Energy storage PACK single-pack convenient charging equalization system and method

Abstract

The invention relates to the technical field of energy storage battery management, in particular to an energy storage PACK single-pack convenient charging equalization system and method, which is in butt joint with the outside of an energy storage PACK pack and comprises a power supply conversion module used for accessing alternating current and converting the alternating current into adjustable direct current, and a battery management module electrically connected with the power supply conversion module and used for storing the adjustable direct current. The battery management module is used for controlling the direct current output of the power supply conversion module, is in communication connection with the energy storage PACK pack, is used for collecting battery state parameters of the PACK pack in real time and generating a control signal based on the battery state parameters, the power distribution module is connected between the power supply conversion module and the power interface in series to form a charging loop, and the power distribution module is connected with the battery management module. And the charging module is used for connecting or disconnecting the charging loop according to the control signal. Through external butt joint and integration of the adjustable power supply and the battery management module, the battery state is monitored in real time, the charging process is controlled, and the technical problems that the equalization speed is low and the effect is poor during charging maintenance of an energy storage PACK single pack are solved.

Description

Technical Field

[0001] This application relates to the technical field of energy storage battery management, and in particular to a convenient charging equalization system and method for a single energy storage PACK. Background Technology

[0002] With the rapid popularization of electrochemical energy storage technology, energy storage power stations have become a common phenomenon in user-side, industrial and commercial, and backup power scenarios. These energy storage systems are usually composed of multiple energy storage PACK packages, but they face complex operation and maintenance challenges in actual use.

[0003] During the routine maintenance and charging of energy storage packs, battery balancing is a key factor in ensuring system capacity and lifespan. Currently, energy storage packs on the market generally suffer from insufficient charging balancing capabilities. Due to inconsistencies between individual battery cells, and the exacerbation of these inconsistencies during long-term cycling due to differences in self-discharge rate, internal resistance, and temperature, maintenance typically relies on simple passive balancing within the pack or basic BMS management functions.

[0004] However, internal passive balancing suffers from high energy loss, low balancing efficiency, and slow speed, making it difficult to quickly and effectively repair PACK packets that have developed serious inconsistencies. Summary of the Invention

[0005] In view of this, this application provides a convenient charging equalization system for a single energy storage PACK. By externally connecting and integrating an adjustable power supply and battery management module, it can monitor the battery status in real time and control the charging process, thus solving the technical problems of slow equalization speed and poor effect when maintaining and charging a single energy storage PACK.

[0006] This application provides a convenient charging and balancing system and method for a single energy storage PACK, which adopts the following technical solution: a convenient charging and balancing system for a single energy storage PACK, which interfaces with the external part of the energy storage PACK, including a power conversion module, a battery management module and a power distribution module integrated in the enclosure; A power conversion module is used to connect to AC power and convert it into adjustable DC power; The battery management module is electrically connected to the power conversion module to control the DC output of the power conversion module, and is communicatively connected to the energy storage PACK to collect the battery status parameters of the PACK in real time and generate control signals based on the battery status parameters. The power distribution module is connected in series between the power conversion module and the energy storage PACK to form a charging circuit; The power distribution module, connected to the battery management module, is used to connect or disconnect the charging circuit according to control signals.

[0007] By adopting the above technical solution, the system can function as an independent external device, flexibly adapting to different models of energy storage PACKs. The battery management module accurately acquires the voltage, temperature, and other status parameters of each battery cell within the pack through real-time communication, thereby controlling the power conversion module to output the most suitable DC charging voltage and current, and managing the on / off state of the power distribution circuit. This enables adjustable charging and active balancing of the PACK, effectively correcting inconsistencies between batteries and improving the overall usable capacity and lifespan of the PACK.

[0008] Optionally, control signals are generated based on battery state parameters, including: Constant current-constant voltage charging of the energy storage PACK is performed based on battery state parameters; When the battery status parameters exceed the preset first safety threshold, a control signal is generated to shut down the charging circuit. When the battery status parameters are not higher than the preset second safety threshold, a control signal is generated to connect the charging circuit. The second safety threshold is lower than the first safety threshold.

[0009] By adopting the above technical solution, safe and automatic charging management of the energy storage PACK is achieved. First, efficient energy replenishment is achieved through a standard constant current-constant voltage charging mode. When abnormal battery status is detected, such as voltage or temperature exceeding a first safety threshold, the charging circuit can be immediately cut off to prevent overcharging or overheating. Once the parameters fall back below a safe second threshold, charging automatically resumes. This hysteretic comparison control strategy avoids frequent switching on and off at critical points, ensuring both charging safety and the continuity and reliability of the charging process. More importantly, by dynamically adjusting the charging state, stable and controllable external conditions are created for active balancing. Based on real-time, detailed battery state parameters, the battery management module guides the individual battery cells within the PACK towards voltage consistency during the constant voltage charging phase by precisely controlling the DC output voltage or periodically adjusting the charging strategy. This indirectly achieves active balancing of the entire PACK at the system level, fundamentally correcting inconsistencies between batteries.

