New energy automobile active safety separation system based on redundant battery module and automobile chassis

Abstract

The invention provides a new energy automobile active safety separation system based on redundant battery modules and an automobile chassis, the system comprises at least two mutually redundant battery modules, the battery modules are mutually independent in physical, electrical and thermal management and control, the battery modules are connected in parallel to supply power to the whole automobile in normal, and any module can be used as the other module for hot backup; the risk monitoring and intelligent decision-making unit takes the battery management system as a core, is internally provided with a thermal runaway prediction algorithm model based on multi-parameter information fusion, judges the thermal runaway risk level of each battery module and generates a separation instruction; the quick separation executing mechanism comprises a locking and releasing device and an auxiliary separation device; the high-voltage system and power switching unit is used for automatically switching the whole vehicle load to the healthy battery module before and after the risk battery module is separated; and the early warning and communication unit is used for sending out in-vehicle warning and out-vehicle early warning information before and after separation. The method has active risk isolation and system function connection capabilities, ensures that a separation path is safer, and improves the safety of public roads.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of new energy vehicle safety technology, and relates to a new energy vehicle active safety separation system based on a redundant battery module and a vehicle chassis. BACKGROUND

[0002] With the popularization of new energy vehicles, the thermal runaway safety risk of power batteries, especially lithium-ion batteries, has become a key challenge restricting the healthy development of the industry. A common consensus in the industry is that under the current technical level, it is impossible to absolutely guarantee that any battery cell or battery pack will not have thermal failure within its life cycle. Under this fundamental premise, the existing safety technology route dominated by passive protection exposes the following three inherent limitations: 1. Fundamental contradiction of safety technology route: lack of transition from "blocking" to "dilution". Most existing technical solutions focus on passive defense, such as strengthening the battery pack shell, filling heat-insulating and flame-retardant materials, and designing pressure relief valves. The core concept of these methods is to "block" and "delay" after thermal runaway occurs, trying to control the danger within the battery pack. However, this method has a ceiling effect: it cannot fundamentally isolate the "danger source" of thermal runaway from the passenger compartment and the vehicle body. Once the thermal runaway chain reaction is triggered, the battery pack will continue to produce high temperature, open fire, and toxic smoke, eventually still seriously threatening the safety of the driver and passenger, and most likely causing the vehicle to burn. Under the premise of being unable to absolutely prevent, relying solely on passive protection has an inherent and insufficient safety upper limit.

[0003] 2. Lack of system function redundancy: "power vacuum" in dangerous situations. Current new energy vehicles usually use single or integrated battery packs for power supply. When thermal runaway occurs in part of the battery pack, the vehicle high-voltage system will perform a complete power-down to ensure high-voltage safety. This will directly cause the vehicle to lose power instantly, making it impossible to actively drive away from high-risk areas such as tunnels, bridges, high-speed traffic, or underground garages during the valuable escape window. This "power vacuum" state greatly increases the risk of secondary accidents (such as rear-end collisions) and the difficulty of emergency evacuation for passengers, leaving them in a passive dangerous situation.

[0004] 3. Lack of early warning and coordination capabilities: from "single vehicle alarm" to "environmental interaction" deficiency. Existing systems have fault diagnosis and alarm functions, but their warning information is usually limited to vehicle instrument panel prompts or simple audio and visual reminders, with limited information transmission range. There is a lack of effective and active information broadcasting and interaction mechanisms for the vehicle's surrounding environment (such as other road users and traffic infrastructure). This results in surrounding vehicles and pedestrians being unable to obtain sufficient warning time and clear avoidance instructions before the accident, making it difficult to prevent secondary disasters or chain accidents caused by the sudden danger of the vehicle.

[0005] In addition, in the few active separation scheme exploration, there is a technical concept of ejecting the battery pack to the side of the vehicle. However, this scheme has a huge safety hazard: its separation path is uncontrollable, and the high-temperature, possibly on fire or exploding battery pack is thrown to the side of the road at high speed, which is easy to hit adjacent lane vehicles, pedestrians or roadside facilities, thereby causing serious secondary collision and fire accidents, posing a major threat to public safety. SUMMARY

[0006] The purpose of the present application is to provide a new energy vehicle active safety separation system based on redundant battery modules and an automobile chassis, which has active risk isolation and system function connection ability, while ensuring that the separation path is safer, effectively improving the safety of public roads.

