Intelligent storage battery state detection system and control method

Abstract

According to the intelligent storage battery state detection system and the control method, a dynamic early warning mechanism is constructed by monitoring voltage parameters of a storage battery device of an aerial work platform and real-time working condition parameters of a vehicle in real time, and early warning prompt is actively triggered when voltage abnormity or an electric quantity critical threshold value is detected; operation interruption caused by insufficient electric quantity in the operation process is effectively prevented, meanwhile, accurate monitoring of storage battery voltage early warning is enhanced through a closed-loop control algorithm, the operation reliability and the use safety of equipment are remarkably improved, and potential safety hazards caused by power supply faults are reduced to the maximum extent; according to the method, a self-adaptive charging strategy is synchronously integrated, bidirectional communication with a lithium battery management system is carried out based on periodic voltage monitoring data, accurate charging control is realized, continuous and stable operation of the aerial work platform is guaranteed, the use efficiency of the storage battery is synchronously improved, the maintenance cost is reduced, and a complete storage battery health management solution is formed.

Description

Technical Field

[0001] The present invention relates to an electric control system for an aerial work platform, and in particular to an intelligent battery status detection system and a control method. Background Art

[0002] Self-propelled aerial work platforms, with their convenience and flexibility, have significantly improved the efficiency of aerial work operations while effectively reducing construction costs. With the rapid development of electrification technology, lithium batteries are increasingly used as the primary power source in aerial work platforms, and the accuracy and safety of their battery control systems are receiving increasing attention. As a backup power source, the battery's charge state directly affects the aerial work platform's endurance and operational stability, making battery status monitoring and precise control particularly important.

[0003] The existing technology uses a programmable controller (PLC) to monitor the battery voltage in real time, compares the collected voltage parameters with the preset threshold, and then starts a timer to record the time parameters for the voltage to continue to be lower than the threshold when the trigger condition is met. When the abnormal voltage lasts for a preset time trigger value, the human-computer interactive display will issue an alarm pop-up window. The disadvantages of this method are: 1) The system's fault diagnosis lacks foresight and cannot predict battery voltage change trends in advance, resulting in delayed fault warnings and increased operational risks; 2) The logic judgment parameters are fixed and cannot be adjusted, which cannot adapt to the individual differences in voltage of different batteries, resulting in insufficient compatibility and applicability; 3) Lack of effective power-down replenishment strategy, the battery is in an undercharged state for a long time, resulting in capacity decay, shortened service life and increased maintenance costs. Summary of the Invention

[0004] In response to the problems existing in the above-mentioned prior art, the present invention provides an intelligent battery status detection system and control method. By real-time monitoring the voltage parameters of the battery device of the aerial work platform and the real-time operating parameters of the vehicle, a dynamic early warning mechanism is constructed. When a voltage abnormality or a critical power threshold is detected, an early warning prompt is actively triggered, effectively preventing operation interruptions caused by insufficient power during operation. At the same time, the closed-loop control algorithm is used to enhance the precise monitoring of battery voltage early warnings, significantly improving the equipment operation reliability and use safety, and minimizing the safety hazards caused by power failures; the method simultaneously integrates an adaptive power replenishment strategy, and conducts two-way communication with the lithium battery management system BMS based on periodic voltage monitoring data to achieve precise power replenishment control, which not only ensures the continuous and stable operation of the aerial work platform, but also simultaneously improves the battery utilization efficiency and reduces maintenance costs, forming a complete battery health management solution; the intelligent battery status detection system and control method can effectively prevent abnormal operation of the aerial work platform due to insufficient battery power, can realize insufficient battery power early warning and provide power replenishment support, and improve the stability and endurance of the aerial work platform.

[0005] Programmable Logic Controller (PLC): An automated control device designed specifically for industrial environments. It controls machine operation through built-in programs, processes sensor signals in real time, and drives actuators to achieve logical control. Battery Management System (BMS): An electronic control system used to monitor and manage battery pack status parameters. It optimizes performance by balancing battery cells to ensure safe and efficient battery operation. Human-Machine Interactive Display: An interface instrument used to monitor and operate aerial work equipment. It displays equipment status, sensor signals, vehicle operating conditions, and other information in real time to assist operators in controlling the vehicle. DC-DC Converter: An electronic device that converts DC power supply voltage levels to accommodate the voltage requirements of different electrical components.

