Super-capacitor accelerated saturation and consistency comprehensive sorting system and method

Abstract

The invention discloses a comprehensive sorting system for accelerated saturation and consistency of a super capacitor. The comprehensive sorting system comprises a main control unit, a monomer analysis subsystem unit, a high-voltage charging unit, an inductive pulse load unit, a system discharging unit, a constant-temperature heating unit, a heat balancing unit and a system power supply management unit, the method can achieve the accelerated stabilization of the comprehensive saturation of a new offline super capacitor monomer, and achieves the 0V initial pretreatment of the super capacitor monomer for the production of a super capacitor module. A modular combination mode is adopted, the tested super-capacitor monomers can be intelligently tested and sorted in batches, and the tested super-capacitor monomers in batches are automatically grouped according to a designed grouping number in a parameter closest mode according to parameters set by man-machine interaction. And the tested batch monomers are discharged integrally. Therefore, the aim of ensuring the consistency, the stability, the safety and the like in later-stage production of the super-capacitor module and a specific super-capacitor application system is fulfilled.

Description

Technical Field

[0001] This invention relates to the field of supercapacitor module technology, specifically to a comprehensive sorting system and method for supercapacitor accelerated saturation and consistency. Background Technology

[0002] With the increasing application of supercapacitors in various fields such as new energy, transportation, industry, military, and medical equipment, and in the form of module units, major supercapacitor manufacturers currently face the following issues in the production process of supercapacitor modules, which require further detailed solutions:

[0003] 1. Newly produced supercapacitor cells, due to inconsistencies in their internal physical and chemical properties, are sorted for consistency before their characteristics are fully solidified and stabilized. This results in errors in the consistency sorting during production as the cells are stored for a certain period and their overall physical and chemical properties become fully saturated. Consequently, variations in performance parameters lead to errors in the sorting results, impacting subsequent supercapacitor module production and making cell grouping difficult.

[0004] 2. Due to the inherent working principle and manufacturing process of supercapacitor cells, they possess certain chemical properties and a weak memory recovery capability. Cells that have undergone 0V discharge on the supercapacitor cell production line may experience a certain degree of voltage recovery after being stored naturally for a period of time.

[0005] 3. During transportation, the internal parameters of newly produced supercapacitor cells may change due to factors such as vibration.

[0006] 4. Because the inherent characteristics of a single supercapacitor cell are equivalent to an RLC series structure, its 0V basic voltage will change to varying degrees under the influence of external electric and magnetic fields.

[0007] 5. During the single-cell production stage of supercapacitors, due to varying levels of process control, some cells may not be properly sealed, or the electrolyte or coating moisture content may exceed the standard. This can lead to varying degrees of leakage during later high-temperature storage or use, affecting the original performance of the supercapacitor cells.

[0008] 6. Due to corrosion from the electrolyte, the contact resistance of the supercapacitor cell's conductive strips, current collector, pin rivets, output pins, etc., will change to some extent over time.

[0009] 7. The incomplete discharge of a single supercapacitor cell can affect the consistency of its sorting results on the single cell production line to varying degrees.

[0010] 8. Other human factors may cause errors in the consistency sorting results. Summary of the Invention

[0011] The purpose of this invention is to provide a supercapacitor-accelerated saturation and consistency integrated sorting system in order to solve the technical problems in the background art.

[0012] To achieve the above objectives, the present invention adopts the following technical solution:

[0013] A supercapacitor-accelerated saturation and consistency integrated sorting system includes:

[0014] The main control unit is used for human-computer interaction, data analysis, and system coordination control.

[0015] The single-cell analysis subsystem unit contains multiple independent modules. Each module is connected to the main control unit via a communication bus and is used to monitor, record and upload the voltage and temperature data of the corresponding supercapacitor cell in real time and to perform single-cell discharge / short-circuit operations.

[0016] The high-voltage charging unit receives instructions from the main control unit via a communication bus and is directly connected to the positive and negative terminals of the supercapacitor module under test to perform high-voltage charging on the series-connected supercapacitor modules.

[0017] The inductive pulse load unit receives frequency control commands from the main control unit via a communication bus and is connected in parallel to the positive and negative terminals of the supercapacitor module under test to perform frequency scanning pulsed high-current discharge.

[0018] The system discharge unit is controlled by the main control unit via a communication bus and is directly connected to the positive and negative terminals of the supercapacitor module under test to achieve 0V discharge of the entire module.

