Electric vehicle battery pack global sensor network deployment method and anti-interference integrated system

Abstract

The invention discloses an electric vehicle battery pack global sensor network deployment method and an anti-interference integrated system. The method comprises the following steps: deploying a thin film thermocouple on a battery cell tab connecting piece; an electrolyte leakage sensor is arranged in a ladle bottom diversion trench and a pole sealing ring; arranging an ultrasonic guided wave sensor on the foam between the battery cells; a ceramic support is fixed on the outer wall of the module to deploy distributed optical fibers; arranging gas sensors at the outlet and the side wall of the explosion-proof valve of the module; arranging an acoustic emission sensor on the module end plate; deploying a pressure sensor in the module airtight cavity; an infrared thermal imaging array is arranged on a lining of the ladle top cover; deploying a laser smoke sensor in the aerosol enrichment area at the top of the bag; microwave radar sensors are arranged on waveguide structures at four corners of the box body; a VOC component sensor is arranged on the top of the cavity in an inverted mode; the electric core level sensor is integrated through a polyimide-based double-sided FPC; module level signals are transmitted through aluminum magnesium alloy wire ducts, and battery pack level signals are integrated through fireproof aluminum alloy sections. According to the technical scheme, all-dimensional fault monitoring can be achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of safety monitoring technology for power batteries of new energy vehicles, and particularly relates to a method for deploying a global sensor network for a battery pack of an electric vehicle and an anti-interference integrated system. BACKGROUND

[0002] A power battery is an important power source for an electric vehicle, and the safety of the power battery is the first problem to be considered and solved in the development of the electric vehicle. The safety monitoring technology for a battery pack of a current electric vehicle faces multiple challenges, mainly including a monitoring blind area, insufficient reliability of a sensor, signal interference and the like.

[0003] For example, a Chinese patent application with the application number CN202010806822.4 discloses a safety monitoring system and method for a power battery pack of a new energy vehicle, which comprises an ambient temperature sensor for detecting the internal temperature of the power battery pack, a smoke sensor for detecting the smoke concentration inside the power battery pack, a liquid leakage sensor for detecting the liquid level of the cooling liquid inside the power battery pack, a first temperature sensor for detecting the temperature of the cooling liquid at the water inlet of the liquid cooling system, and a second temperature sensor for detecting the temperature of the cooling liquid at the water outlet of the liquid cooling system. The safety monitoring system for the power battery pack of the new energy vehicle can detect the temperature of the liquid cooling system, the liquid leakage height and the smoke concentration of the power battery pack in all aspects, improve the safety prevention level of the power battery pack, and reduce the operation risk of the power battery pack.

[0004] For another example, a Chinese patent application with the application number CN01810426483.X discloses a safety monitoring device and method for a power battery of an electric vehicle. The monitoring device comprises a data acquisition system, a data transmission system, a data storage system and a state monitoring system. The state monitoring system comprises a data processing subsystem, an execution module and a remote communication unit. The data acquisition system sends the collected battery state data to the data storage system through the data transmission system for caching, and simultaneously injects the data into the data processing subsystem to detect the internal resistance of the battery monomer through an online parameter identification module. An evaluation index system performs comprehensive evaluation on the safety state of the battery by combining the fuzzy logic reasoning based on multiple factors and multiple levels. According to the evaluation result and in combination with the corresponding control strategy, a control signal is injected into the execution module to realize the monitoring and control of the battery safety. The device has the advantages of systematization and intelligentization, and realizes the monitoring and troubleshooting of the fault vehicle through remote communication technology and in combination with a monitoring platform.

[0005] For another example, Chinese patent application No. CN201711085561.6 discloses a safety monitoring device for a power battery pack, which comprises a shell and a collision sensor, an angle sensor, a humidity sensor, a hydrogen sensor, and a pressure sensor installed on the battery pack. A main control board is arranged inside the shell. The main control board comprises a power module, a PCB connector, a micro-control unit, and a data conversion unit. The power module is connected to the micro-control unit. The collision sensor, the angle sensor, the humidity sensor, the hydrogen sensor, a fire detection alarm, a collision sensor, and the pressure sensor are respectively connected to the PCB connector. The PCB connector is connected to the micro-control unit through the data conversion unit. A smoke alarm is further arranged on the shell and connected to the micro-control unit. The application also provides a monitoring method for the safety monitoring device for the power battery pack. The application can detect the safety state of the power battery pack in real time to prevent the battery pack from catching fire or exploding and improve safety.

[0006] The conventional battery management system (BMS) mainly relies on voltage and temperature monitoring, which is difficult to cover early fault signals such as electrolyte leakage, internal deformation, and gas composition. Electromagnetic interference (EMI) under high-voltage and large-current conditions also seriously affects the accuracy of sensor data. Sensors are prone to failure (such as thermocouple falling off and optical fiber breaking) in a vibrating, high-temperature, and corrosive environment. High-voltage and large-current conditions cause sensor signal crosstalk, resulting in a high false alarm rate. Based on the above technical problems existing in the prior art, the application provides an electric vehicle battery pack global sensing network deployment method and an anti-interference integrated system. SUMMARY

[0007] To solve the above technical problems existing in the prior art, the application provides an electric vehicle battery pack global sensing network deployment method and an anti-interference integrated system.

[0008] The application adopts the following technical solutions:

[0009] The application provides an electric vehicle battery pack global sensing network deployment method, which comprises the following steps:

[0010] Step 1: cell level deployment. A thin-film thermocouple with a thickness of ≤50 μm and a response time of <0.1 s is arranged on the cell tab connecting piece. An electrolyte leakage sensor with a resistance threshold of 5 kΩ is arranged on the package bottom flow guide groove and the pole seal ring. An ultrasonic guided wave sensor with a dielectric loss of <0.001 is arranged on the foam between the cells to form a triple fusion monitoring.

[0011] Step 2, module level deployment, fix ceramic bracket with U-shaped slot width of 1.2mm on the outer wall of the module, and insert the distributed optical fiber into the slot according to the sine wave path; deploy gas sensor with flow rate ≥0.35m / s at the outlet of the explosion-proof valve and the side wall of the module; deploy acoustic emission sensor with sensitivity ≥90dB at the end plate of the module; deploy pressure sensor with range 0-10MPa in the airtight cavity of the module;

[0012] Step 3, battery pack level deployment, deploy infrared thermal imaging array with thermal resistance ≤0.8℃ / W in the inner lining of the pack top cover; deploy laser smoke sensor with optical path length of 180mm in the aerosol enrichment area of the pack top; deploy microwave radar sensor with interference attenuation >60dB in the waveguide structure at the four corners of the box; fix the honeycomb collection cavity on the pack top, and invert the VOC component sensor on the top of the cavity;

[0013] Step 4, three-level interconnection, the cell level sensor is integrated through 0.1mm thick polyimide based double-sided FPC, and the wiring along the large surface of the cell avoids the thermal expansion joint, and the end is connected to the IP67 waterproof connector on the side of the module; the module level signal is transmitted through the aluminum-magnesium alloy wire slot, connected to the module backplane PCB through the ceramic base fiber adapter box, and the electrical clearance between the high voltage area and the signal area is ≥2.5mm; the battery pack level signal is integrated through fireproof aluminum alloy profile, connected to the whole vehicle through waterproof aviation connector, and copper-nickel braided wire harness and ferrite magnetic ring are added at key nodes.