[0006] To achieve the above objectives, the present invention adopts a technical solution: an intelligent battery status detection system, comprising: a programmable controller, a battery management system, a DCDC transformer, a DCDC relay, a battery, a lithium battery, and a human-machine interactive display, wherein the battery supplies power to the programmable controller, the human-machine interactive display, and the battery management system, the battery management system being a lithium battery management system, the programmable controller being communicatively connected to the human-machine interactive display, the lithium battery being connected to the battery via a DCDC transformer, the DCDC transformer being connected to the battery management system via a DCDC relay, the battery management system controlling the operation of the DCDC transformer via the DCDC relay, thereby controlling the lithium battery to charge the battery, and the programmable controller having a built-in voltage acquisition module and a current acquisition module, the voltage acquisition module being used to acquire the battery voltage, and the current acquisition module being used to acquire the discharge current of the battery management system, i.e., the discharge current of the lithium battery.

[0007] The DCDC transformer is used to charge the lithium battery by reducing its voltage.

[0008] The programmable controller (PLC) collects battery voltage parameters in real time and simultaneously receives real-time discharge current data transmitted by the lithium battery management system (BMS). When the vehicle is in an inactive state, the detection system compares the dynamic voltage value and BMS discharge current data with the preset threshold value, and determines the battery voltage level through the logic operation module. When the risk of low power is detected, the human-computer interaction display triggers the early warning mechanism, prompting personnel to execute the charging plan and charge line fault diagnosis. The system supports customizing the early warning threshold through the human-computer interaction interface to achieve adaptive compatibility with the different voltage characteristics of new and old batteries. This solution effectively prevents safety hazards caused by insufficient voltage on aerial work platforms and significantly improves the safety of equipment operation.

[0009] To address the problem of BMS being unable to wake up due to long-term idleness of aerial work platforms, an intelligent charging control system was built. A dedicated charging command communication protocol was established between the programmable controller (PLC) and the lithium battery management system (BMS). An autonomous start and stop configuration option for the charging function was added through the human-machine interactive display. The system automatically starts the voltage monitoring mode when the power is first turned off, and performs battery voltage diagnosis through a periodic BMS wake-up mechanism. When it detects that the battery voltage is lower than the preset charging threshold, the charging program is intelligently activated. When the set voltage recovery value or the maximum charging time limit is reached, the system automatically terminates the charging and enters an energy-saving sleep state. This charging strategy not only ensures that the battery maintains the optimal voltage state, but also achieves a dual improvement in equipment operation stability and energy utilization efficiency, effectively extending the service life of the battery pack.

[0010] The beneficial effects of the present invention are: 1) Real-time collection of BMS discharge current data enables accurate monitoring and fault diagnosis of the charging circuit status. Algorithmic analysis of discharge current characteristics effectively identifies abnormal charging circuit status, provides early warning of potential battery charging circuit faults, and prevents abnormal battery charge drop caused by circuit problems, thereby improving system reliability, enabling preventive maintenance of battery management, and enhancing the safety and stability of the power system. 2) The programmable controller (PLC) logic judgment function has been expanded with a multivariable comparative analysis module and a dynamic threshold algorithm to enable dynamic adjustment of system parameters. The human-computer interaction display interface has been optimized, and visual adjustment of threshold parameters has been supported. This has enhanced the system's adaptability, effectively resolved the issue of individual battery voltage differences, and improved system reliability. 3) A battery recharge strategy is introduced, employing a configurable management mode, allowing users to automatically enable or disable the recharge function based on actual needs, ensuring operational flexibility. An integrated intelligent diagnostic mechanism allows the system to periodically wake up the BMS to perform battery voltage checks, enabling precise status monitoring. Equipped with an automatic recharge control function, the system automatically activates recharge control when a voltage anomaly is detected, effectively ensuring optimal battery operation, improving vehicle reliability, and reducing maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is the structural diagram of the DCDC transformer; Figure 2 This is a logic diagram of the control method of the present invention; Figure 3 This is a flowchart of the early warning and power replenishment control of the present invention; Figure 4 This is a control interaction block diagram of the system of the present invention. DETAILED DESCRIPTION

[0012] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are only used to illustrate the present invention and are not intended to limit the scope of the present invention.

