery groups 21 with the symmetry axis of the electric vehicle's traveling direction. The distance between the two battery groups is, for example, 30 - 50 mm. The space formed realizes the dynamic control of the battery temperature through a forced convection heat dissipation system, and at the same time accommodates the multi - power selective connection device 40. The system adopts a standardized interface design, and the external connecting wires 22 equipped for each battery unit use waterproof quick - plug electrical connectors.

[0034] Reference Figure 2-Figure 7 , the core structure of the multi - power selective connection device 40 includes four groups of connected contacts 41, a mode adjustment mechanism 42, a fouling layer self - cleaning system 43, and an integrated operation and installation disk 44. The technical features of each component are as follows: Connected contacts 41: Adopt a symmetric layout. Each group of connected contacts 41 is equipped with a corresponding fouling layer cleaning structure 43, located on both sides of the mode adjustment mechanism 42; The contact head material is selected as a highly conductive gold - plated copper alloy, and two pairs of positive and negative contact heads are arranged on each side; Connect to the battery pole through a waterproof electrical connector to ensure that the contact resistance ≤ 0.5 mΩ; Adopt a coaxial self - rotation design, and the rotation torque is controlled within 0.8 N•m; The four connected contacts 41 are distributed in an equally - divided circular arc to ensure uniform stress.

[0035] The modular design of the system supports flexibly configuring the number of connected contacts 41 according to actual application requirements, and maintaining a symmetric distribution on both sides of the mode adjustment mechanism 42.

[0036] Key component design of the mode adjustment mechanism 42: Adjusting disk 421: Made of wear - resistant engineering plastics, with a diameter of 80 - 100 mm and a thickness of 1� - 20 mm; Contact distribution: Multiple contacts 4221 are evenly spaced along the circumference at both ends of the adjustment disk 421 (only the contacts at one end of the adjustment disk are shown in the figure). The contacts are made of silver-plated copper alloy with a contact resistance of ≤0.3mΩ; Position combination: Multiple contacts 4221 form several groups of position contact combinations 422. The contacts 4221 of each group of position contact combinations 422 are symmetrically distributed at both ends of the adjustment disk 421. The number of contacts matches the number of connected contacts 41. Circuit design: Each gear contact combination 422 realizes different modes of line connection by adjusting the wire (cross-sectional area ≥ 2.5mm²) inside the disk 421. The contact 4221 can be reused in different gear contact combinations 422, improving space utilization; If a battery in the pack experiences an abnormal condition (voltage <10.5V or current fluctuation exceeds ±20% of the rated value), the system uses a stepper motor to drive the adjustment disc 421 to rotate (angle 0-360°, step angle 15°), reconnecting the battery pack. The stepper motor drive ensures positioning accuracy within ±0.5° and maintains contact pressure within the range of 0.6-0.8MPa.

[0037] refer to Figure 7 、 Figure 8-Figure 9 The fouling layer cleaning structure 43 primarily consists of two arc-shaped contact friction segments 431 for cleaning fouling from the connecting contacts 41, and two arc-shaped contact friction segments 432 for cleaning fouling from the contacts 4221. These friction components are symmetrically mounted on either side of the operating mounting plate 44, positioned between the adjustment disc 421 and their respective connecting contacts 41. The arc-shaped contact friction segments 431 are made of tungsten carbide with a hardness of at least HRA90 and are designed with four connection holes 4312, corresponding one to each connecting contact 41. Key technical parameters are as follows: First friction surface 4311: contacts the connecting contact head 41, with a surface roughness Ra value of 0.8-1.2 μm; Second friction surface 4321: contacts with contact point 4221 and adopts the same surface treatment process; All friction contact surfaces have been treated with anti-oxidation and have a service life of ≥10,000 reciprocating movements. By rotating the mounting plate 44, the first friction surface 4311 of the contact friction arc section 431 and the connecting contact head 41 can be cleaned by relative movement. By rotating the adjusting disc 421, the second friction surface 4321 of the contact friction arc section 432 can clean the contact 4221 by friction. This innovative self-cleaning design effectively solves the fouling problems of traditional systems caused by factors such as environmental oxidation and spark erosion. Through periodic and automatic cleaning during switching, the contact surface roughness is maintained below Ra 1.6μm and the contact resistance is controlled within 0.5mΩ. This design is expected to extend battery life by 30-50% and ensure that the supply voltage fluctuation is ≤±2%.