[0014] Further, in the cell level deployment, the installation of the ultrasonic guided wave sensor includes:

[0015] A circular hole is opened in the cell interval foam A circular hole is opened in the cell interval foam

[0016] Further, in the module level deployment, the sine wave path parameters of the distributed optical fiber are wavelength λ=50mm, amplitude A=8mm, and the spatial resolution is optimized to 0.5cm by the formula λ / (4×A). The fiber ends are fixed with UV glue, and the tensile strength after curing is ≥10MPa.

[0017] Further, in the battery pack level deployment, the waveguide tube of the microwave radar sensor is made of brass H62 material with length-diameter ratio L / D=3:1, and is fixed at an angle of 45° on the side wall of the box with vibration interference attenuation >60dB.

[0018] Further, the spatial resolution of the sine wave path is verified by heat source test. Under the heating plate of 0.5cm×0.5cm, the temperature reading deviation at a distance of 0.25cm from the center of the heat source is <0.5℃.

[0019] The application also provides an electric vehicle battery pack global sensing network anti-interference integrated system, comprising:

[0020] The cell-level wiring unit adopts 0.1mm-thick polyimide-based double-sided FPC, the line width is 0.3mm, the pitch is 0.2mm, the surface gold plating thickness is greater than or equal to 0.05μm, the thin-film thermocouple is connected through a nickel-chromium alloy contact, the contact resistance is less than 10mΩ, the gold finger connector is connected with the electrolyte leakage sensor, the plug force is 1.5N±0.2N, the coaxial shielding terminal is connected with the ultrasonic guided wave sensor, and the characteristic impedance is 50Ω±5%.

[0021] The module-level wiring unit adopts an aluminum-magnesium alloy wire groove with a section of 5mm×3mm, an inner lining ceramic fiber fireproof layer with a thickness of 0.5mm, and a distributed optical fiber with a metal bellow wall thickness of 1mm, the gas sensor cable is a double-twisted wire with aluminum foil and copper mesh double-layer shielding, the acoustic emission sensor cable is a coaxial cable with a magnetic ring filter, and the pressure sensor cable is a four-wire guide line protected by a silica gel sleeve.

[0022] The battery pack-level wiring unit adopts an aluminum alloy shell with a section of 20mm×15mm, an inner filling fireproof expansion glue with an expansion rate of 300%±5%, an infrared thermal imaging array connected through an LVDS differential interface, a transmission rate of 1.5Gbps, a laser smoke sensor connected through a USB 3.0Type-C interface, a microwave radar sensor directly connected through a waveguide tube, a cutoff frequency of 12GHz, a loss of less than 3dB, and a VOC component sensor connected through an RS485 bus, a baud rate of 115200bps.

[0023] The protection unit is wrapped with a copper-nickel braided mesh cable, the coverage rate is greater than 85%, a key node is provided with a ferrite magnetic ring, the resistance is 100Ω@100MHz, the optical fiber is independently placed in a U-shaped metal groove and spaced apart from the power line by greater than or equal to 20mm, and the sealing groove is matched with a silica rubber sealing ring with a compression rate of 25%±2%.

[0024] Further, in the cell-level wiring unit, the welding point tension of the FPC is greater than 5N, the gold plating layer thickness is greater than or equal to 0.8μm, and the contact resistance of the nickel-chromium alloy contact and the thin-film thermocouple after welding is less than 10mΩ.

[0025] Further, in the module-level wiring unit, the fixed pitch of the aluminum-magnesium alloy wire groove is 50mm, the wire groove and the module shell are sealed through a silica sealing ring with a compression rate of 25%±2%, the IP67 protection level, and the 100kHz inverter noise attenuation is 43dB after the magnetic ring filtering is 100Ω@100MHz.

[0026] Further, in the battery pack-level wiring unit, the fireproof expansion glue is 3M TMFIS 110+, 300% ± 5% expansion at 200℃, fire resistance limit 1000℃ / 30min, copper-nickel braided mesh with 16 spindles x 4 layers of twill, resistance < 0.1Ω / m.

[0027] Compared with the prior art, the superior effect of the present application is that:

[0028] 1. The electric vehicle battery pack global sensing network deployment method of the present application, through triple fusion deployment, thin film thermocouple, ultrasonic guided wave sensor, electrolyte leakage sensor, thermal runaway early warning time is improved from traditional 1-2 minutes to ≥5 minutes, electrolyte micro-leakage detection sensitivity reaches 5kΩ resistance change, realizing three-level 12-parameter synchronous monitoring of cell level, module level and battery pack level, solving the single defect of traditional scheme only monitoring temperature / voltage;

[0029] 2. The electric vehicle battery pack global sensing network deployment method of the present application, the 45° inclined waveguide structure realizes vibration suppression through energy decomposition, impedance mismatch and damping effect, the copper-nickel braided mesh and the ferrite magnetic ring combination shielding, the vibration interference attenuation is >60dB, and the electromagnetic interference attenuation is >43dB;

[0030] 3. The electric vehicle battery pack global sensing network deployment method of the present application, the combination of distributed optical fiber, gas sensor, acoustic emission sensor and pressure sensor realizes the cooperative monitoring of local overheating, gas leakage and structure damage in the module;

[0031] 4. The electric vehicle battery pack global sensing network deployment method of the present application, the integration of infrared thermal imaging array, laser smoke sensor, microwave radar sensor and VOC component sensor covers the whole battery pack thermal distribution, aerosol alarm, deformation warning and electrolyte decomposition product monitoring, forming a full-link monitoring system of "single cell-module-pack level";

[0032] 5. The electric vehicle battery pack global sensing network deployment method of the present application, 0.1mm ultra-thin FPC flexible integrated micro-sensor, avoiding the mechanical stress of hard wire layout on the cell tab, the ultrasonic guided wave sensor is fixed through acoustic coupling gel and structural adhesive, adapting to the vibration environment;

[0033] Aluminum-magnesium alloy wire slot lined with ceramic fiber fireproof layer, resistant to mechanical impact; distributed optical fiber chord wave path improves spatial resolution to 0.5cm; fireproof aluminum alloy profile filled with 3M TM FIS 110+ expansion glue, sealing protection of wire harness during fire; fluorine rubber sealing ring, helium leak detection ensures airtightness.