[0019] Both the constant temperature heating unit and the thermal equalization unit are controlled by the main control unit through the communication bus and work together in the sealed experimental chamber. The constant temperature heating unit provides heating power, and the thermal equalization unit achieves temperature equalization inside the chamber by stirring the airflow with a fan.

[0020] The system power management unit interacts with the main control unit via a communication bus and provides operating power to all other units.

[0021] In some embodiments, the main control unit includes a processor and a display module, and sends control commands to all subunits and receives data via a communication bus.

[0022] In some embodiments, each independent module of the unit analysis subsystem comprises:

[0023] Individual fixed bracket, series electromagnetic switch, individual discharge circuit, individual short circuit circuit;

[0024] Voltage and temperature detection circuits are used to monitor individual unit parameters in real time;

[0025] The unit data analysis circuit is used to analyze data and interact with the main control unit through the unit communication circuit.

[0026] A series electromagnetic switch is used to control the connection / disconnection of individual units from the system series circuit. The individual unit presence detection circuit triggers the switch action.

[0027] In some embodiments, the high-voltage charging unit is a constant current constant voltage charger, and its output terminal is directly connected in parallel to the access terminal of the system discharge unit.

[0028] In some embodiments, the inductive pulse load unit includes an electromagnetic energy conversion circuit, the input of which is connected in parallel to the output port of the high-voltage charging unit, and the discharge frequency range covers the equivalent local oscillator frequency of a single supercapacitor RLC.

[0029] In some embodiments, the system discharge unit includes a power resistor network and a switching circuit, with its input terminals directly connected to the positive and negative terminals of the module under test, and the discharge modes include resistor energy consumption, energy feedback, or inverter absorption.

[0030] In some embodiments, the constant temperature heating unit uses quartz heating tubes / resistance wires, which are evenly distributed on the inner wall of the experimental chamber; the fan of the thermal equalization unit is installed in the air duct of the experimental chamber, and the two work together to maintain the temperature inside the chamber.

[0031] In some embodiments, the system power management unit is a switching power supply architecture, with its input connected to three-phase AC power and its output providing matching operating voltage to each unit through independent cables.

[0032] In some embodiments, the communication bus is a CAN bus, with the main control unit acting as the master and the remaining units acting as slaves, forming a bus-type network topology.

[0033] This embodiment also provides a supercapacitor sorting method, including the following steps:

[0034] (1) Discharge all cells to 0V through the system discharge unit;

[0035] (2) Under the control of the constant temperature heating unit and the thermal equilibrium unit, the short-circuited unit is placed in a high temperature environment for several hours;

[0036] (3) Charge the series cells to the target voltage through the high voltage charging unit, and leave them at high temperature and fully charged for several hours;

[0037] (4) Discharge to half-charge state through frequency conversion pulse discharge using inductive pulse load unit, and then recharge to full charge;

[0038] (5) The individual unit analysis subsystem collects voltage / temperature data of each individual unit and uploads it to the main control unit;

[0039] (6) Discharge to 0V through the system discharge unit, short-circuit the individual unit and remove it from the high temperature environment;

[0040] (7) The main control unit automatically groups the data according to the comprehensive performance data, and the grouping results are sent to each individual analysis subsystem unit for display.

[0041] The present invention has the following beneficial effects:

[0042] 1. This invention can perform internal physical and chemical comprehensive saturation acceleration treatment on newly produced supercapacitor cells.

[0043] 2. This invention can stimulate the internal structure of the tested monomer through high-frequency inductive current, thereby stabilizing it and preventing the instability of the monomer from causing safety hazards to later application projects.

[0044] 3. This invention uses intelligent computing, which can greatly save on production manpower.

[0045] 4. The grouping of individual units is more precise than existing methods.

[0046] 5. This invention automatically uses the voltage of a batch of supercapacitors under test to reach the initial theoretical condition of 0V and stabilizes it.

[0047] 6. Upon receiving the test results, the batch of tested supercapacitor cells will be automatically discharged back to 0V, thereby ensuring the safety of equipment and personnel during the production of supercapacitor modules. Attached Figure Description

[0048] Figure 1 This is a block diagram of the system components. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The described embodiments are some, but not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0050] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0051] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0052] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0053] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or display that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or display.

[0054] The following will combine Figure 1 This application provides a detailed description of a supercapacitor-accelerated saturation and consistency integrated sorting system according to its embodiments. It is worth noting that the following embodiments are merely illustrative of this application and do not constitute a limitation thereof.