[0038] The design of the contact friction arc section 431 not only has a cleaning function, but also integrates an electrical isolation function. A complete dwelling space is designed in the area outside the connection hole 4312 to accommodate a connection contact head 41, and dirt is removed through a surface friction force of 3-5N. The system uses step rotation to achieve precise positioning. Combined with the ratchet structure, it can achieve a positioning accuracy of ±0.5° and has a self-locking function, ensuring that the connection contact head 41 can be completely located in the dwelling space to achieve reliable electrical isolation. In terms of contact interface optimization, the inner wall of the connection hole 4312 adopts a 15° chamfer design (depth 0.5-0.8mm) and is anodized. The end of the connection contact head 41 close to the contact 4221 adopts a spherical design and is plated with a 3-5μm gold layer, controlling the friction coefficient between 0.1-0.15 and the operating force below 5N to ensure a smooth and reliable conversion process. To enhance conductivity, the surface of the connecting contact 41 is coated with a 0.2-0.3mm thick conductive elastic layer. Materials such as graphene composites (volume resistivity ≤ 10^-3Ω•cm, elastic deformation 20-30%), doped PEDOT:PSS conductive polymers (conductivity > 1000 S / cm), or beryllium copper alloys (yield strength ≥ 500MPa) are available. This system utilizes a composite material of 8-12 layers of graphene and silicone rubber, which exhibits excellent lateral conductivity (> 5000 S / cm). When the connecting contact 41 enters the connection hole 4312, the conductive elastic layer generates an elastic pressure of 2-3N, ensuring a contact resistance of < 0.3mΩ and reliably supporting instantaneous current transmission of ≥ 100A.

[0039] Refer to the attached diagrams. To achieve compact integration of the mode adjustment mechanism 42 and the fouling layer cleaning mechanism 43, the operating mounting plate 44 employs a symmetrical design. Its core structure comprises two precision-injection-molded mounting discs 441. A cylindrical mounting space 442 (82-85mm diameter, 0.2-0.3mm axial play) is formed between the two discs for mounting the adjustment disc 421. An annular sealing groove (1.5mm deep, 2mm wide) is defined within the inner wall of this space for the sealing ring. The connecting holes 4411 on the mounting discs 441 are precision-machined to maintain high-precision coaxiality with the four connecting holes 4312. The contact friction arc 431 and the contact point friction arc 432 are integrated into the same mounting disc 441 using locating pins and a pressure plate. This design not only ensures precise coaxial mounting of the two friction components but also provides IP54-rated protection for the contacts 4221 via the lip seal, effectively preventing the deposition of environmental contaminants (particle size >10μm). In addition, the single-point drive operation mounting plate 44 (torque 1.2-1.5 N·m) can achieve synchronous rotation of the two friction components (speed ratio 1:1), and the ratchet positioning mechanism improves the efficiency and reliability of dirt cleaning.

[0040] The intricate structure of mounting disc 441 utilizes an integrated design. The arc groove 4412 precisely matches the thickness of the contact friction arc segment 431 and the contact point friction arc segment 432, achieving a clearance of 0.05-0.1mm. Both arc segments utilize precision-machined arc shapes and are precisely mounted within the arc groove 4412 via positioning bosses (2mm height). The contact point friction arc segment 432 penetrates the arc groove 4412 via a precision-machined through-hole (aperture tolerance H7), maintaining a 0.2-0.3mm working clearance with the contact point 4221. This integrated design allows for a more compact installation of the contact friction arc segments 431 and 432.