[0034] 6. The electric vehicle battery pack global sensing network deployment method according to the present application, FPC flexible integration at the cell level avoids mechanical stress on the cell caused by hard wires; aluminum-magnesium alloy wire slots and ceramic fiber fireproof layers at the module level resist interference; high-voltage wires and signal wires are arranged in layers in the fireproof aluminum alloy profile at the battery pack level, and optical fibers are in independent metal slots to reduce signal loss. BRIEF DESCRIPTION OF DRAWINGS

[0035] Figure 1 is a full sensor deployment matrix diagram in the electric vehicle battery pack global sensing network deployment method according to the present application;

[0036] Figure 2 is a sensor and BMS integration diagram in the electric vehicle battery pack global sensing network deployment method according to the present application;

[0037] Figure 3 is a sine wave optical fiber path amplification diagram in the electric vehicle battery pack global sensing network deployment method according to the present application;

[0038] Figure 4 is a battery pack level aluminum alloy wire slot cross-section diagram in the electric vehicle battery pack global sensing network deployment method according to the present application;

[0039] Figure 5 is a pore distribution diagram of the gas collection cavity in the electric vehicle battery pack global sensing network deployment method according to the present application;

[0040] Figure 6 is a cutaway view of the adapter box in the electric vehicle battery pack global sensing network deployment method according to the present application;

[0041] Attachment name:

[0042] 1. Thin film thermocouple; 2. Electrolyte leakage sensor; 3. Ultrasonic sensor; 4. Gas sensor; 5. Acoustic emission sensor; 6. Pressure sensor; 7. Laser smoke sensor; 8. Microwave radar sensor; 9. Distributed optical fiber; 10. Infrared thermal imaging array; 11. Component sensor; 12. BMS master; 13. Module backplane PCB; 14. FPC; 15. ZIF connector; 16. Waterproof aviation contact; 17. Pack level fireproof wire slot; 18. Sine wave optical fiber; 19. Ceramic support; 20. Battery module; 21. Aluminum alloy shell; 22. 3M TM FIS 110+ expansion glue; 23. Copper-nickel braided wire harness; 24. Gas collection cavity; 25. Gas enrichment area; 26. Honeycomb void matrix; 27. Flip-chip VOC component sensor; 28. Electrolyte decomposition gas flow direction; 29. Ceramic matrix; 30. SC / APC interface; 31. PCB; 32. Gold finger PCB contact; 33. Encapsulated heat-conducting silicone; 34. Signal output pad. DETAILED DESCRIPTION

[0043] In order to enable the above-mentioned purposes, features and advantages of the present application to be more clearly understood, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments, and it should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0044] The present application provides a kind of electric vehicle battery pack global sensing network deployment method, comprising:

[0045] Step 1, cell level deployment, deploy thin film thermocouple 1 with thickness ≤50 μm and response time <0.1 s on cell tab connecting piece;Deploy electrolyte leakage sensor 2 with resistance threshold 5 kΩ on package bottom flow guide groove and pole seal ring;Deploy ultrasonic guided wave sensor 3 with dielectric loss <0.001 on inter-cell foam, forming triple fusion monitoring;

[0046] Step 2, module level deployment, fix ceramic bracket 19 with U-shaped groove width 1.2 mm on module outer wall, and clamp distributed optical fiber 9 into the groove according to sine wave path;Deploy gas sensor 4 with flow rate ≥0.35 m / s on module explosion-proof valve outlet and side wall;Deploy acoustic emission sensor 5 with sensitivity ≥90 dB on module end plate;Deploy pressure sensor 6 with range 0-10 MPa on module airtight cavity;

[0047] Step 3, battery pack level deployment, deploy infrared thermal imaging array 10 with thermal resistance ≤0.8 ℃ / W on package top lining;Deploy laser smoke sensor 7 with optical path length 180 mm on package top aerosol enrichment area;Deploy microwave radar sensor 8 with interference attenuation >60 dB on box body four corners waveguide structure;Fix honeycomb-shaped collection cavity on package top, and invert VOC component sensor 11 on the top of the cavity, with detection limit ≤1 ppm;

[0048] Step 4, three-level interconnection, cell level sensors are integrated through 0.1 mm thick polyimide-based double-sided FPC 14, and are wired along the large surface of the cell to avoid thermal expansion joints, and are connected to the module side IP67 waterproof connector at the end;Module level signals are transmitted through aluminum-magnesium alloy wire slot, connected to module backplane PCB 13 through ceramic matrix optical fiber adapter box, and the electrical gap between high voltage area and signal area is ≥2.5 mm;Battery pack level signals are integrated through fireproof aluminum alloy profile, connected to the whole vehicle through waterproof aviation contact 16, and copper-nickel braided wire harness 23 and ferrite magnetic ring are added at key nodes.

[0049] Specifically, as shown in Figure 1 to Figure 2 The full sensor deployment matrix includes cell level, module level and battery pack level;

[0050] The cell level includes a thin film thermocouple 1, an electrolyte leakage sensor 2, and an ultrasonic guided wave sensor 3. The thin film thermocouple 1 is arranged on the cell tab connecting piece with a thickness of ≤50 μm and a response of <0.1 s, which is used for rapid and accurate monitoring of the cell tab temperature and capturing the early abnormal temperature rise of thermal runaway. The cell surface is wiped with alcohol to remove oil and dust, and a heat-conducting silicone grease is applied to enhance heat conduction. The thin film thermocouple 1 is positioned and attached, and the 10×15×0.3 mm ceramic substrate thermocouple is aligned with the cell surface. The spring sheet is compressed, and the stainless steel spring sheet is bridged and fixed with a 5N pressure to ensure tight attachment.

[0051] The electrolyte leakage sensor 2 is arranged at the bottom of the battery pack and the polar column sealing ring, with a resistance threshold of 5 kΩ, which is used to monitor the resistance change caused by electrolyte leakage and timely warn of leakage risk. The bottom of the battery pack is cleaned to ensure no impurities. The micro-arc oxidation copper-nickel alloy electrode grid is embedded with a spacing of 2 mm. Epoxy resin is used to seal the electrode edges to prevent liquid leakage.

[0052] The ultrasonic guided wave sensor 3 is arranged on the foam between the cells with a dielectric loss of <0.001, which is used to identify the ultrasonic signals generated by the boiling of electrolyte in the early stage of thermal runaway. A circular hole is opened on the foam between the cells, filled with 0.1 mm thick acoustic coupling gel to reduce sound wave loss. The ceramic sheet is fixed in the circular hole. The sensor is sealed and fixed with structural adhesive to ensure stability.

[0053] The module level includes a distributed optical fiber 9, a gas sensor 4, an acoustic emission sensor 5, and a pressure sensor 6.