[0013] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present invention pertains. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0014] like Figure 1 、 2 As shown in Figure 4, an intelligent battery status detection system includes: a programmable controller, a battery management system, a DCDC transformer, a DCDC relay, a battery, a lithium battery, and a human-computer interaction display. The battery supplies power to the programmable controller, the human-computer interaction display, and the battery management system. The battery management system is a lithium battery management system. The programmable controller is communicatively connected to the human-computer interaction display. The lithium battery is connected to the battery via a DCDC transformer. The DCDC transformer is connected to the battery management system via a DCDC relay. The battery management system controls the operation of the DCDC transformer via the DCDC relay, thereby controlling the lithium battery to charge the battery. The programmable controller has built-in voltage acquisition module and current acquisition module. The voltage acquisition module is used to acquire the voltage of the battery, and the current acquisition module is used to acquire the discharge current of the battery management system, that is, the discharge current of the lithium battery.

[0015] The battery management system is provided with a main positive relay, and the DCDC transformer is provided with an input line and an output line. The input line adopts a three-wire structure, including DC+, DC- and an enable control line, wherein DC+ and DC- are respectively connected to the positive and negative poles of the lithium battery, and the enable control line forms a linkage control mechanism with the main positive relay through the DCDC relay; the output circuit adopts a DC+ and DC- two-wire structure, directly transmitting the converted electric energy to the battery, and simultaneously powering the battery management system, programmable controller, and human-computer interaction display.

[0016] During the detection system initialization phase, the DCDC relay is connected to a normally closed contact by default. When the battery management system starts up, it outputs a high-level signal to disconnect the main positive relay. At this point, the DCDC relay switches to a normally open contact, de-energizing the enable control line. This design effectively prevents interference from the DCDC transformer's capacitive characteristics on the lithium battery pre-charging process. After the pre-charging process is complete, the battery management system stops outputting a high-level signal, the main positive relay returns to the closed state, and the DCDC relay simultaneously turns on, energizing the enable control line. The DCDC transformer then starts operating and charging the battery. This interlocking mechanism ensures that the voltage conversion process is strictly limited to after the lithium battery has completed its power-up process, significantly improving the safety and voltage control accuracy of the battery charging process.

[0017] To enhance system reliability, a fault warning mechanism based on real-time current monitoring has also been constructed: by continuously collecting lithium battery discharge current data and dynamically comparing it with preset thresholds, abnormal operating conditions such as poor contact of input / output lines can be accurately identified; this mechanism can not only diagnose power supply line faults in a timely manner, but also predict the evolution of battery voltage based on current change trends, thereby triggering protection strategies in advance and effectively maintaining the voltage supply stability and operational safety of the aerial work platform.

[0018] A programmable threshold adjustment module is provided in the human-computer interaction display, and the programmable threshold adjustment module is provided with a fault diagnosis algorithm.

[0019] like Figure 2-3 As shown, a control method for an intelligent battery status detection system presets two key threshold parameters in the fault diagnosis algorithm: the battery voltage threshold K1 and the lithium battery discharge current threshold K2; When the detection system meets the preset operating conditions, if it detects that the real-time battery voltage V is less than K1 and the lithium battery discharge current A is less than K2, it determines that there is an abnormality in the charging circuit and triggers the battery over-discharge warning mechanism. At this time, the human-machine interface will issue a fault prompt. The detection system also configures a dynamic threshold release mechanism, defining the battery voltage recovery threshold K3 as the basis for determining whether the warning is released. After the operator performs the recharging operation, when the battery voltage V>K3, the detection system will determine that the recharging measure is effective based on the gradient characteristics of the continuously rising voltage (dV / dt>0) and automatically release the warning state; conversely, if the battery voltage continues to be lower than K3 and shows a non-restorative downward trend (dV / dt≤0), the warning signal output will be maintained until manual intervention; this dual-threshold judgment architecture constructs a closed-loop control system with self-correction capabilities through an iterative process of state monitoring-warning triggering-feedback adjustment.