[0041] To achieve precise control of the adjustment disc 421, the system features a dedicated transmission mechanism. A fully circumferential adjustment gear 51 is integrated into one of the circular end faces of the adjustment disc 421 and undergoes a precision carburizing and quenching process. This gear forms a 2:1 reduction gear with a 20CrMnTi gear transmission rod 52 (module 1.5, 20 teeth), with gear pair backlash controlled to 0.1-0.15mm. The gear transmission rod 52 is supported at both ends by deep-groove ball bearings (6202-2Z) and extends through the main support tube 11 (axial play ≤0.5mm) to the front section of the locomotive. The system offers two control options: manual control, connected to the adjustment operating unit at the locomotive head via an SAE 6-tooth spline, with an operating torque of ≤2 N·m. Automatic control can be directly driven by a stepper motor (such as the 42 stepper motor, with a torque ≥0.4 N·m) or a servo motor (50-100W), enabling remote automated control. This design enables the system to automatically optimize battery pack switching based on real-time monitoring data (with a scale accuracy of ±1°). To enhance the system's protection, a 45° sector-shaped notch 53 is designed on the mounting disc 441 near the adjustment gear 51. A nitrile rubber sealing lip (1mm thick) is positioned at the edge of the notch, ensuring gear meshing (contact coefficient 1.2-1.4) while also providing IP54-level dustproofing (seal compression rate 15-20%).

[0042] The mechanical operating system of the operating mounting plate 44 also features a quick-change mechanism. High-strength bolts (strength grade 8.8) connect the edges of the two mounting discs 441 to a protruding connector block 443. This connector block 443 features a precision positioning groove for securing a steel wire rope, which connects to a high-strength pull rope 444 via a dedicated ferrule. The pull rope 444's guide system utilizes a guide wheel assembly supported by sealed bearings (6000-2RS), ensuring smooth transmission and extended service life. When manually controlled, the pull rope 444 connects to the starting operating components on the front of the vehicle. When electrically controlled, a small servo motor (torque 0.2-0.4 N·m) can be configured for automated control, with a system response time of ≤200ms.

[0043] The outer wall of the adjustment disk 421 is designed to integrate power supply control. Connecting areas 71 are spaced evenly every 45° around the disk's circumference. These areas are made of a highly conductive composite material. Options include gold-plated copper alloy (conductivity ≥90% IACS), doped silicon-based materials (resistivity ≤0.01 Ω·cm), or graphene composites (sheet resistance <0.1 Ω). This system uses a gold-plated copper alloy with a purity ≥99.9% (coating thickness 3-5μm). Two sets of electrical connections are located on the outer wall of the adjustment disk 421: 16mm² electrical connection wires 61 and electrical contacts 62 made of silver-plated copper alloy (purity ≥99.9%). One set connects to the rear motor and sensor system, while the other connects to low-power devices (such as LCD displays, power consumption ≤2W) at the front of the vehicle. By precisely controlling the rotation of the adjusting disk 421 (angle error ≤±1°), reliable contact (contact resistance ≤0.2mΩ) or disconnection between the connecting area 71 and the electrical contact block 62 is achieved. When the system needs to be temporarily powered off, the non-conductive area can be aligned with the electrical contact block 62, effectively reducing standby power consumption (≤0.1W).

[0044] The outer wall of the adjustment disc 421 also features an innovative design for power-off friction zones 72, interlaced with the connection zones 71. These zones 72 are constructed of a tungsten carbide matrix (HRA90 hardness) and feature specialized microgrooves (0.1mm deep, 0.5mm apart) to form a third friction surface 721. These grooves effectively remove oxides and deposits from the surface of the electrical contact block 62 (thickness ≤ 0.05mm). To ensure contact reliability, the electrical contact block 62 is gold-plated (2-3μm thick) and flexibly connected to the electrical connection cable 61 via a gold-plated compression spring 63 (elastic modulus 10N / mm). The spring force is controlled at 2-3N, ensuring stable contact resistance. All electrical connections 61 in the system are routed in separate zones and housed within a V0 flame retardant housing 80. The arc-shaped notch 81 in the housing 80 creates an interference fit (0.1-0.2mm) with the mounting disc 441, achieving an IP54 protection rating. The monitoring system's electrical conductors 90 (cross-sectional area 2.5 mm²) also utilize the same protection scheme. The system's core functional components are protected by a 2 mm thick PC / ABS protective shield 45 (flammability rating V0). The shield is secured to the connecting bracket 30 with four M4 bolts. Through-holes are arranged in a plum blossom pattern (hole diameter 12 mm, spacing 30 mm) or with a 120° fan-shaped opening (radius 25 mm) to ensure convenient wiring.