[0007] To solve the above technical problems, the present application provides a new energy vehicle active safety separation system based on redundant battery modules, comprising: At least two battery modules are redundant to each other, independent of each other in physical structure, electrical connection, thermal management and control, parallelly connected to supply power to the whole vehicle in normal working state, and any module can be used as a hot backup for another module; A risk monitoring and intelligent decision unit, taking the battery management system as the core, the battery management system is built-in with a thermal runaway prediction algorithm model based on multi-parameter information fusion, which can comprehensively process the data of each sensor in real time, and is used for real-time judgment of the thermal runaway risk level of each battery module based on multi-sensor information fusion, and generates a separation instruction; A quick separation execution mechanism, comprising: a locking release device for realizing high-load locking and instantaneous release of the battery module; an auxiliary disengagement device for providing a downward pushing force after the main locking is released to ensure reliable disengagement of the battery module; A high-voltage system and power switching unit for automatically cutting off the power supply circuit of the risk battery module and switching the load of the whole vehicle to the healthy battery module before and after the separation of the risk battery module; A warning and communication unit for sending in-vehicle warning and external warning information before and after separation.

[0008] Further preferably, an integrated quick plug-in interface is provided between the battery module and the vehicle body, including a high-voltage electrical interface, a low-voltage communication interface and a cooling liquid pipeline interface, the interface has automatic docking and separation functions, and the action of the mechanical locking mechanism is synchronized, wherein the high-voltage electrical interface has arc extinguishing function, and the cooling liquid pipeline interface adopts dry-break quick plug connector.

[0009] Further preferably, the sensors include but are not limited to temperature sensors, voltage sensors, module internal pressure sensors, and gas concentration sensors for detecting electrolyte decomposition products.

[0010] Further preferably, the early warning and communication unit comprises an external sound and light alarm and a vehicle networking communication module, and can broadcast early warning information to surrounding vehicles and roadside equipment.

[0011] The application further discloses a new energy automobile chassis, which comprises a chassis body, at least two battery mounting grooves are formed upward on the lower side of the chassis body, one power battery is mounted in each battery mounting groove, a plurality of support discs are arranged outward on the edge of each power battery close to one end of the corresponding battery mounting groove, and an auxiliary separation device is arranged between each support disc and the bottom of the corresponding battery mounting groove. A battery bearing edge is arranged outward on the side of each power battery away from the opening end of the corresponding battery mounting groove, a plurality of locking release devices are arranged on the outer periphery of each battery mounting groove in the chassis body, each locking release device comprises an electric telescopic mechanism mounted in the chassis body and facing the corresponding battery mounting groove, and a support plug is connected to the telescopic shaft of the corresponding electric telescopic mechanism, each support plug is used for supporting the lower side of the corresponding battery bearing edge, and a plurality of support sliding grooves corresponding to the support plugs in sliding connection are formed in the inner wall of each battery mounting groove. A battery protection plate is detachably connected at the opening end of each battery mounting groove on the lower side of the chassis body, the area of each battery protection plate is greater than the opening area of the corresponding battery mounting groove, each battery protection plate is detachably connected to the lower side of the corresponding power battery, and a rubber sealing strip is arranged on the edge of each battery protection plate.

[0012] The application is further provided that the auxiliary separation device is a pressurized spring.

[0013] The application is further provided that support grooves are formed inward on the upper and lower sides of each support plug, a plurality of support rollers perpendicular to the support grooves are rotatably connected in each support groove, and each support roller protrudes from the upper side or the lower side of the corresponding support plug.

[0014] The application is further provided that the electric telescopic mechanism is an electric hydraulic cylinder.