[0010] Optionally, the battery state parameters include the total voltage and total current of the energy storage PACK; constant current-constant voltage charging of the energy storage PACK based on the battery state parameters includes: The total current is compared with the preset constant current charging value to obtain the current difference; The DC output of the power conversion module is dynamically adjusted based on the current difference until the total current equals the constant current charging value. When the total voltage rises to the preset constant voltage charging value and the charging current begins to decrease, the total voltage is compared with the preset constant voltage charging value to obtain the voltage difference. The DC output of the power conversion module is dynamically adjusted based on the voltage difference until the total voltage equals the constant voltage charging value.

[0011] By adopting the above technical solution and through closed-loop feedback regulation, it is ensured that energy can be replenished quickly with a stable large current in the early stage of charging, and that a stable voltage is maintained in the later stage of charging to prevent overcharging. This not only optimizes charging efficiency, but also provides a stable and controllable charging environment. Through precise charging control, the energy storage PACK can be charged in an orderly manner to a near-fully charged and uniform voltage platform, realizing precise constant current-constant voltage charging control of the energy storage PACK.

[0012] Optionally, the battery status parameters also include the cell voltage and cell temperature of all individual cells in the energy storage PACK; when the battery status parameters exceed a preset first safety threshold, a control signal for shutting off the charging circuit is generated, including: when the cell voltage or cell temperature of any individual cell exceeds the preset first safety threshold, a control signal for shutting off the charging circuit is generated.

[0013] By adopting the above technical solution, and by monitoring each individual cell in the pack, when the voltage or temperature of any individual cell becomes abnormal and exceeds the first safety threshold, the system can immediately cut off the charging circuit, thereby taking action at the incipient stage of the fault to prevent thermal runaway or permanent damage to the entire pack caused by overcharging or overheating of individual cells.

[0014] Optionally, when the battery state parameters are not higher than a preset second safety threshold, a control signal for connecting the charging circuit is generated, including: When the cell voltage and temperature of all individual cells return to normal and are below the preset second safety threshold, a control signal is generated to connect the charging circuit.

[0015] By adopting the above technical solution, the voltage and temperature of all individual cells must recover to below the second safety threshold before the charging circuit can be reconnected. This avoids the problem of frequent switching of the charging circuit due to fluctuations in individual cells at parameter critical points, thus ensuring the stability of the charging process. More importantly, this active balancing strategy can create a safe execution window, ensuring that the system only restarts charging and performs balancing adjustments when the entire battery pack is within an absolutely safe range. This eliminates the possibility of performing high-risk balancing operations at parameter boundaries, improving the effectiveness and reliability of the balancing process.

[0016] Optionally, the power distribution module includes a DC relay; the power distribution module is connected in series between the power conversion module and the power interface to form a charging circuit, including: A DC relay is connected in series between the power conversion module and the power interface to form a charging circuit.

[0017] By adopting the above technical solution, using a DC relay as the core switching component of the charging circuit, it can withstand the large current during system operation and has the characteristic of complete physical isolation. When the battery management module issues a shutdown command, the DC relay can quickly cut off the circuit, ensuring electrical isolation between the power conversion module and the energy storage PACK, fundamentally eliminating potential dangers.

[0018] Optionally, the power distribution module may also include a drive circuit; The drive circuit is connected to the battery management module to receive control signals; The drive circuit is connected to the DC relay and is used to drive the DC relay to turn the charging circuit on or off according to the control signal.

[0019] By adopting the above technical solution, the low-power digital control signal emitted by the battery management module is accurately and quickly converted into the drive current required to directly drive the DC relay coil. This design not only effectively isolates the control unit from the power unit, protecting the delicate management chip from electrical interference such as the back electromotive force generated when the relay operates, but also ensures that every turn-off or turn-on command is executed immediately and without fail.

[0020] Optionally, control signals are generated based on battery state parameters, and previously included: The battery status parameters are validated and filtered to obtain battery processing data. Based on battery processing data, calculate at least one of the following: the voltage range, the highest voltage, the lowest voltage, and the average voltage of all individual cells in the energy storage PACK.

[0021] By adopting the above technical solution, the collected raw state parameters are preprocessed and feature values ​​are extracted before the control signal is generated. Validity verification and data filtering remove invalid data and noise caused by electromagnetic interference or sampling anomalies, ensuring data accuracy and reliability. Based on this, by calculating key statistical characteristics such as the cell voltage range, highest and / or lowest voltage, and average voltage, the battery management module can accurately quantify the degree of imbalance between individual battery cells within the energy storage PACK from a data perspective.

[0022] Optionally, it also includes a human-machine interface, which is electrically connected to the battery management module and is used to display battery status parameters in real time.