[0045] The battery switching and fouling cleaning process of this system is as follows: Basic operation process: 1. Startup process: In manual control: operate the starting operating component of the front part of the vehicle, and pull the pulling rope 444 (stroke 15-20mm) to drive the two mounting discs 441 to rotate synchronously In automatic control: the control system drives the servo motor to achieve precise synchronous rotation of the two mounting discs 441 2. Contact establishment: The connecting contact head 41 slides into the corresponding connecting hole 4312 and the connecting hole 4411 at a speed of 0.2-0.3m / s. Positioning accuracy ≤ 0.1mm, contact pressure maintained at 0.6-0.8MPa The monitoring system collects battery status in real time through high-precision sensors: Voltage monitoring: resolution ±0.01V Current monitoring: range 0-100A, accuracy 0.5% 3. Mode switching: Manual mode: Adjust the operating components through the headstock (maximum operating torque 2N•m) Automatic mode: via stepper motor or servo motor (speed 60-120rpm) Drive the adjustment disc 421 to rotate accurately to the target position (positioning accuracy ±1°) The gear contact assembly 422 forms a stable contact with the communication contact head 41 (contact resistance ≤ 0.3 mΩ).

[0046] The monitoring system uses a 32-bit microprocessor to monitor key battery parameters in real time, including voltage (10.5-14.4V), charge and discharge current (-50A to +50A), temperature (-20°C to 60°C), and internal resistance (5-15mΩ). The system automatically triggers protection mechanisms when abnormal conditions occur, such as battery voltage falling below 10.5V, temperature exceeding 55°C, discharge current exceeding 45A, or a sudden change in internal resistance exceeding 30%. Debris removal is performed automatically when switching between modes or periodically according to the maintenance schedule. Operating at a pressure of 0.6-0.8MPa, it effectively removes oxidation and spark corrosion deposits up to 0.02-0.05mm thick, ensuring contact resistance remains below 0.5mΩ and power transmission efficiency exceeding 99.5%. The system supports multiple operating modes: standard 48V mode (four cells in series), 36V emergency mode (three cells in series, automatically skipping faulty cells), 24V emergency mode (two cells in series), and a diagnostic mode for evaluating individual battery performance. Each mode has a corresponding contact connection strategy to ensure reliable operation of the system under various working conditions.

[0047] In the specific design and implementation of the system, a series of core technical safeguard measures are adopted. Each set of contacts is equipped with a clear polarity identification and integrated with an anti-reverse connection protection mechanism; a sufficient safety distance is maintained between contacts to prevent the risk of short circuit; the cleaning structure design ensures that all contact positions can be covered. The switching mechanism adopts a one-way rotation design to avoid poor contact caused by repeated switching; an overlapping area is set during the contact transition to ensure power supply continuity; all gears are equipped with clear markings and reliable positioning structures.

[0048] It should be noted that the specific parameters involved in this system are all preferred implementation schemes and can be appropriately adjusted according to actual application requirements. For example: the battery specifications can be selected with different voltage levels according to the vehicle requirements, the contact safety distance can be adjusted accordingly based on the working voltage level, the size and pressure of the friction cleaning structure can be optimized according to the use environment, the reduction ratio and operating torque of the transmission mechanism can be adjusted based on the requirements of operation convenience, and the sampling frequency and accuracy of the monitoring system can be set according to the application scenario requirements.

[0049] This embodiment is mainly optimized for the application scenario of two-wheeled electric vehicles. On the premise of ensuring safety and reliability, all technical parameters can be reasonably adjusted to meet different application requirements.