[0020] The control method is based on a multi-level threshold judgment and a closed-loop feedback mechanism. Its core control logic consists of the following two collaborative modules: (1) Real-time status diagnosis and dynamic warning module: The detection system uses a programmable controller to build a three-level progressive monitoring system: 1) Main circuit power-on confirmation stage: Real-time acquisition of the lithium battery main positive relay pull-in status signal to determine the power system power-on integrity; 2) Charging circuit health diagnosis stage: After confirming that the main circuit is powered on, the battery management system discharge current A is synchronously monitored and compared with the preset threshold K2 in real time to identify functional abnormalities in the charging circuit; 3) Battery degradation warning phase: Continuously monitor the battery terminal voltage V. When V < K1, the timing monitoring mechanism is activated. The detection system quantifies the duration of the abnormal state using a timer T. If T ≥ a set threshold, a fault code R is triggered and a dual-mode warning is implemented: a pop-up warning message is generated on the turntable human-machine interface, and the power indicator on the platform operation terminal switches to a 500ms periodic flashing mode. This module uses a closed-loop reset mechanism. The warning state is released when the battery voltage returns to V > K3. If V < K3 persists, the alarm signal is maintained, forming a self-sustaining feedback control loop.

[0021] (2) Power replenishment maintenance module in low power mode: In response to equipment downtime, the detection system adopts a condition-triggered intelligent wake-up strategy: 1) During the power-off initialization phase, the programmable controller performs lithium battery state-of-charge (SOC) detection and battery management system voltage fault diagnosis in parallel, establishing a dual-criteria decision-making mechanism: when SOC ≤ N1 and the battery management system has no voltage fault, the automatic wake-up function is activated; otherwise, maintaining the battery management system voltage stability is prioritized; 2) Configurable wake-up protocol: A wake-up function configuration option is added to the human-machine interface. When the "Off" configuration is selected, the battery management system enters the sleep state directly after power is removed. When the "On" configuration is selected, the battery management system executes a periodic wake-up protocol (period t1, single wake-up duration t2). During the wake-up period, the battery voltage is dynamically monitored. If V ≤ N2 is detected, constant current charging is initiated. The charging termination condition is reaching the time threshold t3 or the voltage returns to V ≥ N3. If SOC ≤ N1 or a BMS voltage fault is detected during the wake-up period, charging is immediately terminated and the system enters the sleep state. This strategy can significantly reduce system maintenance costs by suppressing deep discharge of the battery.

[0022] The human-computer interaction display can send out an alarm pop-up window for early warning according to the above method.

[0023] By judging battery charging circuit faults, the potential voltage trend of the battery can be more accurately controlled, improving the timeliness and accuracy of early warnings; the dynamic threshold early warning algorithm is compatible with battery voltage differences and improves the system's adaptability; the intelligent battery charging strategy effectively ensures the battery's working status and increases the battery's durability.

[0024] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An intelligent battery status detection system, characterized in that: include: A programmable controller, a battery management system, a DCDC transformer, a DCDC relay, a battery, a lithium battery, and a human-machine interactive display. The battery supplies power to the programmable controller, the human-machine interactive display, and the battery management system. The battery management system is a lithium battery management system. The programmable controller is communicatively connected to the human-machine interactive display. The lithium battery is connected to the battery via a DCDC transformer. The DCDC transformer is connected to the battery management system via a DCDC relay. The battery management system controls the operation of the DCDC transformer via the DCDC relay, thereby controlling the lithium battery to charge the battery. The programmable controller has built-in voltage acquisition modules and current acquisition modules. The voltage acquisition module is used to acquire the voltage of the battery, and the current acquisition module is used to acquire the discharge current of the battery management system, i.e., the discharge current of the lithium battery.

2. An intelligent battery status detection system according to claim 1, characterized in that: The battery management system is provided with a main positive relay, and the DCDC transformer is provided with an input line and an output line. The input line adopts a three-wire structure, including DC+, DC- and an enable control line, wherein DC+ and DC- are respectively connected to the positive and negative poles of the lithium battery, and the enable control line forms a linkage control mechanism with the main positive relay through the DCDC relay; the output circuit adopts a DC+ and DC- two-wire structure, directly transmitting the converted electric energy to the battery, and simultaneously powering the battery management system, programmable controller, and human-computer interaction display.