[0015] The application is further provided that a threaded hole is formed through each support disc, a plurality of connecting holes corresponding to the positions of the threaded holes are formed in each battery protection plate, and the battery protection plate and the power battery are connected through bolts penetrating the connecting holes and the threaded holes.

[0016] Compared with the prior art, the application has the following beneficial effects: 1. Realize the fundamental change of safety concept: from "passive containment" to "active isolation". The invention breaks through the passive idea of "delaying" and "controlling" thermal runaway in the existing technology, and fundamentally removes the "danger source" by quickly and actively physically separating the redundant battery module with thermal runaway risk from the vehicle body, avoiding the continuous invasion of high temperature, open fire and toxic gas to the passenger compartment and the vehicle body, thereby effectively preventing the disastrous consequences of vehicle burning.

[0017] 2. The first two-way redundant power supply architecture ensures emergency escape ability in extreme situations. Through the design of two completely symmetrical and mutually hot backup battery modules, the system can seamlessly switch to independent power supply of healthy modules when any single module fails. This provides the vehicle with the vital "limp home" power in dangerous situations, enabling the driver and passengers to actively drive away from high-risk areas such as tunnels, bridges or congested traffic, creating valuable escape opportunities.

[0018] 3. Design a safe and controllable downward separation path to greatly reduce the risk of secondary injury. Unlike the dangerous "lateral ejection" scheme in existing technology, the invention creatively adopts a downward vertical separation scheme. This path limits the separated high-temperature battery module to a limited area directly below the vehicle, avoiding the secondary accidents of collision and fire caused by throwing it to the adjacent lane or sidewalk, significantly improving the safety of public roads.

[0019] 4. Realize the early warning upgrade from "single vehicle safety" to "inter-vehicle coordinated safety". The V2X communication module integrated by the system can broadcast warning information to surrounding vehicles and roadside devices when danger occurs, upgrading the internal alarm of a single vehicle to a coordinated warning with the outside world (V2X), giving surrounding traffic participants sufficient reaction time and effectively preventing secondary disasters such as chain collisions, improving the overall road safety level. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 is the overall structure schematic diagram of embodiment two; Figure 2 is an exploded view for showing the power battery in the chassis body; Figure 3 for showing the internal structure of the battery mounting groove; Figure 4 for showing the connection of the power battery and the locking release device; Figure 5 for showing the overall structure of the locking release device; Figure 6 for showing the rubber sealing strip on the battery protection plate.

[0021] Wherein, 1, chassis body; 2, battery mounting groove; 3, power battery; 4, support disc; 5, pressurized spring; 6, battery bearing edge; 7, electric telescopic mechanism; 8, support plug; 9, support sliding groove; 10, support roller; 11, battery protection plate; 12, rubber sealing strip; 13, threaded hole; 14, connecting hole; 15, bolt. DETAILED DESCRIPTION

[0022] The application is further described in detail below with reference to the drawings and specific embodiments. The advantages and features of the application will be more apparent from the following description. It should be noted that the drawings are very simplified and all use non-precise proportions, only to facilitate and clarify the purpose of assisting the description of the embodiments of the application. The same or similar reference signs in the drawings represent the same or similar parts.

[0023] Embodiment 1, a new energy vehicle active safety separation system based on redundant battery modules, comprising: Two mutually redundant battery modules (A module and B module): The A module and the B module are independent of each other in physical structure, electrical connection, thermal management and control.

[0024] In the normal working state, the A module and the B module are connected in parallel through the high-voltage power distribution system of the vehicle, and jointly serve as the power supply of the whole vehicle to provide abundant power output for the vehicle.

[0025] The two modules are completely symmetrical and equivalent in function, that is, either module can serve as a hot backup for the other module. In an emergency, when the A module is at risk, the system switches to independent power supply by the B module; when the B module is at risk, the system switches to independent power supply by the A module, realizing true bidirectional redundancy protection and uninterrupted power connection.

[0026] Risk monitoring and intelligent decision unit: Taking the battery management system (BMS) as the core, a variety of sensors are independently deployed inside each battery module (A and B), including but not limited to temperature sensors, voltage sensors, module internal air pressure sensors, and gas concentration sensors (such as CO, VOCs sensors) for detecting electrolyte decomposition products.