[0023] By adopting the above technical solution, the total voltage and current of the PACK, as well as the voltage, temperature, and calculated imbalance of each individual cell, can be displayed in real time. This allows operators to intuitively monitor the real-time dynamics of the charging and balancing process and accurately grasp the health status of each cell and the balancing progress of the entire energy storage PACK.

[0024] A convenient charging equalization method for a single energy storage PACK, applied to a convenient charging equalization system for a single energy storage PACK, includes the following steps: The power conversion module converts the incoming AC power into adjustable DC power. The battery management module establishes a communication connection with the energy storage PACK and collects the battery status parameters of the energy storage PACK. Based on battery state parameters, generate control signals; According to the control signal, the power distribution module connects or disconnects the charging circuit; The charging circuit is formed by connecting the power conversion module and the energy storage PACK through the power distribution module in series.

[0025] By adopting the above technical solution, the internal state of the PACK is continuously acquired through real-time communication, and the output of the DC power supply and the on / off state of the charging circuit are dynamically adjusted accordingly. This achieves a closed-loop adaptive charging and balancing mode that interfaces with the external energy storage PACK. By deeply integrating the charging process with the active balancing strategy, and automatically and seamlessly switching between various modes such as constant current charging, constant voltage charging, and safety pause based on real-time feedback of the battery status, energy replenishment is efficiently completed and inconsistencies between batteries are actively corrected while ensuring absolute safety. Ultimately, this achieves the technical effect of restoring the PACK capacity and extending its service life.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. The power conversion module, battery management module, and power distribution module are integrated into the enclosure. The power conversion module is used to accept AC power and convert it into adjustable DC power. The battery management module is electrically connected to the power conversion module to control the DC output of the power conversion module and communicates with the energy storage PACK to collect the battery status parameters of the PACK in real time and generate control signals based on the battery status parameters. The power distribution module is connected in series between the power conversion module and the energy storage PACK to form a charging circuit. The power distribution module is connected to the battery management module to connect or disconnect the charging circuit according to the control signal. It can actively regulate the entire charging equalization process according to the actual state of the battery cells inside the PACK, thereby efficiently and safely repairing battery inconsistencies without disassembling the PACK, improving the usable capacity and cycle life of the energy storage system, and solving the technical problems of slow equalization speed and poor effect of single energy storage PACK during maintenance charging. 2. By setting a safety threshold control strategy based on the voltage and temperature of individual cells and linking it with a DC relay, rapid on / off protection of the charging circuit is achieved, preventing safety risks caused by overcharging or overheating of individual cells during the charging equalization process. This provides a reliable guarantee for the system to perform efficient active equalization operations near extreme parameters, and solves the technical problem of not being able to perform deep equalization of severely inconsistent PACK packages due to insufficient safety protection in traditional maintenance methods. Attached Figure Description

[0027] Figure 1 This is a structural block diagram of a convenient charging and equalization system for a single energy storage PACK provided in an embodiment of this application; Figure 2 This is a schematic diagram of a convenient charging and equalization system for a single energy storage PACK provided in an embodiment of this application; Figure 3 This is a schematic diagram of a convenient charging and equalization device for a single energy storage PACK provided in an embodiment of this application; Figure 4 This is a flowchart illustrating the steps of a convenient charging equalization method for a single energy storage PACK provided in an embodiment of this application. Figure 5 This is a flowchart illustrating the steps of a convenient charging equalization method for a single energy storage PACK provided in an embodiment of this application.

[0028] In the picture, 1 is the foolproof base. Detailed Implementation

[0029] This application can be widely used in various energy storage battery PACK operation and maintenance scenarios, such as: battery pack maintenance of industrial and commercial energy storage stations, on-rack balancing of home energy storage, battery maintenance of electric vehicle battery swapping stations, capacity restoration of backup power for communication base stations, and sorting and processing of waste batteries before their reuse.

[0030] This application provides a convenient charging and equalization system for a single energy storage PACK, which can be directly applied to on-site maintenance, warehouse capacity allocation, and after-sales service outlets. The system can be operated by power station maintenance personnel, battery repair technicians, or battery swapping robots. As a standalone portable device, this system offers an efficient, safe, and low-cost solution to the voltage and capacity imbalance problem caused by long-term use, mixed batch use, or single-pack replacement of battery packs.

[0031] Specifically, the system externally interfaces with the energy storage PACK to be maintained via a power interface and a communication interface. The power interface is integrated into a dedicated foolproof base 1. Through an asymmetrical design in its physical structure, it ensures that the PACK can only be connected to the system in one correct orientation, fundamentally eliminating the risk of reverse power connection due to misoperation and achieving hardware reverse connection protection.