[0050] Embodiment 2 In this embodiment, the intelligent battery pack dynamic management and self-cleaning switching system is applied to large electric logistics vehicles. Since logistics vehicles have high requirements for cruising range and load capacity, the system is configured with 6 groups of 72V battery units and adopts a "pin" shaped three-row layout design. The battery units are fixed under the vehicle frame through strengthened bottom brackets, and the brackets are made of aluminum alloy profiles (6063-T5), with the characteristics of light weight and high strength (flexural strength ≥ 160MPa).

[0051] The multi-power selective connection device 40 has carried out the following optimized designs for high-voltage and large-current scenarios: Improvement of the connected contact head system: The contact head is made of copper-chromium-zirconium alloy material (hardness HV200 - 240), and the thickness of the silver plating layer is increased to 8 - 10μm; the single contact area is increased to 20mm², and the contact resistance is reduced to 0.2mΩ; Integration of the cooling system: Micro-channels (diameter 2mm) are designed inside the connected contact head 141, and forced cooling is achieved through circulating liquid (thermal conductivity ≥ 0.8W / m•K); the contact pressure is increased to 1.0 - 1.2MPa to ensure stable conductive performance under the condition of large current (≥ 200A).

[0052] Optimization of the fouling cleaning structure: The cleaning arc section is made of nano-ceramic material (hardness HRA95) and sprayed with a molybdenum disulfide lubricating layer (thickness 2-3μm). The micro-groove depth is increased to 0.15mm, and the spacing is reduced to 0.3mm, improving the cleaning effect. An automatic lubrication system is added, which regularly sprays high-performance conductive grease through a micro-injection device (flow rate 0.1-0.2ml / min). Mode adjustment mechanism upgrade: The diameter of the adjustment disc has been increased to 120-150mm and is made of carbon fiber composite material, reducing its weight by 30%. The gear contact combination adopts a modular design, supporting 8 different battery series and parallel combinations. The drive system uses a servo motor (power 200W) with a response time of ≤100ms. A new CAN bus communication interface has been added to transmit system operating parameters in real time.

[0053] Monitoring system enhancements: The voltage monitoring range has been expanded to 60-85V; the current monitoring accuracy has been improved to 0.2%; and a new battery pack energy management algorithm has been added that can dynamically adjust the discharge strategy based on load demand.

[0054] Fault warning function: Based on deep learning algorithms, it can predict possible battery abnormalities 30-50 hours in advance.

[0055] Remote monitoring function: Data can be uploaded to the cloud through the 4G module, supporting remote diagnosis and maintenance.

[0056] This system is particularly suitable for long-distance logistics and delivery scenarios. Through intelligent scheduling algorithms, it can achieve: dynamic balancing of battery packs, extending service life by 20-30%; automatically adjusting output power according to road conditions, increasing driving range by 15-25%; supporting rapid switching of emergency modes to ensure reliable completion of delivery tasks; and improving the overall system efficiency to 99.8%, reducing annual maintenance costs by 40%.