[0054] The distributed optical fiber 9 is arranged on the outer wall of the module with a spatial resolution of 0.5 cm, which is used to realize distributed monitoring of the temperature field of the battery pack and locate the local overheating area. A U-shaped groove with a width of 1.2 mm is fixed on the outer wall of the module. The optical fiber is clamped into the groove according to the sine wave path with a wavelength of λ = 50 mm and an amplitude of A = 8 mm. The ends of the optical fiber are cured with UV glue to prevent displacement.

[0055] The gas sensor 4 is arranged at the outlet of the module explosion-proof valve and the module side wall with a flow rate of ≥0.35 m / s, which is used to detect the combustible gas discharged by the module in the early stage of thermal runaway. A Φ6.1 mm hole is drilled in the module side wall. The sensor is fixed with M6×0.75 threads. A polytetrafluoroethylene filter membrane is installed to filter impurities.

[0056] The acoustic emission sensor 5 is arranged on the module end plate with a sensitivity of ≥90 dB, which is used to capture acoustic emission signals such as micro-cracks in the cell and electrolyte leakage, and locate the fault source. M3 screw holes are processed on the module end plate. The contact surface is coated with zinc borate heat-conducting paste to improve heat dissipation efficiency. The bolt is tightened with a torque of 2 N·m to ensure that the sensor is in close contact with the module. ​

[0057] Pressure sensor 6, deployed in the module airtight cavity, range 0-10 MPa, for monitoring the cell swelling pressure; a Φ3mm pressure hole is opened in the module airtight cavity; a fluorine rubber O-ring is pressed in to ensure airtightness; a sensor flange is fixed to prevent gas leakage;

[0058] The battery pack level includes an infrared thermal imaging array 10, a laser smoke sensor 7, a microwave radar sensor 8, and a component sensor 11.

[0059] Among them, the infrared thermal imaging array 10 is deployed in the top cover lining of the battery pack, with a thermal resistance ≤0.8℃ / W, for visual monitoring of the top thermal field of the battery pack, and positioning the single cell overheating position; a mounting groove with a tolerance of ±0.1mm is processed on the inner wall of the upper cover, a 10μm diamond film is plated on the surface of the sensor to enhance wear resistance and heat conduction, and a heat-conducting adhesive is used to fix the sensor to ensure the accuracy of thermal imaging.

[0060] The laser smoke sensor 7 is deployed in the top aerosol enrichment area of the battery pack, with a light path length of 180mm, for high-sensitivity detection of aerosol particles generated by thermal runaway and timely alarm; a rubber base with a Shore hardness of 60A is fixed on the top cover beam to reduce vibration and noise, the coaxiality of the laser and the receiver is adjusted, with a deviation ≤0.5°, to ensure the accuracy of the light path.

[0061] The microwave radar sensor 8 is deployed in the waveguide structure at the four corners of the box, with an interference attenuation >60dB, for monitoring the internal structural deformation of the battery, and adapting to extreme vibration conditions; a Φ8mm hole is opened in the side wall of the battery pack, a waveguide tube made of brass H62 material is installed, with a length-diameter ratio L / D=3:1, and the sensor is fixed at a 45° inclination to optimize the detection range.

[0062] The component sensor 11 is fixed on the top of the battery pack with a honeycomb-shaped collection cavity, and the VOC component sensor 11 is inverted on the top of the cavity, with a detection limit ≤1ppm(DMMP), for monitoring the volatile organic compounds decomposed from the electrolyte, and the component sensor 11 is a VOC sensor specifically for detecting the decomposition products of the electrolyte, as shown in Figure 5 The gas enrichment area 25 is located at the top tapered area of the gas collection cavity 24, and the gas collection cavity 24 is provided with a honeycomb gap matrix 26, and an inverted VOC component sensor 27 is arranged on the upper part of the gas collection cavity 24, and the electrolyte decomposition gas flow direction 28 is used to indicate the flow direction of the decomposition gas, which improves the gas sampling efficiency, and the sensor is inverted on the top of the cavity to avoid dust deposition, and the interface is filled with sealing glue to prevent gas leakage. The performance comparison of the triple fusion deployment, thin film thermocouple 1, ultrasonic guided wave device 3 and electrolyte leakage sensor 2 with a single sensor is shown in the following table 1:

[0063] Table 1

[0064]

[0065] Sensor installation key points, precision control, involving dimensional tolerance, such as installation groove ±0.1mm, pressure 5N, torque 2N·m and other parameters need to be strictly calibrated;

[0066] Material adaptation, heat-conducting silicone grease, epoxy resin, fluororubber and other materials need to be compatible with the battery environment, high temperature resistant, corrosion resistant.

[0067] Further, in the cell level deployment, the installation of the ultrasonic guided wave sensor 3 includes:

[0068] A circular hole is opened in the cell interval foam 0.1mm thick acoustic coupling gel is injected, the acoustic coupling gel has a viscosity range of 8500±500cP, measured by Brookfield DV2T at 25℃; the acoustic coupling gel has a viscosity of 8500±500cP measured by Brookfield DV2T, the acoustic impedance is matched with the foam / ceramic sheet, and after fixing the piezoelectric ceramic sheet, the structural adhesive is cured, and the shear strength after curing is ≥5MPa.

[0069] Further, in the module level deployment, as shown in Figure 3 The sine wave path parameters of the distributed sine wave fiber 18 are wavelength λ=50mm, amplitude A=8mm, and the spatial resolution is optimized to 0.5cm through the formula λ / (4×A), the fiber ends are fixed with UV glue, the tensile strength after curing is ≥10MPa, and the sine wave fiber 18 is arranged in the battery module 20 through the ceramic support 19.

[0070] Further, in the battery pack level deployment, the waveguide tube of the microwave radar sensor is made of brass H62 material, the length-diameter ratio L / D=3:1, and is fixed at an inclination of 45° on the side wall of the box, and the vibration interference attenuation is >60dB.

[0071] Further, the spatial resolution of the sine wave path is verified by heat source test, and under the 0.5cm×0.5cm heating sheet, the temperature reading deviation at 0.25cm from the center of the heat source is <0.5℃.

[0072] The application also provides an anti-interference integrated system of an electric vehicle battery pack global sensing network, comprising:

[0073] The cell level wiring unit adopts 0.1mm thick polyimide based double-sided FPC14, the line width is 0.3mm, the pitch is 0.2mm, the surface gold plating thickness is ≥0.05μm, the thin film thermocouple 1 is connected through a nickel-chromium alloy contact, the contact resistance is <10mΩ, the gold finger connector connects the electrolyte leakage sensor 2, the plug force is 1.5N±0.2N, the coaxial shielded terminal connects the ultrasonic guided wave sensor 3, and the characteristic impedance is 50Ω±5%;

[0074] The modular wiring unit has an aluminum-magnesium alloy cable tray with a cross-section of 5mm×3mm and an inner ceramic fiber fireproof layer with a thickness of 0.5mm. The distributed optical fiber passes through a 9-metal corrugated pipe with a wall thickness of 1mm. The gas sensor 4 cable is a twisted pair cable with double shielding of aluminum foil and copper mesh. The acoustic emission sensor 5 cable is a coaxial cable with magnetic ring filtering. The pressure sensor 6 cable is a four-wire conductor protected by a silicone sheath.