[0032] Specifically, after the device successfully connects to and powers on the energy storage PACK to be maintained via the power and communication interface, the system can achieve active charging and precise balancing of a single pack. For example, during routine inspections of energy storage power stations, if the voltage of a battery pack deviates significantly from the cluster average, this system can be used for independent balancing maintenance without removing or disassembling the entire battery cluster, greatly improving operational efficiency. Furthermore, in battery swapping stations, this system can be used to quickly calibrate the capacity and voltage of battery packs from different batches with slight voltage differences, ensuring the consistency of the batteries on the rack and thus guaranteeing the power performance of the entire energy storage system or vehicle.

[0033] The convenient charging and balancing system for a single energy storage PACK provided in this application addresses the long-standing technical pain points in the industry, such as the need for unpacking during balancing operations, the time-consuming nature of the process, high costs, and the lack of individual cell protection. This improves the management efficiency and economics of energy storage batteries throughout their entire lifecycle. Furthermore, the system design and application strictly adhere to battery safety management standards, incorporating multiple protection mechanisms to ensure convenient balancing while fundamentally eliminating safety risks such as overcharging and overheating, thus protecting personal and property safety.

[0034] It should be noted that the energy storage PACK single-pack convenient charging and equalization system described in this application adopts a highly integrated integrated design, which is composed of a power conversion module, a battery management module and a power distribution module.

[0035] Preferably, the system is built using a modular integrated architecture, with all core components integrated into a portable case.

[0036] Please refer to Figures 1-3 A convenient charging and equalization system for a single energy storage PACK, which interfaces with the external energy storage PACK via a power interface and a communication interface, includes a power conversion module, a battery management module, and a power distribution module. A power conversion module is used to connect to AC power and convert it into adjustable DC power; The battery management module is electrically connected to the power conversion module to control the DC output of the power conversion module, and is communicatively connected to the energy storage PACK to collect the battery status parameters of the PACK in real time and generate control signals based on the battery status parameters. The power distribution module is connected in series between the power conversion module and the power interface to form a charging circuit; The power distribution module is connected to the battery management module and is used to connect or disconnect the charging circuit according to the control signal.

[0037] It should be noted that the power conversion module refers to the energy conversion unit that converts the incoming AC mains power into DC power required for charging the battery pack. Its output voltage range is adjustable between 40V and 130V, and the maximum output current is not less than 30A. Technicians can flexibly set the output parameters according to the rated voltage of the PACK to be balanced and the current status.

[0038] Preferably, the power conversion module is equipped with a CAN communication interface and is connected to the battery management module. The battery management module sends commands to the power conversion module through the CAN bus to dynamically set its output voltage limit and output current limit, thereby achieving precise control of the DC output and ensuring the safety of the charging process and the effective execution of the equalization strategy.

[0039] The power distribution module, serving as the on / off execution unit of the main charging circuit, consists of a high-power DC relay and a drive circuit. By connecting the DC relay in series in the main charging circuit, it receives and quickly responds to on / off commands issued by the battery management module, achieving real-time protection and precise balancing strategies. Specifically, the DC relay is connected in series between the power conversion module and the power interface to form a charging circuit.

[0040] Furthermore, to enhance system safety, a fuse is connected in series in the charging circuit between the DC relay and the power interface. Under normal fault conditions, the DC relay will be the first to respond to the battery management module's command and quickly disconnect the circuit; in the event of extreme faults such as severe short circuits, the fuse will act as a final safety measure to blow in a timely manner, completely cutting off the circuit and preventing the accident from escalating.

[0041] In this embodiment, the battery management module monitors and analyzes the battery status parameters in real time, generates control signals based on the battery status parameters, and then the power distribution module connects or disconnects the charging circuit based on the control signals to achieve safety protection and equalization intervention.

[0042] Preferably, the battery management module refers to the battery management system (BMS). The battery management module communicates with the energy storage PACK package through a communication interface to collect the battery status parameters of the PACK package in real time.

[0043] The battery status parameters include total voltage, total current, cell voltage and cell temperature of all cells in the energy storage PACK.

[0044] Preferably, the battery state parameters are validated and filtered to obtain battery processing data; based on the battery processing data, at least one of the following is calculated: the range, highest voltage, lowest voltage, and average voltage of all individual cells in the energy storage PACK.

[0045] In this embodiment, the battery management module interacts with the slave control unit (BMU) in the PACK package through a preset communication protocol (such as CAN 2.0B) to obtain the voltage and temperature sampling values ​​of all individual cells at a fixed acquisition period (such as 100ms). At the same time, the built-in 16-bit ADC acquisition chip monitors the total voltage and total current of the PACK package in real time.

[0046] It is worth mentioning that, during the data processing stage, the system first verifies the validity of the original sampled values, eliminating abnormal values ​​caused by communication interference or invalid data due to electromagnetic interference or sampling anomalies. A first-order hysteresis filtering algorithm is then applied to the continuously sampled data to suppress signal noise, ultimately obtaining stable and reliable battery processing data. Based on the processed data, the microcontroller of the battery management module executes a voltage characteristic value calculation program, analyzing and updating characteristic values ​​such as the voltage range, highest voltage, lowest voltage, and arithmetic mean voltage of individual battery cells in real time, ensuring the accuracy and reliability of the data.

