Intelligent current sensor and application thereof in new energy automobile
The intelligently designed current sensor solves the problems of temperature drift and durability, achieves high-precision measurement and adaptability to complex environments, improves the communication and integration efficiency of the battery management system for new energy vehicles, and ensures battery safety and system reliability.
Patent Information
- Application Number
- CN202511293960.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-11
- Publication Date
- 2025-12-05
AI Technical Summary
Existing current sensors exhibit temperature drift across the entire temperature range, resulting in decreased measurement accuracy, poor linearity, and difficulty in meeting high-precision requirements. Furthermore, they lack durability and adaptability in complex automotive environments, and have low communication and system integration efficiency.
An intelligent current sensor was designed, which includes modules for current measurement, temperature detection, temperature correction, filtering, signal preprocessing, self-diagnosis and self-repair, communication interface, and data analysis. It adopts high-temperature resistant materials and protective coatings, and combines big data and artificial intelligence algorithms to achieve temperature compensation, signal filtering, and real-time monitoring. It supports multiple communication protocols and has self-diagnosis and self-repair functions.
It improves the measurement accuracy and stability of the sensor across the entire temperature range, enhances environmental adaptability, enables efficient data interaction and system integration, improves the safety and reliability of the battery management system, and reduces maintenance costs.
Abstract
Description
TECHNICAL FIELD
[0001] The application belongs to the technical field of intelligent sensors, and particularly relates to an intelligent current sensor and application thereof in a new energy automobile. BACKGROUND
[0002] In recent years, the rapid growth of production and sales of new energy automobiles and the large-scale promotion of energy storage systems have greatly promoted the development of battery management system technology. The current sensor plays a core role in the new energy automobile and is involved in battery management, motor control, and charging system, etc. as it undertakes the core monitoring function in the battery management system and ensures safe and efficient operation of the battery by detecting the charging and discharging current in real time.
[0003] The existing current sensor can realize basic current detection function, but obvious temperature drift phenomenon often occurs in the full temperature range, resulting in decreased measurement accuracy and poor linearity, which is difficult to meet the demand of high-precision battery management. In addition, in the complex vehicle environment, it often faces multiple challenges such as high temperature, vibration, and humidity, and the material and structure design has shortcomings in durability and adaptability. Meanwhile, in terms of communication, it is also difficult to realize efficient data interaction and system integration with the battery management system. SUMMARY
[0004] The application aims to provide an intelligent current sensor with simple structure and reasonable design and application thereof in a new energy automobile.
[0005] The application achieves the above-mentioned purpose through the following technical solutions.
[0006] An intelligent current sensor comprises:
[0007] A current measurement module for collecting original current signals;
[0008] A temperature detection module for detecting the ambient temperature in real time;
[0009] A temperature correction module for temperature compensation of current measurement values in the full temperature range;
[0010] A filter processing module for filtering noise and abnormal signals of the original current signals by using a self-developed filtering algorithm, accurately capturing current changes, and outputting current change curves before and after filtering;
[0011] A signal preprocessing module comprising a signal preamplification circuit, an ADC chip acquisition module, and a noise control circuit;
[0012] A communication interface module for data interaction and collaborative control with external electronic systems;
[0013] Self-diagnosis and self-repair module for real-time monitoring of sensor status and initiating repair mechanisms in case of failure;
[0014] Microprocessor module for implementing data acquisition, analysis and remote transmission;
[0015] Data analysis and machine learning module for implementing fault diagnosis and prediction functions.
[0016] As a further optimization of the present application, the temperature correction module performs full-temperature range temperature drift compensation through big data analysis and least squares method, keeping the full-range current measurement accuracy within 0.3%.
[0017] As a further optimization of the present application, the current measurement module adopts a shunt structure and has a high-temperature resistant material and a protective coating, and the protective coating includes a surface nickel plating and a base tin plating structure.
[0018] As a further optimization of the present application, the filter processing module can output the current change curve before and after filtering and provide auxiliary information for battery health and safety management.
[0019] As a further optimization of the present application, the communication interface module supports multiple in-vehicle communication protocols and can communicate with the battery management system.
[0020] As a further optimization of the present application, the microprocessor module integrates artificial intelligence algorithms, which can automatically identify abnormal current changes and generate warning signals
[0021] An application of an intelligent current sensor in a new energy vehicle, the sensor is installed in the power battery system of the new energy vehicle and is in communication connection with the battery management system, and the charging and discharging current of the battery pack is monitored in real time.