[0075] Battery pack-level wiring unit, with a 20mm × 15mm aluminum alloy casing 21, such as Figure 4 As shown, the internal filling is 3M with an expansion rate of 300% ± 5%. TM The FIS 110+expansion adhesive 22 and infrared thermal imaging array are connected via LVDS differential interface with a transmission rate of 1.5Gbps. The laser smoke sensor 7 is connected via USB 3.0 Type-C interface. The microwave radar sensor 8 is directly connected via waveguide with a cutoff frequency of 12GHz and a loss of <3dB. The VOC component sensor 11 is connected via RS485 bus with a baud rate of 115200bps.

[0076] The protective unit is equipped with a copper-nickel braided wire harness 23 wrapped around the cable, with a coverage rate of >85%. Ferrite magnetic rings are set at key nodes, 100Ω@100MHz. The optical fiber is independently placed in a U-shaped metal groove and the distance between it and the power line is ≥20mm. The sealing groove is matched with a silicone rubber sealing ring, with a compression rate of 25%±2%.

[0077] Specifically, the cell-level wiring is based on flexible integration; the wiring carrier uses a 0.1mm thick polyimide-based double-sided FPC flexible circuit board with a line width of 0.3mm / spacing of 0.2mm, gold-plated surface, thickness ≥0.05μm, temperature resistance rating -40℃~150℃, and UL 94V-0 certification.

[0078] Sensor connection method: Thin film thermocouple 1, nickel-chromium alloy contacts are soldered onto FPC 14, contact resistance <10mΩ;

[0079] Electrolyte leakage sensor 2, the grid electrode gold fingers are inserted into the FPC connector, the insertion and extraction force is 1.5N±0.2N;

[0080] Ultrasonic guided wave sensor 3, with coaxial shielded terminal crimped to FPC pad, characteristic impedance 50Ω±5%;

[0081] All cell-level sensor wiring harnesses are combined, routed along the large surface of the cell, avoiding thermal expansion joints, with a 2mm gap reserved, and the ends are integrated into the waterproof connector on the side of the module, IP67 rating, AMPHELITE series;

[0082] Module level wiring, core anti-interference protection; backbone harness structure, aluminum-magnesium alloy wire slot, cross section 5mm x 3mm, lined with ceramic fiber fireproof layer, thickness 0.5mm, wire slot fixed interval 50mm, M3 rivet lock;

[0083] Sensor cable type: distributed optical fiber, cable specification Armored optical cable, stainless steel wire weaving, protection design through metal corrugated pipe, wall thickness 1mm;

[0084] Gas sensor 4, cable specification twisted pair shielded wire AWG22, aluminum foil and copper mesh double-layer shielding protection design;

[0085] Acoustic emission sensor 5, cable specification coaxial cable RG178, magnetic ring filter protection design 100MHz;

[0086] Pressure sensor 6, cable specification four-wire AWG24, silica gel sleeve protection;

[0087] As Figure 6 shown, key switching design, switching through ceramic base 29 optical fiber switching box, its size is 20x15x10mm, SC / APC interface 30, signal access module backplane PCB 31, 4-layer board, FR-4 material, gold finger PCB contact 32 gold plated lamination PCB 31 pad, filled with heat-conducting silicone 33 gap between ceramic base 29 and PCB 31, signal output pad 34 through copper wire and gold finger contact 32 direct electrical connection, high voltage area (>60V) and signal area (<5V) layered layout, minimum electrical gap 2.5mm, meet IEC 60664 standard;

[0088] Battery pack level wiring, core high reliability integration; pack level fireproof wire slot 17, main channel uses cross section 20mm x 15mm aluminum alloy profile, filled with 3M TM FIS 110+ expansion glue 22, expansion rate 300%±5%, triggered at 200℃, fire resistance limit 1000℃ / 30min, UL 94V-0; branch channel is diameter 8mm silica gel hose, electrolyte corrosion resistance grade G3; when the temperature is lower than 200℃, the expansion glue does not trigger expansion, the expansion rate is 0%; when the temperature is above 200℃, the expansion rate increases exponentially with the increase of temperature, the formula is 300*(1-e-0.035*(T-200)), where T is temperature (unit: ℃);

[0089] Sensor dedicated interface: infrared thermal imaging array 10, LVDS differential interface 4 pairs of signal lines, transmission rate 1.5Gbps;

[0090] Laser smoke sensor 7, USB 3.0 Type-C interface, 5Gbps full duplex;

[0091] Microwave radar sensor 8, waveguide direct connection, brass H62, cutoff frequency 12 GHz, loss <3 dB;

[0092] VOC component sensor 11, RS485 bus, twisted pair AWG20, baud rate 115200 bps;

[0093] Vehicle-level integration, wire harness outlet: connected to the vehicle through waterproof aviation contact 16 (TE Deutsch HD30 series), pin definition includes power / ground / CAN bus / redundant signal;

[0094] EMC protection: cable wrapped with copper-nickel braided mesh wire harness 23, coverage >85%, key nodes added ferrite magnetic ring, 100Ω@100MHz.

[0095] Three-level wiring interconnection specification: cell to module level conversion, FPC 14 end connected to module backplane PCB 13 through ZIF connector 15 (zero insertion force), gold-plated contact points, thickness ≥0.8μm, insertion life >500 times;

[0096] Module to pack level conversion, module backplane PCB 13 output uses high-voltage interlock HVIL connector, TE AMP+ series, wire harness is sealed with silicone seal ring at the module shell, compression ratio 25%±2%;

[0097] Realization process of silicone seal ring compression ratio 25%±2%:

[0098] Design and processing:

[0099] Sealing groove processing, groove depth 3.0mm, ±0.05mm, slow wire cutting, smooth surface without burrs;

[0100] Seal ring manufacturing, silicone rubber material, diameter 4.0mm, ±0.03mm, Shore hardness 60A±5A;

[0101] Preparation before assembly:

[0102] Cleaning, wipe the sealing groove with alcohol to remove impurities;

[0103] Inspection, seal ring diameter sampling inspection, silicone-based lubricant to prevent friction;

[0104] Installation and compression:

[0105] Positioning and embedding, use tooling to place the seal ring in the groove, 45° beveled interface, no twisting;

[0106] Step-by-step tightening, 1st 2N·m torque, compression ratio 15%; 2nd 4N·m torque, compression ratio 20%; 3rd 6N·m torque, 25%±2%, real-time monitoring by laser sensor;

[0107] Seal test:

[0108] Helium mass spectrometer leak detection, leakage rate < 1 x 10-3Pa.m 3 / s, ISO 15848;

[0109] Temperature cycle verification, -40℃~125℃ cycle 1000 times, compression rate attenuation ≤5%.