Claims

1. A battery pack dynamic management method using a battery pack dynamic management and self-cleaning switching system, characterized in that: The switching system includes: A frame, which includes a main support pipe and multiple groups of side support groups connected to the main support pipe. The side support groups are arranged in a three-sided surrounding shape and form an installation position for placing batteries. An installation box body arranged in the installation position. The installation box body has drainage holes and a ventilation structure. Multiple battery groups installed in the installation box body. The multiple battery groups are designed in a "field" shape layout, and there is a heat dissipation space between the multiple battery groups. A multi-power selective connection device installed in the frame. The multi-power selective connection device includes: Multiple groups of connection contacts for electrically connecting to the multiple battery groups. The surface of the connection contacts is coated with a conductive elastic layer. A mode adjustment mechanism. The mode adjustment mechanism includes an adjustment disc. At both ends of the adjustment disc, multiple contacts are equally spaced along the circumferential direction. The multiple contacts form several groups of gear position contact combinations. Multiple connection areas are provided on the outer peripheral wall of the adjustment disc, and power-off friction areas are provided between the connection areas. The gear position contact combinations adopt a modular design to achieve different battery series-parallel combinations. A dirt layer cleaning structure arranged between the adjustment disc and the connection contacts for cleaning the dirt on the surfaces of the connection contacts and the contacts. An operation installation disc for installing the adjustment disc and the dirt layer cleaning structure; and A transmission mechanism. The transmission mechanism includes an adjustment gear arranged at the edge of the end face of the adjustment disc and a gear transmission rod meshing with the adjustment gear; A monitoring system, the monitoring system includes: A voltage monitoring unit for monitoring the voltage of the battery group. A current monitoring unit for monitoring the charging and discharging current of the battery group. A temperature monitoring unit for monitoring the temperature of the battery group. An internal resistance monitoring unit for monitoring the internal resistance of the battery group; and A control unit for controlling the mode adjustment mechanism to perform mode switching according to the monitoring data. A power supply control system. The power supply control system includes: Two groups of electrical connection devices arranged on the outer peripheral wall of the adjustment disc. Each group of electrical connection devices includes an electrical connection wire and an electrical contact block. A gold-plated compression spring arranged between the electrical contact block and the electrical connection wire; and An installation housing for accommodating the electrical connection wire. The installation housing forms a sealed fit with the operation installation disc. The management method includes the following steps: A real-time monitoring step, including: Monitoring the voltage parameters of multiple battery groups. The monitoring range of the voltage parameters is 10.5 - 14.4V. Monitoring the current parameters of multiple battery groups. The monitoring range of the current parameters is -50A to +50A. Monitoring the temperature parameters of multiple battery groups. The monitoring range of the temperature parameters is -20°C to 60°C. Monitoring the internal resistance parameters of multiple battery groups. The monitoring range of the internal resistance parameters is 5 - 15mΩ. An abnormal judgment step, including: Judging whether the voltage is lower than 10.5V. Judging whether the temperature exceeds 55°C. Judging whether the discharge current exceeds 45A. Judging whether the internal resistance mutation exceeds 30%. A mode switching step, including: When abnormal parameters are detected, controlling the adjustment disc to rotate to switch the connection mode of the battery group. Control the rotation speed of the regulating disc within the range of 60-120 rpm; Ensure that the positioning accuracy of the adjustment disc is within the range of ±1°; Debris cleaning steps include: Automatically clean the dirt when switching to battery pack connection mode; Perform scale removal according to a pre-set maintenance schedule; Cleaning is carried out at a pressure of 0.6-0.8MPa.

2. The battery pack dynamic management method according to claim 1, characterized in that: The mode switching step includes: Manual control mode: By operating the starting operating component on the front part of the vehicle; The installation disc is rotated by pulling the pull rope, and the travel of the pull rope is 15-20mm; Drive the adjusting disc to rotate by using an adjusting operating component with an operating torque not exceeding 2N•m; or Automatic control mode: The mounting disc is driven to rotate by a servo motor; The disc is driven and adjusted to rotate by a stepper motor or a servo motor; The system response time does not exceed 200ms.

3. The battery pack dynamic management method according to claim 1, characterized in that: The fouling cleaning step specifically includes: Cleaning the surface of the contact head by using the first friction surface of the contact friction arc segment; Cleaning the contact surface through the second friction surface of the contact friction arc segment; Removes oxidation and spark corrosion deposits with a thickness of 0.02-0.05mm; Check the contact resistance value and repeat the cleaning process when the contact resistance is greater than 0.5mΩ.

4. The battery pack dynamic management method according to claim 1, characterized in that: The connection modes in the mode switching step include: standard working mode: 48V mode: four batteries are connected in series, used for standard working conditions; emergency working mode: 36V mode: three batteries are connected in series, automatically skipping the faulty battery; 24V mode: two batteries are connected in series, used for emergency working conditions; diagnostic working mode: single battery mode: used for single battery performance evaluation.

5. The battery pack dynamic management method according to claim 1, characterized in that: After the mode switching step, a connection checking step is also included: Check the contact status between the connecting contact head and the connecting hole; Ensure that the contact pressure is maintained within the range of 0.6-0.8MPa; Ensure that the contact resistance does not exceed 0.3mΩ; Check whether the power transmission efficiency reaches above 99.5%.

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