[0047] Furthermore, based on the characteristic values ​​such as the voltage range, highest voltage, lowest voltage, and arithmetic mean voltage of individual cells obtained through real-time analysis, the degree of imbalance between individual cells within an energy storage PACK can be accurately quantified from a data perspective. Specifically: Suppose that the energy storage PACK consists of N cells connected in series, and the set of individual cell voltages is {V1, V2, ..., V...} N}

[0048] First, calculate the voltage set {V1,V2,...,V...} N Basic statistics of} 1) The average voltage μ is expressed as: Where μ is the arithmetic mean of the voltages of all individual cells; N is the number of cells; V i Let be the voltage of the i-th individual cell. In this embodiment, the average voltage is used to characterize the central tendency of the voltage distribution.

[0049] 2) Voltage range, its expression is: R = max({V1,V2,…,V...) N})-min({V1,V2,…,V N}); Where R is the voltage range; max({V1,V2,…,V N}) represents the maximum value in the voltage set, i.e., the highest single cell voltage V. max min({V1,V2,…,V N}) represents the minimum value in the voltage set, i.e., the lowest single-cell voltage V. minIn this embodiment, the voltage range can directly reflect the absolute discrete range of voltage distribution within the battery pack, and can serve as the most intuitive indicator for measuring overall imbalance.

[0050] 3) Voltage standard deviation σ, the expression is: In this embodiment, the standard deviation can sensitively characterize the overall deviation of all individual voltages from the average value, making up for the shortcomings of the range, which only focuses on the extreme values ​​at both ends and ignores the overall internal distribution.

[0051] In the actual assessment of imbalance, the calculated range R and standard deviation σ are compared with preset multi-level thresholds. Let the first-level equilibrium threshold be R. th1 and σ th1 The level 2 warning threshold is R. th2 and σ th2 And satisfy R th2 >R th1 , σ th2 >σ th1 .

[0052] Preferably, when the range R ≤ R th1 And σ≤σ th1 When the PACK is determined to be in an equalized state, the standard constant current-constant voltage charging process is executed, which specifically includes: The total current is compared with the preset constant current charging value to obtain the current difference; The DC output of the power conversion module is dynamically adjusted based on the current difference until the total current equals the constant current charging value. When the total voltage rises to the preset constant voltage charging value and the charging current begins to decrease, the total voltage is compared with the preset constant voltage charging value to obtain the voltage difference. The DC output of the power conversion module is dynamically adjusted based on the voltage difference until the total voltage equals the constant voltage charging value.

[0053] In this embodiment, during the constant current charging phase, the battery management module collects the total current I of the PACK pack at fixed intervals (e.g., 10 times per second). pack And compare it with the preset constant current charging setting value I set Compare and calculate the current error e I =I set -I pack Then, the current error value e I The signal is fed into a digital PID (proportional-integral-derivative) controller, which outputs a corresponding pulse-width modulation (PWM) signal or analog voltage signal to the feedback control terminal of the power conversion module. This dynamically adjusts the DC output voltage, forming a negative feedback closed loop. This adjustment process continues until e...I It approaches 0, meaning the actual total current stabilizes at the constant current charging set value.

[0054] When the battery management module detects the total voltage V pack Rise to the preset constant voltage charging setting value V set When the charging current has exceeded its peak and begins to show a continuous downward trend, the system determines that the constant current charging phase has ended and automatically switches to the constant voltage charging phase. In this phase, the control core switches to the voltage loop. The battery management module then calculates the voltage error e. V =V set -V pack Similarly, a control signal is generated through a PID controller to adjust the output of the power conversion module, ensuring that its DC output voltage is precisely stabilized at the constant voltage charging setpoint. As charging progresses, the charging current will naturally decrease due to the increase in battery potential. When the current drops to the preset charging termination current (e.g., 0.05C), the battery management module determines that charging is complete and controls the power distribution module to disconnect the charging circuit.

[0055] It should be noted that constant current-constant voltage charging needs to be performed under the premise that the PACK pack is well balanced, in order to fully charge the battery at the optimal speed and efficiency, while ensuring basic safety during the charging process.

[0056] Preferably, when R is satisfied th1 <R≤R th2 or σ th1 <σ≤σ th2 At this point, the system determines the voltage imbalance to be moderate. In this state, the system will intervene in the basic charging process with a pulse-based balancing strategy. This involves dynamically switching the charging circuit on and off based on the individual cell voltage to suppress the rise of the highest-voltage cell and promote overall voltage convergence. Specifically: When the cell voltage or cell temperature of any single cell exceeds a preset first safety threshold, a control signal is generated to shut off the charging circuit. When the cell voltage and temperature of all individual cells return to normal and are below the preset second safety threshold, a control signal is generated to connect the charging circuit.