[0027] The BMS has a thermal runaway prediction algorithm model based on multi-parameter information fusion, which can comprehensively process the data of each sensor in real time, calculate the thermal runaway risk probability of each module, and make risk level judgments (such as normal, warning, high risk) accordingly, so as to make decisions on whether to trigger the separation program and generate separation instructions.

[0028] The rapid separation execution mechanism comprises: Lock release device, used to realize high load locking and instantaneous release of the battery module; Auxiliary release device, used to provide downward pushing force after the main lock is released, ensuring reliable release of the battery module.

[0029] Integrated quick plug-in interface: The connection interface of each battery module and the vehicle body integrates automatic quick docking / separation devices of high-voltage electrical interface, low-voltage communication interface, and cooling liquid pipeline interface.

[0030] The high-voltage interface adopts an automatic docking device with arc extinguishing function; the cooling pipeline adopts a dry-break quick plug connector that can be automatically sealed during separation to prevent cooling liquid leakage. The docking and separation actions of all interfaces are coordinated and synchronized with the locking and release processes of the mechanical locking mechanism.

[0031] High-voltage system and power switching unit: The vehicle high-voltage distribution system is designed with a quick switching logic. When the system decides to separate a certain risk module (such as module A), it will first control the high-voltage contactor of the module to be cut off, and then automatically switch the entire high-voltage load to the healthy module (such as module B) for power supply at the moment of separation action completion, realizing seamless connection of power output.

[0032] Early warning and communication unit: The system includes a multi-level warning system, including an external sound and light alarm (such as a specific frequency buzzer and flashing light).

[0033] The system integrates a vehicle-to-everything (V2X) communication module, which can broadcast high-level warning information (such as "battery separation of this vehicle, please avoid") to surrounding vehicles and roadside devices before or at the start of the separation program, realizing vehicle-road cooperative warning.

[0034] Working method Based on the above system, the working method of the present application includes the following steps, and the core logic has complete symmetry to cope with two risk scenarios. Taking "A module risk" as an example: Monitoring and decision-making: BMS determines that the thermal runaway risk probability of A module exceeds the safety threshold and reaches the separation level through sensors and prediction algorithms.

[0035] Warning: The system immediately activates the sound and light alarm and broadcasts warning information to the surrounding environment through V2X.

[0036] Safety preparation: BMS executes the pre-separation safety sequence: first, cut off the high-voltage contactor of A module, and confirm that the high-voltage loop is disconnected.

[0037] Perform main separation: BMS triggers the electromagnetic release mechanism, and the main mechanical locking device of A module is unlocked, and the auxiliary release device pushes the battery pack to fall.

[0038] Complete separation: A module is completely separated from the vehicle body downward under the action of gravity free fall or gas push.

[0039] Power switching: The high-voltage system is automatically and seamlessly switched to independent power supply by the healthy B module.

[0040] Emergency driving: The vehicle enters "limp mode" and prompts the driver to safely drive away.

[0041] Example 2, reference Figures 1-6 On the basis of the active safety separation system of new energy vehicles based on redundant battery modules involved in Example 1, a new energy vehicle chassis is further proposed. The chassis includes a chassis body 1, two battery mounting grooves 2 are opened upward on the lower side of the chassis body 1, which correspond to the A and B battery modules in Example 1 respectively. Each battery mounting groove 2 is mounted with a power battery 3, and each power battery 3 is provided with a support disc 4 at the dead angle position of the edge of the side close to the opening end of the corresponding battery mounting groove 2. Each support disc 4 is provided with a pressurized spring 5 between the corresponding battery mounting groove 2 and the bottom, which is in a compressed state after the battery is mounted, and can quickly pop the power battery 3 downward.