3. An intelligent battery status detection system according to claim 2, characterized in that: During the initialization phase of the detection system, the DCDC relay is connected to the normally closed contact by default. When the battery management system is started, it disconnects the main positive relay by outputting a high-level signal. At this time, the DCDC relay switches to the normally open contact, and the enable control line is in the power-off state. After the pre-charging process is completed, the battery management system stops the high-level output, the main positive relay returns to the closed state, and the DCDC relay is turned on synchronously to energize the enable control line. The DCDC transformer then starts running and charges the battery.

4. The intelligent battery status detection system according to claim 2, characterized in that: A programmable threshold adjustment module is provided in the human-computer interaction display, and the programmable threshold adjustment module is provided with a fault diagnosis algorithm.

5. The control method of an intelligent battery status detection system according to claim 4, characterized in that: Two key threshold parameters are preset in the fault diagnosis algorithm: battery voltage threshold K1 and lithium battery discharge current threshold K2; When the detection system meets the preset operating conditions, if it detects that the real-time battery voltage V is less than K1 and the lithium battery discharge current A is less than K2, it determines that there is an abnormality in the charging circuit and triggers the battery over-discharge warning mechanism. At this time, the human-machine interface will issue a fault prompt. The detection system also configures a dynamic threshold release mechanism, defining the battery voltage recovery threshold K3 as the basis for determining whether the warning is released. After the operator performs the recharging operation, when the battery voltage V>K3, the detection system will determine that the recharging measure is effective based on the gradient characteristics of the continuously rising voltage, and automatically cancel the warning state; on the contrary, if the battery voltage continues to be lower than K3 and shows a non-restorative downward trend, the warning signal output will be maintained until manual intervention.

6. The control method of an intelligent battery status detection system according to claim 5, characterized in that: The control method is based on a multi-level threshold judgment and closed-loop feedback mechanism. Its core control logic includes: a real-time status diagnosis and dynamic early warning module, which specifically includes: The detection system uses a programmable controller to build a three-level progressive monitoring system: 1) Main circuit power-on confirmation stage: Real-time acquisition of the lithium battery main positive relay pull-in status signal to determine the power-on integrity of the power system; 2) Charging circuit health diagnosis stage: After confirming that the main circuit is powered on, the battery management system discharge current A is synchronously monitored and compared with the preset threshold K2 in real time to identify functional abnormalities in the charging circuit; 3) Battery degradation warning stage: Continuously detect the battery terminal voltage V, and start the timing monitoring mechanism when it is detected that V < K1; the detection system quantifies the duration of the abnormal state through the timer T. If T ≥ the set threshold, the fault code R is triggered and a dual-mode warning is executed: the turntable human-computer interaction interface generates a pop-up alarm instruction, and the power indicator light of the platform operation terminal switches to a 500ms periodic flashing mode; the module adopts a closed-loop reset mechanism. When the battery voltage returns to V> K3, the warning state is released. If it continues to be in V< K3, the alarm signal is maintained, forming a self-sustaining feedback control loop.

7. The control method of an intelligent battery status detection system according to claim 6, characterized in that: The core control logic also includes: a power replenishment maintenance module in low power consumption mode, which specifically includes: In response to equipment downtime, the detection system adopts a condition-triggered intelligent wake-up strategy: During the power-off initialization phase, the programmable controller performs lithium battery state-of-charge detection and battery management system voltage fault diagnosis in parallel, establishing a dual-criteria decision-making mechanism: when SOC ≤ N1 and the battery management system has no voltage fault, the automatic wake-up function is activated; otherwise, maintaining the battery management system voltage stability is prioritized; 2) Configurable wake-up protocol: A wake-up function configuration option is added to the human-machine interface. When the "Off" configuration is selected, the battery management system enters the sleep state directly after power is removed. When the "On" configuration is selected, the battery management system executes a periodic wake-up protocol, dynamically monitoring the battery voltage during the wake-up period. If V≤N2 is detected, constant current charging is initiated. The charging termination condition is reaching the time threshold or the voltage recovers to V≥N3. If SOC≤N1 or a BMS voltage fault is detected during the wake-up period, the charging is immediately terminated and the battery enters the sleep state.

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