Forklift insulation monitoring alarm system and method applying distributed BMS

Abstract

The invention discloses a forklift insulation monitoring alarm system and method applying a distributed BMS, the system comprises bottom layer software and application layer software, the bottom layer software comprises a sensor acquisition module, a clock module, a data storage module, a fault storage module, a UART communication module, an RS485 communication module, an IIC communication module and a CAN communication module, the application layer software comprises an insulation detection module, a BMS state monitoring module, a battery equalization management module, a fault diagnosis module and an alarm module. The method comprises the following steps: S1, monitoring a system current value through a sensor; s2, calculating an insulation resistance value and an SOC; according to the method, an insulation algorithm and an SOC algorithm are fused, so that the cross-correlation factor of the insulation resistance value of the power utilization module and the insulation resistance value of the whole system is greatly reduced, the anti-interference capability of the system is improved, the accuracy of a measurement result is ensured, and the method has a wide application prospect and is beneficial to popularization and application.

Description

Technical Field

[0001] The present invention relates to the field of information technology, and in particular to a forklift insulation monitoring and alarm system and method using a distributed BMS. Background Art

[0002] Currently, battery-powered forklifts face insulation issues between the forklift battery and the vehicle chassis due to various factors, including the operating environment and the aging of the battery itself and the connecting cables. As a result, the battery voltage often exceeds the safe voltage range, necessitating insulation resistance testing to mitigate safety risks. However, current insulation testing systems are mostly single-function and susceptible to environmental interference. Therefore, there is an urgent need to develop a distributed BMS-based forklift insulation monitoring and alarm system and method to address these technical issues.

[0003] In view of this, the present invention is proposed. Summary of the Invention

[0004] The purpose of the present invention is to provide a forklift insulation monitoring and alarm system and method using a distributed BMS, which integrates an insulation algorithm and a SOC algorithm, greatly reducing the cross-correlation factor between the insulation resistance of the power module and the insulation resistance of the entire system, improving the system's anti-interference ability, ensuring the accuracy of the measurement results, and having broad application prospects, and is conducive to popularization and application.

[0005] In order to achieve the above-mentioned objectives, the present invention provides a forklift insulation monitoring and alarm system using a distributed BMS, including underlying software and application layer software. The underlying software includes a sensor acquisition module, a clock module, a data storage module, a fault storage module, a UART communication module, an RS485 communication module, an IIC communication module and a CAN communication module. The application layer software includes an insulation detection module, a BMS status monitoring module, a battery balancing management module, a fault diagnosis module and an alarm module.

[0006] The present invention also provides a forklift insulation monitoring and alarm method using a distributed BMS, the method using the forklift insulation monitoring and alarm system, comprising the following steps:

[0007] S1: monitor the system current value through the sensor;

[0008] S2: Calculate insulation resistance and SOC;

[0009] S3: Display and store insulation resistance and alarm information.

[0010] Preferably, in S1, the measurement circuit includes an external residual current transformer. Except for the ground wire, all conductors of a voltage system are fed through the transformer. In a healthy system, the sum of all flowing currents is zero, and no voltage is generated in the current transformer. If a ground fault occurs and current flows to the earth, the sensor will detect the current caused by the current difference in the current transformer. When the sensor is disconnected or the current transformer coil is damaged, the module will enter the alarm state, and the warning and alarm LED indicators will flash. The measurement range = range (Range) * proportional factor (Factor). The alarm relay will be activated after reaching 100% of the adjusted response value. The warning value is set every 10 ranges between 10%-100%. The potentiometer sets the switch delay from 0-10 seconds, which will act on the warning and alarm.

[0011] Preferably, in S2, the residual current sensor monitors the power module connected to the system, and transmits the detection value to the MCU through RS485 communication. After the system stabilizes, the insulation algorithm and SOC algorithm are used to analyze the value to obtain the current status of the BMS, whether there is leakage in the power module, the remaining battery capacity and the battery health.

[0012] Preferably, in S3, according to the conclusion of S2, the MCU drives the battery to complete the balancing management, the alarm module provides status prompts, and the data is stored in the system in the form of curves and logs. Important monitoring data and alarm information are displayed on the forklift dashboard via CAN communication.

[0013] The present invention provides a forklift insulation monitoring and alarm system and method using a distributed BMS, which has the following beneficial effects.

[0014] 1. This invention combines distributed BMS monitoring to effectively avoid environmental interference and improve measurement accuracy and stability. By integrating the insulation algorithm with the SOC algorithm, the cross-correlation factor between the insulation resistance of the power module and the insulation resistance of the entire system is greatly reduced, improving the system's anti-interference ability and ensuring the accuracy of the measurement results.

[0015] 2. The present invention can save costs, shorten verification cycles, and save development time. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a structural block diagram of a forklift insulation monitoring and alarm system using a distributed BMS provided by the present invention;

[0017] Figure 2 This is a flow chart of a forklift insulation monitoring and alarm method using a distributed BMS provided by the present invention. DETAILED DESCRIPTION

[0018] The present invention will be further described below with reference to specific embodiments and accompanying drawings to facilitate understanding of the present invention.