[0022] As a further optimization of the present application, the sensor performs remote data transmission and analysis through a cloud platform, further combines artificial intelligence algorithms to realize intelligent decision-making and vehicle safety improvement, and saves installation space through miniaturization and integration design, supporting compact vehicle layout.
[0023] The beneficial effects of the present application are:
[0024] The present application improves the precision and stability of the current sensor by setting the temperature detection module and the temperature correction module. In terms of actual measurement accuracy, it can ensure the measurement accuracy within the working temperature range. At the same time, by selecting high-temperature resistant materials, adding protective coatings and designing waterproof and dustproof structures, the environmental adaptability of the sensor is improved to ensure its adaptation to complex automotive environments. Furthermore, in terms of communication, efficient data exchange and system integration of the battery management system are realized. DETAILED DESCRIPTION
[0025] The following further describes the present application in detail, it is necessary to point out here that the following detailed description is only used to further illustrate the present application, and cannot be understood as limiting the scope of protection of the present application, and those skilled in the art can make some non-essential improvements and adjustments to the present application according to the above application content.
[0026] Embodiment: An intelligent current sensor, comprising:
[0027] A current measurement module is used to collect the original current signal, the current measurement module adopts a shunt structure and has a high-temperature-resistant material and a protective coating, and the protective coating includes a surface nickel plating and a base tin plating structure, the environmental adaptability is enhanced by setting the current detection module, the environmental adaptability of the sensor is improved by selecting the high-temperature-resistant material, increasing the protective coating, and designing a waterproof and dustproof structure, and the sensor is ensured to adapt to the complex environment of the automobile;
[0028] A temperature detection module is used to detect the environmental temperature in real time, and a temperature correction module is used to compensate the current measurement value in the full-temperature range, the temperature correction module compensates the full-temperature range by big data analysis and the least square method, so that the full-range current measurement accuracy is maintained within 0.3%, and the accuracy and stability of the current sensor are improved by setting the temperature detection module and the temperature correction module, and the working temperature range can be ensured in terms of actual measurement accuracy;
[0029] A filter processing module is used to filter out noise and abnormal signals of the original current signal by using a self-developed filtering algorithm, accurately capture the current change, and output the current change curve before and after filtering, and the filter processing module can output the current change curve before and after filtering and provide auxiliary information for battery health and safety management;
[0030] A signal preprocessing module includes a signal preamplification circuit, an ADC chip acquisition module, and a noise control circuit, the signal preprocessing module amplifies, denoises, and digitizes the weak sensor signal to provide reliable data with high quality and high precision for subsequent processing, which not only improves the measurement accuracy and stability of the entire system, but also enhances the anti-interference ability;
[0031] A self-diagnosis and self-repair module is used to monitor the sensor state in real time and start the repair mechanism when a fault occurs, the reliability and safety of the system can be greatly improved by setting the self-diagnosis and self-repair module, the equipment can be self-repaired or degraded when a fault occurs, avoiding shutdown accidents, at the same time, it can significantly reduce the long-term maintenance cost, through predictive maintenance and autonomous repair, the need for manual maintenance and unexpected downtime losses are reduced.
[0032] A communication interface module is used for data interaction and cooperative control with external electronic systems. The communication interface module supports multiple in-vehicle communication protocols and can communicate with the battery management system. A microprocessor module is used for data acquisition, analysis, and remote transmission. The microprocessor module incorporates artificial intelligence algorithms that can automatically identify abnormal current changes and generate warning signals. Through the built-in microprocessor and communication interface module, real-time data acquisition, analysis, and remote transmission are achieved. Combined with artificial intelligence algorithms, abnormal current changes can be automatically identified, potential faults can be timely warned, and vehicle safety and maintenance efficiency can be improved.
[0033] A data analysis and machine learning module is used for fault diagnosis and prediction functions.
[0034] An intelligent current sensor is installed inside the power battery pack of a new energy vehicle and communicates with the battery management system through a CAN bus to monitor the current signal of the power battery pack during charging and discharging. The sensor transmits data remotely and analyzes it through a cloud platform, further combines artificial intelligence algorithms to achieve intelligent decision-making and vehicle safety improvement. The intelligent sensor can monitor the state of the vehicle in real time and transmit data to the cloud for analysis to improve the safety and efficiency of the vehicle. The intelligent sensor will play a more important role in the vehicle electronic system. The intelligent sensor will not only be a data acquisition device, but also a core component that can achieve intelligent decision-making and control.