[0055] Example 1:

[0056] like Figure 1 As shown, this invention discloses a supercapacitor accelerated saturation and consistency integrated sorting system. It includes a main control unit, a single-cell analysis subsystem unit, a high-voltage charging unit, an inductive pulse load unit, a system discharge unit, a constant-temperature heating unit, a thermal equalization unit, and a system power management unit. Wherein:

[0057] The main control unit is used for human-computer interaction, data analysis, and system coordination control.

[0058] The single-cell analysis subsystem unit contains multiple independent modules. Each module is connected to the main control unit via a communication bus and is used to monitor, record and upload the voltage and temperature data of the corresponding supercapacitor cell in real time and to perform single-cell discharge / short-circuit operations.

[0059] The high-voltage charging unit receives instructions from the main control unit via a communication bus and is directly connected to the positive and negative terminals of the supercapacitor module under test to perform high-voltage charging on the series-connected supercapacitor modules.

[0060] The inductive pulse load unit receives frequency control commands from the main control unit via a communication bus and is connected in parallel to the positive and negative terminals of the supercapacitor module under test to perform frequency scanning pulsed high-current discharge.

[0061] The system discharge unit is controlled by the main control unit via a communication bus and is directly connected to the positive and negative terminals of the supercapacitor module under test to achieve 0V discharge of the entire module.

[0062] Both the constant temperature heating unit and the thermal equalization unit are controlled by the main control unit through the communication bus and work together in the sealed experimental chamber. The constant temperature heating unit provides heating power, and the thermal equalization unit achieves temperature equalization inside the chamber by stirring the airflow with a fan.

[0063] The system power management unit interacts with the main control unit via a communication bus and provides operating power to all other units.

[0064] During the production of supercapacitor modules, the supercapacitor cells from the supercapacitor cell production department or manufacturer are first fully discharged in batches. Then, these batches of products are kept in a short-circuit state in the same constant-temperature environment for several hours to undergo a high-temperature accelerated comprehensive saturation treatment, aiming to stabilize the physical and chemical saturation levels of the target cells.

[0065] Then, under high-temperature conditions, the tested batch of individual cells are charged in series with high voltage. Based on the number of cells in series, after charging to the target voltage, a high-temperature full-charge rest period of several hours is performed, followed by a second high-temperature accelerated comprehensive saturation acceleration process to evaluate the self-discharge of the batch of individual cells. Then, an inductive pulse load is used to perform frequency-changing scanning pulse high-current discharge from low to high frequency, with the frequency domain including the individual cell RLC equivalent local oscillator frequency, for further frequency response characteristic acceleration processing. When the overall voltage is discharged to half-charge, the total voltage is charged again to a fully charged state. At this time, each individual cell analysis subsystem unit records its own unit voltage and process data, and uploads its values ​​and numbers to the main control unit via the communication bus.

[0066] Then, the entire tested capacitor is discharged to 0V through the system discharge unit, and each supercapacitor cell is short-circuited and maintained for a period of time through the individual cell analysis system. The system automatically exits the constant temperature mode for the tested batch of cells. Cells with leakage are removed by visual inspection, and then the target number of groups is set through the main control unit's setting interface. The system automatically sorts all remaining cells according to their comprehensive evaluation values ​​and automatically groups them to the nearest group according to the set group number. This achieves the comprehensive effect of the invention.

[0067] This invention enables accelerated saturation stabilization of newly produced supercapacitor cells while simultaneously achieving 0V initial pre-processing of supercapacitor cells for supercapacitor module production. Employing a modular assembly method, it allows for intelligent batch testing and sorting of supercapacitor cells. Based on parameters set via human-machine interface, the tested batch of supercapacitor cells is automatically grouped according to the designed grouping quantity and the parameter closestity. The tested batch of cells is then discharged as a whole. This ensures consistency, stability, and safety in subsequent supercapacitor module production and specific supercapacitor application systems.

[0068] The main control unit is primarily responsible for human-computer interaction, such as system parameter input and display output, as well as collecting data uploaded by each individual analysis subsystem unit, performing statistical and overall data analysis, and controlling the operation of the system's charging and discharging units.