[0019] like Figure 1 The figure shows a block diagram of a forklift insulation monitoring and alarm system using a distributed BMS provided by the present invention. The forklift insulation monitoring and alarm system using a distributed BMS includes underlying software and application layer software. The underlying software includes a sensor acquisition module, a clock module, a data storage module, a fault storage module, a UART communication module, an RS485 communication module, an IIC communication module, and a CAN communication module. The application layer software includes an insulation detection module, a BMS status monitoring module, a battery balancing management module, a fault diagnosis module, and an alarm module.

[0020] The present invention also provides a forklift insulation monitoring and alarm method using a distributed BMS, such as Figure 2 FIG. 1 is a flow chart of a forklift insulation monitoring and alarm method using a distributed BMS provided by the present invention. The method uses the forklift insulation monitoring and alarm system described above and includes the following steps:

[0021] S1: monitor the system current value through the sensor;

[0022] The measurement circuit contains an external residual current transformer. Except for the ground wire, all conductors of a voltage system are fed by the transformer. In a healthy system, the sum of all flowing currents is zero, and no voltage is generated in the current transformer. If a ground fault occurs and current flows to the earth, the sensor will detect the current caused by the current difference in the current transformer. When the sensor is disconnected or the current transformer coil is damaged, the module will enter the alarm state, and the warning and alarm LED indicators will flash. The measurement range = range (Range) * scale factor (Factor). The alarm relay will operate after reaching 100% of the adjusted response value. The warning value is set every 10 ranges between 10%-100%. The potentiometer sets the switch delay from 0-10 seconds, which will act on the warning and alarm.

[0023] S2: Calculate insulation resistance and SOC;

[0024] The residual current sensor monitors the power consumption modules connected to the system and transmits the detection values to the MCU via RS485 communication. After the system stabilizes, the insulation algorithm and SOC algorithm are used to analyze the values to determine the current status of the BMS, whether there is leakage in the power consumption module, the remaining battery capacity and the battery health.

[0025] S3: Display and store insulation resistance and alarm information.

[0026] Based on the conclusions drawn by S2, the MCU drives the battery to complete balancing management, the alarm module provides status prompts, and the data is stored in the system in the form of curves and logs. Important monitoring data and alarm information are displayed on the forklift dashboard via CAN communication.

[0027] This invention incorporates distributed BMS monitoring to effectively avoid environmental interference and improve measurement accuracy and stability. By integrating the insulation algorithm with the SOC algorithm, the cross-correlation factor between the insulation resistance of the power module and the insulation resistance of the entire system is significantly reduced, improving the system's anti-interference capability and ensuring the accuracy of measurement results. This invention also saves costs, shortens verification cycles, and reduces development time.

[0028] This document uses specific examples to illustrate the inventive concept in detail. The above embodiments are only intended to help understand the core concept of the present invention. It should be noted that any obvious modifications, equivalent substitutions, or other improvements made by a person skilled in the art without departing from the inventive concept should be included within the scope of protection of the present invention.

Claims

1. A forklift insulation monitoring and alarm system using a distributed BMS, characterized in that: It includes bottom-layer software and application-layer software. The bottom-layer software includes a sensor acquisition module, a clock module, a data storage module, a fault storage module, a UART communication module, an RS485 communication module, an IIC communication module, and a CAN communication module. The application-layer software includes an insulation detection module, a BMS status monitoring module, a battery balancing management module, a fault diagnosis module, and an alarm module.

2. A forklift insulation monitoring and alarm method using a distributed BMS, characterized in that: The method adopts the forklift insulation monitoring alarm system according to claim 1, comprising the following steps: S1: monitor the system current value through the sensor; S2: Calculate insulation resistance and SOC; S3: Display and store insulation resistance and alarm information.

3. The forklift insulation monitoring and alarm method using a distributed BMS according to claim 2 is characterized in that: In S1, the measurement circuit includes an external residual current transformer. Except for the ground wire, all conductors of a voltage system are fed by the transformer. In a healthy system, the sum of all flowing currents is zero, and no voltage is generated in the current transformer. If a ground fault occurs and current flows to the earth, the sensor will detect the current caused by the current difference in the current transformer. When the sensor is disconnected or the current transformer coil is damaged, the module will enter the alarm state, and the warning and alarm LED indicators will flash. The measurement range = range (Range) * scale factor (Factor). The alarm relay will operate after reaching 100% of the adjusted response value. The warning value is set every 10 ranges between 10%-100%. The potentiometer sets the switch delay from 0-10 seconds, which will act on the warning and alarm.

4. The forklift insulation monitoring and alarm method using a distributed BMS according to claim 3 is characterized in that: In S2, the residual current sensor monitors the power module connected to the system and transmits the detection value to the MCU through RS485 communication. After the system stabilizes, the insulation algorithm and SOC algorithm are used to analyze the value to obtain the current status of the BMS, whether there is leakage in the power module, the remaining battery capacity and the battery health.

5. The forklift insulation monitoring and alarm method using a distributed BMS according to claim 4 is characterized in that: In S3, based on the conclusion of S2, the MCU drives the battery to complete the balancing management, the alarm module provides status prompts, and the data is stored in the system in the form of curves and logs. Important monitoring data and alarm information are displayed on the forklift dashboard via CAN communication.

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