[0035] The current measurement module uses a shunt structure, the main material is a high-precision alloy resistor, and the surface is plated with nickel and then tin, effectively improving corrosion resistance and mechanical strength. It can work stably in the range of -40℃ to 125℃. The temperature detection module collects environmental temperature in real time. The temperature correction module compensates for real-time temperature drift based on the pre-stored multi-temperature point resistance coefficient curve and the least squares algorithm, so that the current measurement accuracy in the full range (±500A) is better than 0.3%, and the linearity deviation is not more than 0.2%.
[0036] The original current signal is converted to a digital signal by the pre-amplification circuit in the signal preprocessing module and the ADC acquisition module, and is denoised and filtered by the filter processing module using a self-developed filtering algorithm. The algorithm effectively identifies current mutations and outputs waveform curves before and after filtering. These data can be used to evaluate the battery health status and provide safety warnings.
[0037] The microprocessor module incorporates a convolutional neural network (CNN) algorithm that analyzes the processed current data in real time, automatically identifies abnormal charging and discharging behavior, and generates a fault warning signal. The self-diagnosis and self-repair module continuously monitors the status of each unit of the sensor and can automatically switch to a backup circuit or reinitialize the corresponding subsystem when problems such as ADC sampling abnormalities or communication interruptions are detected.
[0038] The sensor supports CAN and LIN protocols through a communication interface module, can interact with multiple electronic control units of the whole vehicle, in addition, current data can be uploaded to a cloud platform through a 4G / 5G module, combined with historical data and an artificial intelligence model to further optimize battery management strategies, predict service life and discover system-level risks in advance;
[0039] The sensor adopts a highly integrated design, the volume is significantly reduced, is convenient to arrange in limited space, is beneficial to vehicle lightweight and structure optimization, and improves system compactness and reliability.
[0040] The above-mentioned embodiments only express several embodiments of the present application, the description is more specific and detailed, but it cannot be understood as the limitation of the patent scope of the present application. It should be pointed out that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which belong to the protection scope of the present application.
Claims
1. An intelligent current sensor, characterized by, The application relates to a sensor for monitoring the charging and discharging current of a new energy vehicle power battery system. The sensor comprises the following modules: a current measurement module for collecting original current signals; a temperature detection module for real-time detection of ambient temperature; a temperature correction module for temperature compensation of current measurement values in a full-temperature range; a filter processing module for filtering noise and abnormal signals from the original current signals by using a self-developed filtering algorithm, accurately capturing current changes, and outputting current change curves before and after filtering; a signal preprocessing module including a signal preamplification circuit, an ADC chip acquisition module and a noise control circuit; a communication interface module for data interaction and collaborative control with external electronic systems; a self-diagnosis and self-repair module for real-time monitoring of sensor status and starting a repair mechanism when a fault occurs; a microprocessor module for realizing data acquisition, analysis and remote transmission; 2. The intelligent current sensor of claim 1, wherein: a data analysis and machine learning module for realizing fault diagnosis and prediction functions.
3. The intelligent current sensor of claim 1, wherein: The temperature correction module performs full-temperature range temperature drift compensation through big data analysis and the least square method, so that the full-range current measurement accuracy is maintained within 0.3%.
4. The intelligent current sensor of claim 1, wherein: The current measurement module adopts a shunt structure and has high-temperature-resistant materials and a protective coating, and the protective coating comprises a surface nickel plating and a base tin plating structure.
5. The intelligent current sensor of claim 1, wherein: The filter processing module can output current change curves before and after filtering and provide auxiliary information for battery health and safety management.
6. The intelligent current sensor of claim 1, wherein: The communication interface module supports multiple in-vehicle communication protocols and can communicate with a battery management system.
7. The intelligent current sensor according to any one of claims 1-6, applied in a new energy vehicle, characterized in that, The microprocessor module integrates an artificial intelligence algorithm and can automatically identify abnormal current changes and generate a warning signal.
8. The application of the intelligent current sensor according to claim 7 in new energy vehicles, characterized in that, The sensor is installed in a new energy vehicle power battery system and is in communication connection with a battery management system to monitor the charging and discharging current of a battery pack in real time. The sensor transmits and analyzes data remotely through a cloud platform, and further combines an artificial intelligence algorithm to realize intelligent decision-making and vehicle safety improvement.