[0069] The individual unit analysis subsystem is the core testing component of the tested individual unit. It includes an individual unit mounting bracket, a series electromagnetic switch, an individual unit discharge circuit, an individual unit short-circuit circuit, a unit data analysis circuit based on a microcontroller or DSP, a voltage and temperature detection circuit, a unit data display circuit, an individual unit exit control circuit, a unit communication circuit, and an individual unit presence detection circuit. In the unit system, when a supercapacitor is manually installed onto the bracket, the individual unit presence detection circuit detects that the supercapacitor is in place and automatically closes the series electromagnetic switch, connecting the corresponding supercapacitor to the system. Otherwise, the unit is short-circuited via the short-circuit circuit. Throughout the testing and sorting process, the voltage and temperature of the supercapacitor in this unit are monitored in real time by the voltage and temperature detection circuit. The microcontroller or DSP in this unit analyzes and records the parameter change curves, and displays the analysis results on the unit display screen. When initial discharge or short-circuit processing is required for a single unit, the unit control circuit controls the discharge or short-circuit circuit to discharge or short-circuit the supercapacitor. Throughout the process, each unit communicates with the system control unit in real time through its own communication circuit, uploading its results data to the system control unit. Once the test is complete and the grouping results are analyzed by the system control unit, the system control unit sends the grouping results to each sub-analysis unit, and the unit display circuit displays the group number. At this point, the unit can be manually exited by pressing the unit's individual cell exit button, which will disconnect the series electromagnetic switch of the supercapacitor in the corresponding cell, and the supercapacitor cell under test in this unit will automatically exit the system.

[0070] The high-voltage charging unit employs a dedicated high-voltage charger for supercapacitors, developed in-house. The system control unit analyzes the number of units connected in series and calculates the required voltage and current based on data uploaded from each sub-analysis unit. Charging data is transmitted to the charger in real-time via a communication bus, controlling the charger to uniformly charge the entire supercapacitor under test.

[0071] The inductive pulse load unit employs an electromagnetic inductive energy conversion circuit to perform high-voltage inductive pulse discharge on the entire supercapacitor system under test. Its discharge frequency operates based on frequency data issued by the system control unit according to the tested capacity and number of series capacitors. The frequency conversion is a calculated frequency curve, whose frequency domain includes the characteristic frequencies of individual RLC capacitors. Through this strong pulse circuit processing, the electrodes inside each supercapacitor under test are pulsed and stimulated, causing mechanical oscillations at the corresponding frequency curve, further promoting the saturation of the electrode coating and electrolyte.

[0072] The system discharge unit mainly consists of a discharge resistor and a control switch. Its function is to discharge the entire supercapacitor through control commands issued by the system's main control unit at the beginning of the test and at the test result, so that its overall voltage reaches 0V.

[0073] The constant temperature heating unit uses a distributed electric heater to heat the interior of the experimental chamber in real time by issuing control commands and target temperatures through the system control unit, and automatically controls the heating power based on the distributed temperature and average temperature analyzed by the system control unit.

[0074] The thermal equalization unit uses an industrial fan and communication control circuit, in conjunction with the experimental chamber and mechanical structure air duct, to circulate and stir the hot air inside the experimental chamber, thereby achieving thermal equalization inside the experimental chamber.

[0075] The power management unit of the system adopts a digital power supply method to convert the three-phase AC input power supply into different DC and AC voltages required by each unit of the system, ensuring that each unit can work normally under the unified control of the system control unit.

[0076] Preferably, the main control unit uses a 14-inch configuration screen in conjunction with a DSP to achieve human-computer interaction and comprehensive data analysis functions.

[0077] Preferably, the individual analysis subsystem unit adopts an independent module design, and the system flexibly combines the number of modules of its individual analysis subsystem unit according to its scale.

[0078] Preferably, the single-unit analysis subsystem unit uses a microcontroller as the data analysis and control device.

[0079] Preferably, the unit display of the single-unit analysis subsystem is an OLED display, which is suitable for its high-temperature environment requirements.

[0080] Preferably, the high-voltage charging unit uses a supercapacitor-specific high-voltage charger independently developed by our company, which has a wide input and output voltage range and charging characteristics that are more suitable for conventional double-layer supercapacitors.

[0081] Preferably, the inductive pulse load unit employs an electromagnetic power energy conversion circuit to convert the capacitor's electrical energy into high-frequency pulsed electromagnetic energy with varying frequency. This causes it to exhibit high-frequency inductive characteristics relative to the supercapacitor under test.

[0082] Preferably, the system discharge unit uses a power resistor to achieve high-voltage DC discharge, ensuring the stability of the unit system during long-term operation.

[0083] Preferably, the constant temperature heating unit uses a quartz heating tube to heat the experimental chamber and optimizes the saturation of the supercapacitor cells under test through quartz infrared radiation.