[0042] Each power battery 3 extends outward from the side away from the opening end of the corresponding battery mounting groove 2, and four locking release devices are provided on the outer periphery of each battery mounting groove 2 in the chassis body 1. Each locking release device includes an electric telescopic mechanism 7 mounted in the chassis body 1 and facing the inside of the corresponding battery mounting groove 2, and a support plug 8 connected with the telescopic shaft of the corresponding electric telescopic mechanism 7. Among them, the electric telescopic mechanism 7 adopts an electric hydraulic cylinder. Each support plug 8 is used to support the lower side of the corresponding battery carrying edge 6, and the battery is locked and fixed in the chassis body 1 by the supporting action of the support plug 8 on the battery carrying edge 6. The inner wall of each battery mounting groove 2 is provided with four support sliding grooves 9 corresponding to the support plugs 8 and slidably connected, and the support sliding grooves 9 play a supporting role for the support plugs 8 to enhance the carrying capacity of the support plugs 8. The upper and lower sides of each support plug 8 are inwardly provided with a support groove, and a plurality of support rollers 10 perpendicular to the support groove are rotatably connected in each support groove, and each support roller 10 extends out of the upper side or lower side of the corresponding support plug 8. The support rollers 10 are in direct contact with the battery carrying edge 6 and the support sliding grooves 9, so that the support plug 8 can be easily pulled out under the weight of the power battery 3.

[0043] The lower side of the chassis body 1 is detachably connected with a battery protection plate 11 at the opening end of each battery mounting groove 2, the area of each battery protection plate 11 is greater than the opening area of the corresponding battery mounting groove 2, and the edge of each battery protection plate 11 is provided with a rubber sealing strip 12. A threaded hole 13 is formed through each support disc 4, four connecting holes 14 corresponding to the positions of the threaded holes 13 are formed in each battery protection plate 11, and the battery protection plate 11 is connected with the power battery 3 through a bolt 15 penetrating the connecting holes 14 and the threaded holes 13. With the upward pulling force of the power battery 3 on the battery protection plate 11, the battery protection plate 11 is tightly attached to the lower side of the chassis body 1, thereby ensuring the sealing effect of the power battery 3.

[0044] Working principle: when the BMS detects that a certain power battery 3 has a risk of thermal runaway and determines that the separation operation needs to be performed, the support plug 8 is gradually pulled out under the drive of the electric telescopic mechanism 7, at this time, the power battery 3 loses the supporting force and is pushed downward and pops out under the joint action of its own gravity and the pressing spring 5. During the falling of the module, since the battery protection plate 11 is directly connected with the power battery 3, the battery protection plate 11 also falls off at the same time. At the same time, the high-voltage system automatically switches to independent power supply of the healthy module, the vehicle enters the "limp mode", the instrument panel displays prompt information, guides the driver to safely drive away from the high-risk area, effectively avoids the whole vehicle burning and secondary disasters caused by battery thermal runaway, and protects the safety of the driver and the surrounding traffic participants.

[0045] It should be further pointed out that all "provides" and similar descriptions in the present application (especially the specification) express that there is a connection relationship between two structures, but the specific connection means is not limited too much, and is usually a conventional connection means, that is, it should be understood that the means is prior art and does not need to be described too much. For example, "m is provided with n", only expresses that m structure has n structure, and the specific connection between the two is through welding, riveting, adhesive connection or integral molding, which is within the protection scope of the present application; for example, "x is provided with y", only expresses that y and x can rotate relative to each other, and as for whether the two are connected through a bearing or y directly penetrates x to rotate with x, or other realizable ways, which are within the protection scope of the present application.

[0046] The above description is only a description of the preferred embodiments of the present application, and is not any limitation on the scope of the present application, any change and modification of the present application made by the person skilled in the art according to the above disclosure is within the protection scope of the claims.