[0110] Intra-package trunk cabling, high-voltage lines (red) and signal lines (blue) are arranged in layers, the upper layer high-voltage line spacing ≥ 15mm, the lower layer signal line is isolated by a 0.5mm metal partition; the optical fiber is independently placed in a U-shaped metal groove (wall thickness 1mm), and is spaced ≥ 20mm from the power line;

[0111] The process quality control standards of the wiring scheme are shown in Table 2:

[0112] Table 2

[0113] Process Detection item Standard value Test method FPC soldering Solder joint tension ＞5N IPC-610 G8.2.5 Wire slot installation Vibration displacement <0.2mm @ 50Hz / 10G GB / T31467.3 Waveguide tube airtightness Helium mass spectrum leak detection <1 x 10"3Pa-m 3 / s]] ISO15848 Fireproof glue filling Filling rate after expansion ＞98％ UL1709 EMC performance Radiation emission CLASS3 (30-200MHz) CISPR25

[0114] Further, in the cell-level wiring unit, the solder joint tension of the FPC 14 is > 5N, the gold plating layer thickness is ≥ 0.8μm, and the contact resistance after welding the nickel-chromium alloy contact and the thin film thermocouple 1 is < 10mΩ.

[0115] Further, in the module-level wiring unit, the fixed spacing of the aluminum-magnesium alloy wire slot is 50mm, the M3 rivet is locked, the wire slot is sealed from the module shell through a silicone seal ring, the compression rate is 25%±2%, the IP67 protection level, and after magnetic ring filtering 100Ω@100MHz, the 100kHz inverter noise attenuation is 43dB.

[0116] Further, in the battery pack-level wiring unit, the fireproof expansion adhesive is 3M TM FIS 110+, 200℃ trigger expansion rate is 300%±5%, fire resistance limit 1000℃ / 30min, copper-nickel braided wire harness 23 braided mode is 16spins x 4 layers of twill, resistance < 0.1Ω / m.

[0117] The global sensing matrix layer deployment method of the application: at the cell level, the "thin film thermocouple 1, ultrasonic sensor 3 and electrolyte leakage sensor 2" triple fusion deployment is created to capture microsecond-level thermal / acoustic anomalies; at the module level, the distributed optical fiber 9 is wired according to the sine wave path λ=50mm, A=8mm, and the spatial resolution is improved to 0.5cm; at the battery pack level, the microwave radar is installed at an inclination of 45°, and the vibration interference attenuation is > 60dB.

[0118] The process of improving the spatial resolution to 0.5cm;

[0119] Optimized path, traditional straight path resolution = fiber spacing = 20 mm; the effective probe point density of the sine path of the application is improved by 4 times, the resolution = λ / (4xA) = 50 mm / (4*8) = 1.56 mm, and the actual value is 0.5 cm due to the limitation of the grating;

[0120] Verification data:

[0121] Heat source test, 0.5cm*0.5cm heating sheet is arranged on the surface of the module;

[0122] Optical fiber response, temperature reading deviation <0.5℃ at 0.25cm from the center of the heat source;

[0123] Traditional scheme comparison: 1cm spacing optical fiber cannot identify <1cm hot area.

[0124] Contribution mechanism process of microwave radar 45° inclination to vibration interference attenuation >60dB:

[0125] Energy decomposition principle:

[0126] Vibration wave propagation direction, perpendicular to the battery box wall, Z-axis direction;

[0127] 45° inclination waveguide, vibration energy is decomposed into two components:

[0128] Normal component Fn: perpendicular to the waveguide wall, absorbed / dissipated by the waveguide material;

[0129] Tangential component Ft: parallel to the waveguide wall, part of which is transmitted to the sensor;

[0130] Energy attenuation rate, 10log 10 (Fn 2 / Ft 2 ) = 20log 10 (cotθ), the theoretical attenuation is 20dB when θ = 45°;

[0131] Triple attenuation mechanism:

[0132] Angle energy decomposition, contribution 20dB, vibration wave is decomposed at 45° interface, normal component accounts for 71%(cos45° = 0.707), and tangential component accounts for 29%(sin45°);

[0133] Waveguide impedance mismatch, contribution 30dB, brass H62 waveguide (acoustic impedance 39.7MRayl) and aluminum alloy box (17MRayl) impedance ratio 2.33, reflection loss rises;

[0134] Boundary damping effect, contribution 10dB, waveguide box welding interface filled with silicon-based damping glue, loss factor tanδ = 0.8, consumes vibration energy;

[0135] Implementation process:

[0136] First, waveguide structure design:

[0137] Material selection, brass H62, density 8.4 g / cm 3 , elastic modulus 110 GPa, high damping characteristics;

[0138] Geometric parameters, length-diameter ratio L / D = 3:1, length 24 mm, hole diameter Φ8 mm; inner wall thread M8x0.5, increase vibration scattering surface;

[0139] Welding process, laser deep penetration welding, penetration 1.2 mm, solder containing 5% Ag, enhance interface damping;

[0140] Second, the inclination positioning process:

[0141] Box opening, Φ8.05±0.01mm, H7 tolerance;

[0142] Waveguide welding, special fixture fixed 45° inclination, error ≤0.5°, argon shielded welding, anti-oxidation;

[0143] Damping filling, waveguide box gap injection of silicon-based damping glue, Dow Corning 3-6262;

[0144] Finally, sensor installation:

[0145] Threaded connection, sensor screw into waveguide internal thread, pre-tightening torque 0.6 N·m;

[0146] Locking glue, Loctite 243 thread glue, anti-loose;

[0147] Vibration transfer function test, GB / T 31467.3;

[0148] Vibration frequency 50 Hz, rigid installation 112 dB, 45° waveguide installation 47 dB, attenuation 65 dB;

[0149] Vibration frequency 100 Hz, rigid installation 118 dB, 45° waveguide installation 52 dB, attenuation 66 dB;

[0150] Vibration frequency 200 Hz, rigid installation 125 dB, 45° waveguide installation 58 dB, attenuation 67 dB;

[0151] Vibration frequency 500 Hz, rigid installation 130 dB, 45° waveguide installation 68 dB, attenuation 62 dB;

[0152] 200 Hz is the main vibration frequency band of battery pack, motor harmonic and road excitation.

[0153] This invention features a rigid-flexible three-level cabling architecture. At the battery cell level, a 0.1mm ultra-thin FPC (resistant to 150℃) is used to integrate a micro-sensor. At the module level, aluminum-magnesium alloy cable trays and ceramic fiber fireproof layers resist mechanical impact. At the package level, the main cable tray is filled with intelligent expansion adhesive with a 300% expansion rate, which seals and protects the cable harness in case of fire.