[0084] Preferably, the system power management unit adopts a switching power supply method to improve power efficiency, safety, and stability, and further reduce unit output.

[0085] Preferably, the system uses CAN communication.

[0086] The above description is merely a preferred embodiment of the present invention and is intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A supercapacitor-accelerated saturation and consistency integrated sorting system, characterized in that, include: The main control unit is used for human-computer interaction, data analysis, and system coordination control. The single-cell analysis subsystem unit contains multiple independent modules. Each module is connected to the main control unit via a communication bus and is used to monitor, record and upload the voltage and temperature data of the corresponding supercapacitor cell in real time and to perform single-cell discharge / short-circuit operations. The high-voltage charging unit receives instructions from the main control unit via a communication bus and is directly connected to the positive and negative terminals of the supercapacitor module under test to perform high-voltage charging on the series-connected supercapacitor modules. The inductive pulse load unit receives frequency control commands from the main control unit via a communication bus and is connected in parallel to the positive and negative terminals of the supercapacitor module under test to perform frequency scanning pulsed high-current discharge. The system discharge unit is controlled by the main control unit via a communication bus and is directly connected to the positive and negative terminals of the supercapacitor module under test to achieve 0V discharge of the entire module. Both the constant temperature heating unit and the thermal equalization unit are controlled by the main control unit through the communication bus and work together in the sealed experimental chamber. The constant temperature heating unit provides heating power, and the thermal equalization unit achieves temperature equalization inside the chamber by stirring the airflow with a fan. The system power management unit interacts with the main control unit via a communication bus and provides operating power to all other units.

2. The system according to claim 1, characterized in that: The main control unit includes a processor and a display module, and sends control commands to all sub-units and receives data through a communication bus.

3. The system according to claim 1, characterized in that: Each independent module of the unit analysis subsystem includes: Individual fixed bracket, series electromagnetic switch, individual discharge circuit, individual short circuit circuit; Voltage and temperature detection circuits are used to monitor individual unit parameters in real time; The unit data analysis circuit is used to analyze data and interact with the main control unit through the unit communication circuit. A series electromagnetic switch is used to control the connection / disconnection of individual units from the system series circuit. The individual unit presence detection circuit triggers the switch action.

4. The system according to claim 1, characterized in that: The high-voltage charging unit is a constant current and constant voltage charger, and its output terminal is directly connected in parallel to the input terminal of the system discharge unit.

5. The system according to claim 1, characterized in that: The inductive pulse load unit includes an electromagnetic energy conversion circuit, whose input is connected in parallel to the output port of the high-voltage charging unit, and the discharge frequency range covers the equivalent local oscillator frequency of a single supercapacitor RLC.

6. The system according to claim 1, characterized in that: The system discharge unit includes a power resistor network and a switching circuit. Its input terminal is directly connected to the positive and negative terminals of the module under test. The discharge modes include resistor energy consumption, energy feedback, or inverter absorption.

7. The system according to claim 1, characterized in that: The constant temperature heating unit uses quartz heating tubes / resistance wires, which are evenly distributed on the inner wall of the experimental chamber; the fan of the thermal equalization unit is installed in the air duct of the experimental chamber, and the two work together to maintain the temperature inside the chamber.

8. The system according to claim 1, characterized in that: The system power management unit is a switching power supply architecture. Its input is connected to three-phase AC power, and its output provides matching operating voltage to each unit through independent cables.

9. The system according to claim 1, characterized in that: The communication bus is a CAN bus, with the main control unit acting as the master and the other units acting as slaves, forming a bus network topology.

10. A supercapacitor sorting method based on the system of any one of claims 1-9, characterized in that... Includes the following steps: (1) Discharge all cells to 0V through the system discharge unit; (2) Under the control of the constant temperature heating unit and the thermal equilibrium unit, the short-circuited unit is placed in a high temperature environment for several hours; (3) Charge the series cells to the target voltage through the high voltage charging unit, and leave them at high temperature and fully charged for several hours; (4) Discharge to half-charge state through frequency conversion pulse discharge using inductive pulse load unit, and then recharge to full charge; (5) The individual unit analysis subsystem collects voltage / temperature data of each individual unit and uploads it to the main control unit; (6) Discharge to 0V through the system discharge unit, short-circuit the individual unit and remove it from the high temperature environment; (7) The main control unit automatically groups the data according to the comprehensive performance data, and the grouping results are sent to each individual analysis subsystem unit for display.

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