[0057] In this embodiment, during the constant current charging process, the system scans the voltage of all individual battery cells in real time. and temperature The first safety threshold includes the overvoltage protection point V. ovp and over-temperature protection point T ot Once the voltage of any single cell is detected (V ovp (For overvoltage protection points) or temperature (T otIf the circuit is over-temperature protected, it will immediately exceed the current constant current or constant voltage control and send a low-level (or high-level) shutdown signal to the drive circuit of the power distribution module. The signal drives the DC relay coil to de-energize, causing its normally open main contacts to quickly open, forcibly cutting off the main charging circuit and preventing the highest voltage cell from further developing into an overcharged state, thus achieving voltage clamping.

[0058] After the charging circuit is shut off, the system continuously monitors the status of all individual battery cells. The system only generates a reconnection signal when both of the following conditions are met simultaneously: the status of the elevator electrical circuits meets the second safety threshold. The second safety threshold includes the recharge voltage point and the operating temperature range. 1) Voltage conditions: Voltage of all individual cells All need to decrease and stabilize at V rch Below the (recharge voltage point), i.e., max{V1,V2,…,V N}≤V rch And usually V is set rch <V ovp This creates hysteresis to prevent frequent on / off cycles.

[0059] 2) Temperature conditions: Temperature of all individual battery cells All have returned to the normal operating temperature range (T). normal Within.

[0060] When the above conditions are met, the battery management module sends an activation signal to the drive circuit of the power distribution module, which in turn drives the relay contacts to close, restoring the charging circuit and repeating the equalization judgment.

[0061] In this embodiment, a cycle of monitoring-shutdown-waiting-recovery may occur multiple times during a complete charging process, thus forming a pulsed charging current on a macroscopic scale. This strategy, through microscopic active intervention, can effectively limit the voltage increase of high-voltage cells, providing catch-up time for cells with lower capacity or lower voltage, and ultimately causing the voltage of all individual cells in the PACK to converge and become consistent, achieving safe and efficient online balancing.

[0062] Preferably, when R > R th2 Or σ > σ th2 If the system determines that the battery is severely unbalanced, it will issue an audible and visual alarm and halt the charging process to prevent safety risks caused by overcharging or aging of individual battery cells.

[0063] In this embodiment, the severe imbalance state determination and handling mechanism serves as the system's ultimate safety defense. When the battery management module detects in real-time that either the voltage range R or the voltage standard deviation σ exceeds the secondary warning threshold (i.e., R...), the system will take action. th2 or σ th2Upon this event, the severe imbalance handling procedure is immediately triggered. This procedure performs the following non-automatically recoverable protection operations: 1) Permanently stop charging: The battery management module sends a lockout shutdown signal to the power distribution module. This signal drives the DC relay to disconnect the charging circuit and prohibits all requests for automatic reconnection charging until the system is manually reset by maintenance personnel. This fundamentally cuts off the energy input and prevents the risk of thermal runaway that may be caused by continuous charging under severely inconsistent conditions.

[0064] 2) Activate audible and visual alarm: The battery management module simultaneously drives the audible and visual alarm unit connected to its control port. For example, it controls a red LED indicator to enter fast-flash mode and triggers a buzzer to emit a continuous alarm sound, providing clear and urgent visual and auditory indications to on-site operators, indicating that there is a safety hazard that needs to be dealt with immediately.

[0065] 3) Record and report fault information: When issuing an alarm, the battery management module will record a fault log in its non-volatile memory, including information such as timestamp, range R, standard deviation σ, and the specific cell voltage that triggered the alarm. If the system is equipped with remote communication capabilities (such as a 4G or Wi-Fi module), it will automatically upload this fault log and alarm signal to the cloud management platform to notify the remote monitoring center.

[0066] In this embodiment, this setting is designed for abnormal conditions such as permanent damage or connection failures that may exist inside the battery pack, which are beyond the correction range of pulse equalization. Forced charging is high-risk, and this design ensures the highest level of safety and reliability in complex application scenarios.

[0067] Preferably, the system also includes a human-machine interface, which is electrically connected to the battery management module and is used to display battery status parameters in real time.

[0068] In this embodiment, the human-machine interface can be an LCD screen integrated on the surface of the portable case. The screen can be connected to the microcontroller unit of the battery management module via SPI or I2C communication bus.

[0069] During system operation, the battery management module encapsulates key battery status parameters and system status information into data frames at a fixed refresh cycle (e.g., once per second) and sends them to the LCD display driver chip.