[0154] Comparison of DSC thermal analysis data, taking ternary lithium batteries as an example;

[0155] Within the temperature range of 150-180℃, the SEI film decomposes but does not expand, remaining in a stable state.

[0156] Temperature range 200-220℃, the diaphragm melts and begins to expand at a rate of 5% / s;

[0157] Temperature range 250-300℃, positive electrode decomposes, 300% full fill;

[0158] Temperature range >300℃, thermal runaway, carbonized protective layer formed.

[0159] This invention features a highly reliable connection process, a cell-to-module transition, a ZIF connector with 15mm gold plating (0.8μm), and a 500-cycle mating life design; it also ensures airtightness: helium leak detection <1×10⁻⁶. -3 Pa·m 3 / s(ISO 15848), fluororubber seal compression ratio 25%±2%;

[0160] Compression fatigue test data for fluororubber sealing rings, GB / T 7759:

[0161] Compression rate 20%, permanent deformation rate 3.2% after 10,000 cycles, leakage rate 5×10⁻³ Pa·m 3 / s;

[0162] Compression rate 25%, permanent deformation rate 4.8% per 10,000 cycles, leakage rate 8×10 -4 Pa·m 3 / s;

[0163] Compression rate 30%, permanent deformation rate 12.7% per 10,000 cycles, leakage rate 2×10 -3 Pa·m 3 / s;

[0164] Select 25%, balance sealing leakage rate <10 -3 Durability deformation rate < 5%.

[0165] Example

[0166] The target of the implementation is a ternary lithium battery pack for a certain vehicle model, with a capacity of 90kWh, consisting of 12 modules;

[0167] Deployment process:

[0168] Cell level, 288 cell tab attached film thermocouple 1, response 0.08s, 96 ultrasonic guided wave sensors 3 embedded in foam layer;

[0169] Module level, each module outer wall is provided with a distributed optical fiber 9, a sine path λ=50mm, an acoustic emission sensor 5 is installed on the end plate, and a pretightening torque is 2N·m;

[0170] Battery pack level, the top cover lining is integrated with an infrared thermal imaging array 10, the thermal resistance is 0.75℃ / W, the microwave radar is fixed in a four-corner waveguide structure, and the inclination angle is 45°;

[0171] Signal integration, all sensor signals are transmitted to the BMS main control 12 through three-level wiring, FPC→aluminum-magnesium wire groove→fireproof aluminum alloy profile, and then uploaded to the cloud platform through the CAN bus.

[0172] Embodiment

[0173] Implementation object, lithium iron phosphate battery adaptation scheme:

[0174] Thermocouple thickness, 50μm for ternary lithium battery, 60μm for lithium iron phosphate battery, and 30% for LFP expansion rate;

[0175] Ultrasonic guided wave frequency, 100kHz for ternary lithium battery, 80kHz for lithium iron phosphate battery, and 15% for LFP acoustic impedance;

[0176] Leakage resistance threshold, 5kΩ for ternary lithium battery, 3kΩ for lithium iron phosphate battery, and 20% for LFP electrolyte conductivity;

[0177] Optical fiber sine amplitude, 8mm for ternary lithium battery, 10mm for lithium iron phosphate battery, and 25% for LFP module stiffness.

[0178] Response curve of electrolyte leakage resistance from 5kΩ to 1kΩ, test device, electrolyte dripping device, EC:DEC=1:1, flow rate 0.1mL / min; electrode grid spacing 2mm, initial resistance 5kΩ, 25℃ dry environment;

[0179] Response curve R(t)=1+4e-0.02t(R:kΩ,t:s); t=0s: R=5kΩ, initial state; t=30s: R=3.2kΩ, triggering a first alarm; t=200s: R=1kΩ, triggering a second alarm; sensor response time: <5s, resistance change >10%.

[0180] The application has full-dimensional fault monitoring capability, synchronously captures 12 types of fault signals, covers temperature, leakage, gas, deformation and the like, and the thermal runaway early warning time is advanced by ≥5 minutes, compared with the traditional BMS which is only advanced by 1-2 minutes.

[0181] The electrolyte leakage detection sensitivity reaches 5kΩ of resistance change, the dielectric loss of ultrasonic wave recognition electrolyte boiling is less than 0.001, and early microsecond-level abnormal response is realized;

[0182] The extreme environment reliability of the application is improved, the sensor installation stability is stable, the vibration displacement is less than 0.2mm, the verification standard is GB / T 31467.3, the fire safety is 1000℃ / 30min of fire resistance limit of wire slot, the verification standard is UL 94V-0, the air tightness is less than 1*10-3Pa.m / s, the verification standard is ISO 15848, the environmental tolerance is -40℃~150℃ of FPC temperature resistance, and the verification standard is UL 94V-0 authentication; 3

[0183] The signal accuracy and anti-interference performance of the application, the temperature monitoring accuracy, the spatial resolution of the distributed optical fiber 9 reaches 0.5cm, the traditional scheme is 1~2cm, the thermal resistance of the infrared thermal imaging array 10 is less than or equal to 0.8℃ / W, the anti-interference design is high-voltage / signal line layered isolation, the minimum gap is 2.5mm, the insulation standard meets IEC 60664, the magnetic ring filter is 100Ω@100MHz, the copper-nickel braided mesh shielding is covered more than 85%, and the radiation emission meets CISPR 25CLASS 3;

[0184] Specifically, the magnetic ring filter is a Fair-Rite 2673622401 type, the parameter is 100Ω@100MHz, and the frequency response is 10MHz-1GHz;

[0185] The copper-nickel braided wire harness 23 is a 16-spindle*4-layer diagonal braided wire harness, the coverage rate is 85±2%, and the resistance is less than 0.1Ω / m;

[0186] EMC test data: interference source 200A direct current charging, without protection 85dBμV, the application 42dBμV, attenuation 43dBμV, interference source 100kHz inverter noise, without protection 78dBμV, the application 35dBμV, attenuation 43dBμV.

[0187] The test condition of the thermal resistance of the infrared thermal imaging array 10 being less than or equal to 0.8℃ / W is a test standard ASTM D5470, an environmental vacuum cavity, a pressure less than 10-3Pa, a heat source 5*5mm ceramic heating sheet, a power density 2W / cm 2 , a high-precision heat flow sensor for temperature measurement, an error ±0.1℃, and a result 0.75±0.05℃ / W, N=15 times of test;

[0188] The test basis of the signal loss being reduced by 40% is as follows: ​

[0189] Transmission loss @ 1550nm, fiber direct wiring 2.1dB / km, metal slot protection 1.26dB / km, loss reduction 40%;

[0190] Vibration interference displacement, fiber direct wiring 0.8mm, metal slot protection 0.15mm, loss reduction 81%;

[0191] Test method: light source 1550nm laser, output power 10mW; receiving end optical spectrum analyzer, YOKOGAWA AQ6370D; vibration condition 50Hz / 10G, GB / T 31467.3.