Claims

1. A new energy vehicle active safety separation system based on redundant battery modules, characterized in that, include: At least two redundant battery modules are independent in terms of physical structure, electrical connection, thermal management and control. They are connected in parallel to power the vehicle under normal operating conditions, and either module can serve as a hot backup for the other. The risk monitoring and intelligent decision-making unit is centered on the battery management system. The battery management system has a built-in thermal runaway prediction algorithm model based on multi-parameter information fusion. This model can process data from various sensors in real time to determine the thermal runaway risk level of each battery module in real time based on the fusion of information from multiple sensors and generate separation commands. The rapid separation actuator includes: a locking release device for achieving high-load locking and instantaneous release of the battery module; and an auxiliary release device for providing a downward pushing force after the main locking is released to ensure reliable release of the battery module. The high-voltage system and power switching unit are used to automatically cut off the power supply circuit of the risky battery module before and after the module is disconnected and switch the vehicle load to the power supply of the healthy battery module. The warning and communication unit is used to issue in-vehicle warnings and external warning information before and after separation.

2. The active safety separation system for new energy vehicles based on redundant battery modules according to claim 1, characterized in that, The battery module is connected to the vehicle body via an integrated quick-connect interface, including a high-voltage electrical interface, a low-voltage communication interface, and a coolant pipeline interface. The interface has automatic docking and disconnection functions and works in sync with the mechanical locking mechanism. The high-voltage electrical interface has an arc-extinguishing function, and the coolant pipeline interface uses a dry-break quick-connect connector.

3. The active safety separation system for new energy vehicles based on redundant battery modules according to claim 1, characterized in that, The sensors include, but are not limited to, temperature sensors, voltage sensors, internal pressure sensors of the module, and gas concentration sensors for detecting electrolyte decomposition products.

4. The active safety separation system for new energy vehicles based on redundant battery modules according to claim 1, characterized in that, The warning and communication unit includes an external sound and light alarm and a vehicle network communication module, which can broadcast warning information to surrounding vehicles and roadside equipment.

5. A new energy vehicle chassis, based on the new energy vehicle active safety separation system based on redundant battery modules as described in any one of claims 1-4, comprising a chassis body (1), characterized in that, The bottom plate body has at least two battery mounting slots (2) on its lower side facing upwards. Each battery mounting slot (2) has a power battery (3) installed in it. Each power battery (3) has multiple support plates (4) on its edge near the opening end of the corresponding battery mounting slot (2). Each support plate (4) is provided with the auxiliary disengagement device between it and the bottom of the corresponding battery mounting slot (2). Each power battery (3) has a battery bearing edge (6) on the side away from the opening end of the corresponding battery mounting slot (2). Multiple locking and releasing devices are provided on the outer periphery of each battery mounting slot (2) in the chassis body (1). Each locking and releasing device includes an electric telescopic mechanism (7) installed in the chassis body (1) and facing the corresponding battery mounting slot (2), and a support strip (8) connected to the telescopic shaft of the corresponding electric telescopic mechanism (7). Each support strip (8) is used to support the lower side of the corresponding battery bearing edge (6). Multiple support grooves (9) are opened on the inner wall of each battery mounting slot (2) and are slidably connected to the support strips (8) one by one. A battery protection plate (11) can be detachably connected to the lower side of the chassis body (1) at the opening end of each battery mounting slot (2). The area of ​​each battery protection plate (11) is larger than the opening area of ​​the corresponding battery mounting slot (2). Each battery protection plate (11) is detachably connected to the lower side of the corresponding power battery (3). Each battery protection plate (11) is provided with a rubber sealing strip (12) on its edge.

6. A new energy vehicle chassis according to claim 5, characterized in that, The auxiliary disengagement device is a pressure spring (5).

7. A new energy vehicle chassis according to claim 5, characterized in that, Each support bar (8) has a support groove on both the upper and lower sides. Each support groove is rotatably connected to multiple support rollers (10) perpendicular to it. Each support roller (10) extends out of the upper or lower side of the corresponding support bar (8).

8. A new energy vehicle chassis according to claim 5, characterized in that, The electric telescopic mechanism (7) is an electric hydraulic cylinder.

9. A new energy vehicle chassis according to claim 5, characterized in that, Each support plate (4) is provided with a threaded hole (13), and each battery protection plate (11) is provided with multiple connecting holes (14) corresponding to the positions of the threaded holes (13). The battery protection plate (11) and the power battery (3) are connected by bolts (15) passing through the connecting holes (14) and the threaded holes (13).

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