[0070] In this embodiment, the displayed content adopts a layered and grouped layout, capable of displaying information such as PACK-level overview, cell-level key data, system status, and alarms. The PACK-level overview refers to the total PACK voltage, total current, current charging status (e.g., "constant current charging," "constant voltage charging," "balancing," "alarm"), and cumulative charging capacity. Cell-level key data is displayed by scrolling or listing the voltage of all individual cells, with the highest voltage V highlighted. max With the lowest voltage V min Simultaneously, it displays the calculated voltage range R. The system status and alarms are based on real-time calculated balance indicators (such as voltage standard deviation σ), and when the system enters a state of moderate imbalance or triggers severe imbalance protection, it displays corresponding status information such as balancing in progress or severe imbalance, as well as prompts such as protection in progress and specific alarm codes.

[0071] In addition, the human-computer interaction interface can also be equipped with several physical buttons, such as selection buttons and confirmation buttons, allowing users to view different information pages, query historical alarm records, or view some charging parameters within a safe and permissible range without relying on external devices, thereby improving the convenience of equipment operation and the intuitiveness of on-site maintenance.

[0072] Preferably, the DC relay includes a positive relay and a precharge relay.

[0073] In this embodiment, to avoid the instantaneous high current surge caused by the initial zero voltage of the capacitors in the PACK when the charging circuit is connected, the power distribution module adopts a dual relay topology structure of positive relay + pre-charge relay + pre-charge resistor to construct a graded conduction charging circuit protection mechanism. The positive relay is the final actuator switch of the main charging circuit, capable of carrying the system's rated operating current (e.g., 30A). The pre-charge relay and pre-charge resistor are connected in series, and then in parallel with the positive relay to form the pre-charge branch. The resistance value of the pre-charge resistor needs to be calculated and determined based on the PACK capacitor capacity and the allowable peak pre-charge current; typically, a 10-50Ω / 50W power resistor is selected to limit the initial surge current during the pre-charge stage to a safe range (e.g., ≤5A).

[0074] During the charging circuit startup phase, the battery management module follows a control logic of pre-charging followed by main circuit activation, completing the circuit activation in two steps: 1) Pre-charge stage: The battery management module first sends a pre-charge control signal to the drive circuit, driving the pre-charge relay to engage. At this time, the DC power output from the power conversion module flows into the PACK pack through the pre-charge relay-pre-charge resistor-power interface path, slowly charging the capacitors inside the pack. During this process, the battery management module monitors the rate of increase of the total voltage of the PACK pack in real time. When the total voltage rises from the initial value (such as 0V or residual voltage) to more than 90% of the output voltage of the power conversion module and remains stable for 1-3 seconds, the pre-charge process is considered complete, the capacitors inside the pack are fully charged, and the risk of circuit surge is eliminated.

[0075] 2) Main Circuit On-line Phase: After pre-charging is complete, the battery management module sends a positive relay engagement signal to the drive circuit. After detecting the engagement status signal from the positive relay (confirmed via auxiliary contacts or voltage detection), a pre-charge relay de-energization signal is sent after a 50-100ms delay. This delay design avoids a brief circuit break during the switching between the two relays, ensuring a continuous and stable charging current. Finally, the charging current flows to the PACK pack through the low-impedance main path of the positive relay-power interface, and the system enters the constant current charging or equalization charging phase.

[0076] During the charging circuit shutdown phase, the battery management module employs a logic of first disconnecting the main charging current and then disconnecting the pre-charge current (if the pre-charge relay is not disconnected). It prioritizes disconnecting the positive relay to quickly stop the main charging current, and then decides whether to disconnect the pre-charge relay based on the system status, further ensuring the safety of the shutdown process. Simultaneously, the drive circuit incorporates overcurrent protection and back EMF absorption circuits. When abnormal current occurs at the moment the relay engages or disengages, or when the coil is de-energized and generates reverse voltage, the current is quickly limited and reverse energy is absorbed to prevent damage to the battery management module's control chip, ensuring the reliability of the relay operation and the long-term stability of the entire power distribution module.

[0077] The implementation principle of this application embodiment is as follows: By integrating the power conversion module, battery management module, and power distribution module into one unit, an externally independent energy storage PACK single-pack charging balancing system is constructed. First, the power conversion module converts the incoming AC power into adjustable DC power. The battery management module establishes real-time communication with the energy storage PACK via a communication interface, continuously collecting state parameters such as total voltage, total current, and voltage and temperature of all individual cells within the pack. After validity verification and data filtering, characteristic values ​​such as cell voltage range, highest / lowest voltage, and average voltage are calculated to quantify the degree of battery imbalance. Based on this, a control signal is dynamically generated to regulate the DC output of the power conversion module, achieving constant current-constant... The voltage charging mode switching adapts to the needs of different charging stages. On the other hand, it controls the graded action of the positive relay, pre-charge relay and pre-charge resistor in the power distribution module: at startup, the capacitor pre-charge is completed by limiting the inrush current through the pre-charge branch, and then the main circuit is turned on to enter stable charging. In case of abnormality (such as the individual cell voltage / temperature exceeding the first safety threshold), the circuit is immediately cut off. After normal recovery (all individual cell parameters are below the second safety threshold), it is reconnected. At the same time, the status parameters are displayed in real time through the human-machine interface. Finally, without disassembling the pack, safe and efficient active equalization of energy storage PACK single pack charging is achieved, which solves the problems of low efficiency, poor safety and complicated operation of traditional equalization methods.