[0192] The application is not limited by the above examples, the above examples and the description described are only to illustrate the principles of the application, and the application can have various changes and improvements without departing from the spirit and scope of the application, and the changes and improvements all fall within the scope of the claimed application. The scope of protection of the application is defined by the appended claims.

Claims

1. A method for deploying a global sensor network for an electric vehicle battery pack, the method comprising: determining a plurality of sensor locations for a plurality of sensors; and deploying the plurality of sensors at the plurality of sensor locations. Comprising: Step 1, cell level deployment, deploy a thin film thermocouple with thickness ≤50 μm and response time <0.1 s on the cell tab connector; deploy an electrolyte leakage sensor with resistance threshold 5 kΩ on the bottom of the package and the sealing ring of the pole; deploy an ultrasonic guided wave sensor with dielectric loss <0.001 on the foam between the cells, forming a triple fusion monitoring; Step 2, module level deployment, fix a ceramic bracket with U-shaped groove width 1.2 mm on the outer wall of the module, and insert the distributed optical fiber into the groove according to the sine wave path; deploy a gas sensor with flow rate ≥0.35 m / s at the outlet of the module explosion-proof valve and the side wall; deploy an acoustic emission sensor with sensitivity ≥90 dB on the module end plate; deploy a pressure sensor with range 0-10 MPa in the module airtight cavity; Step 3, battery pack level deployment, deploy an infrared thermal imaging array with thermal resistance ≤0.8 ℃ / W in the package top lining; deploy a laser smoke sensor with optical path length 180 mm in the package top aerosol enrichment area; deploy a microwave radar sensor with interference attenuation >60 dB in the waveguide structure at the four corners of the box; fix a honeycomb-shaped collection cavity on the package top, and invert the VOC component sensor on the cavity top; Step 4, three-level interconnection, the cell level sensor is integrated through a 0.1 mm thick polyimide-based double-sided FPC, and the wiring along the large surface of the cell avoids the thermal expansion joint. The end is connected to the IP67 waterproof connector on the side of the module. The module level signal is transmitted through the aluminum-magnesium alloy wire groove, connected to the module backplane PCB through the ceramic matrix optical fiber adapter box, and the electrical clearance between the high voltage area and the signal area is ≥2.5 mm. The battery pack level signal is integrated through a fireproof aluminum alloy profile, connected to the vehicle through a waterproof aviation connector, and the key nodes are added with copper-nickel braided wire harness and ferrite magnetic ring.

2. The method of claim 1, wherein, In the cell level deployment, the installation of the ultrasonic guided wave sensor includes: In the cell interval foam open Round hole, inject 0.1mm thick acoustic coupling gel, acoustic coupling gel is Brookfield DV2T measured viscosity 8500±500cP, acoustic impedance matches the foam / ceramic sheet, after fixing the piezoelectric ceramic sheet, use structural adhesive to cure, the shear strength after curing is ≥5MPa.

3. The method of claim 1, wherein, In the module level deployment, the sine wave path parameters of the distributed optical fiber are wavelength λ=50 mm, amplitude A=8 mm, and spatial resolution is optimized to 0.5 cm through the formula λ / (4×A). The two ends of the optical fiber are fixed with UV glue, and the tensile strength after curing is ≥10 MPa.

4. The method of claim 1, wherein, In the battery pack level deployment, the waveguide tube of the microwave radar sensor is made of brass H62 material with length-diameter ratio L / D=3:1, and is fixed at an angle of 45° on the side wall of the box with vibration interference attenuation >60 dB.

5. The method of claim 3, wherein, The spatial resolution of the sine wave path is verified by heat source test. Under the 0.5 cm×0.5 cm heating sheet, the temperature reading deviation at a distance of 0.25 cm from the center of the heat source is <0.5 ℃.

6. An anti-interference integrated system for an electric vehicle battery pack global sensing network, applied to the electric vehicle battery pack global sensing network deployment method of any one of claims 1 to 5, characterized in that, Comprising: The cell level wiring unit adopts a 0.1 mm thick polyimide-based double-sided FPC with a line width of 0.3 mm, a pitch of 0.2 mm, a gold plating thickness of ≥0.05 μm, and is connected to the thin film thermocouple through a nickel-chromium alloy contact. The contact resistance is <10 mΩ, the gold finger connector connects the electrolyte leakage sensor with a plug force of 1.5 N±0.2 N, and the coaxial shield terminal connects the ultrasonic guided wave sensor with a characteristic impedance of 50 Ω±5%. Module level wiring unit, aluminum magnesium alloy wire slot section 5mm x 3mm, lined with ceramic fiber fireproof layer thickness 0.5mm, distributed optical fiber through metal corrugated pipe wall thickness 1mm, gas sensor cable is aluminum foil and copper mesh double shielded twisted pair, acoustic emission sensor cable is coaxial cable with magnetic ring filter, pressure sensor cable is silica gel sleeve protection four-wire guide wire; Battery pack level wiring unit, section 20mm x 15mm aluminum alloy shell, filled with fireproof expansion glue with expansion rate 300% ± 5%, infrared thermal imaging array through LVDS differential interface connection, transmission rate 1.5Gbps, laser smoke sensor through USB3.0Type-C interface connection, microwave radar sensor through waveguide direct connection, cutoff frequency 12GHz, loss <3dB, VOC component sensor through RS485 bus connection, baud rate 115200bps; Protection unit, cable wrapped with copper nickel braid wire harness, coverage >85%, key nodes set ferrite magnetic ring, 100Ω@100MHz, optical fiber is independently placed in U-shaped metal slot and the power line spacing ≥20mm, sealing groove and silicone rubber sealing ring cooperation, compression ratio 25% ± 2%.

7. The anti-jamming integrated system of the global sensing network of the electric vehicle battery pack according to claim 6, characterized in that, In the cell level wiring unit, the solder joint tension of FPC is >5N, the thickness of gold plating layer is ≥0.8μm, and the contact resistance after welding of nickel-chromium alloy contact and thin film thermocouple is <10mΩ.

8. The anti-jamming integrated system of the global sensing network of the electric vehicle battery pack according to claim 6, characterized in that, In the module level wiring unit, the fixed spacing of aluminum magnesium alloy wire slot is 50mm, M3 rivet is locked, the wire slot and the module shell are sealed by silicone sealing ring with compression ratio 25% ± 2%, IP67 protection level, after magnetic ring filter 100Ω@100MHz, 100kHz inverse noise attenuation 43dB.

9. The anti-jamming integrated system of the global sensing network of the electric vehicle battery pack according to claim 6, characterized in that, In the battery pack level wiring unit, the fireproof expansion adhesive is 3M TM FIS110+, 300% ± 5% expansion rate triggered at 200°C, fire resistance limit 1000°C / 30min, copper-nickel braid wire harness braiding method is 16 spindles x 4 layers of twill, resistance <0.1 Ω / m.

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