[0078] Please refer to Figures 1-3 A convenient charging equalization method for a single energy storage PACK includes: Step 201: The power conversion module converts the incoming AC power into adjustable DC power.

[0079] Step 202: Establish a communication connection between the battery management module and the energy storage PACK, and collect the battery status parameters of the energy storage PACK.

[0080] Step 203: Generate a control signal based on the battery state parameters.

[0081] Step 204: According to the control signal, the power distribution module connects or disconnects the charging circuit.

[0082] The charging circuit is formed by connecting the power distribution module in series between the power conversion module and the energy storage PACK.

[0083] In this embodiment, the convenient charging and balancing method for a single energy storage PACK is implemented by the convenient charging and balancing system for a single energy storage PACK. Its specific content and logic are similar to those of the convenient charging and balancing system for a single energy storage PACK, and will not be described again here.

[0084] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A convenient charging and equalization system for an energy storage PACK single package, which is connected to the outside of the energy storage PACK package through a power interface and a communication interface, characterized in that, The power conversion module, the battery management module and the power distribution module are integrated in the box; The power conversion module is used for converting alternating current into adjustable direct current; The battery management module is electrically connected with the power conversion module, is used for controlling the direct current output of the power conversion module, and is in communication connection with the energy storage PACK package, is used for collecting the battery state parameters of the PACK package in real time, and generates a control signal based on the battery state parameters; The power distribution module is connected in series between the power conversion module and the power interface, forming a charging loop; The power distribution module is connected with the battery management module, and is used for turning on or turning off the charging loop according to the control signal.

2. The energy storage PACK single-pack convenient charging equalization system according to claim 1, characterized in that, The control signal is generated based on the battery state parameters, including: Constant current-constant voltage charging is performed on the energy storage PACK package based on the battery state parameters; When the battery state parameters exceed a preset first safety threshold, a control signal for turning off the charging loop is generated; When the battery state parameters are not higher than a preset second safety threshold, a control signal for turning on the charging loop is generated; The second safety threshold is lower than the first safety threshold.

3. The energy storage PACK single pack convenient charging equalization system according to claim 2, characterized in that, The battery state parameters include the total voltage and total current of the energy storage PACK package; and the constant current-constant voltage charging is performed on the energy storage PACK package based on the battery state parameters, including: The total current is compared with a preset constant current charging value to obtain a current difference value; The direct current output of the power conversion module is dynamically adjusted based on the current difference value until the total current is equal to the constant current charging value; When the total voltage rises to a preset constant voltage charging value and the charging current begins to decrease, the total voltage is compared with the preset constant voltage charging value to obtain a voltage difference value; The direct current output of the power conversion module is dynamically adjusted based on the voltage difference value until the total voltage is equal to the constant voltage charging value.

4. The energy storage PACK single pack convenient charging equalization system according to claim 2, characterized in that, The battery state parameters further include the cell voltage and cell temperature of all monomers in the energy storage PACK package; and when the battery state parameters exceed a preset first safety threshold, the control signal for turning off the charging loop is generated, including: When the cell voltage or cell temperature of any monomer exceeds a preset first safety threshold, the control signal for turning off the charging loop is generated.

5. The energy storage PACK single pack convenient charging equalization system according to claim 4, characterized in that, When the battery state parameters are not higher than a preset second safety threshold, the control signal for turning on the charging loop is generated, including: When the cell voltage and temperature of all monomers return to normal and are lower than a preset second safety threshold, the control signal for turning on the charging loop is generated.

6. The energy storage PACK single pack convenient charging equalization system according to claim 1, characterized in that, The power distribution module includes a direct current relay; and the power distribution module is connected in series between the power conversion module and the power interface, forming a charging loop, including: The direct current relay is connected in series between the power conversion module and the power interface, forming a charging loop.

7. The energy storage PACK single pack convenient charging equalization system according to claim 6, characterized in that, The power distribution module further includes a driving circuit; The driving circuit is connected with the battery management module and is used for receiving the control signal; The driving circuit is connected with the direct-current relay, and is used for driving the direct-current relay to turn on or turn off the charging circuit according to the control signal.

8. The energy storage PACK single pack convenient charging equalization system according to claim 1, characterized in that, The generating control signal based on the battery state parameter further comprises: The battery state parameter is subjected to validity verification and data filtering processing to obtain battery processing data. Based on the battery processing data, at least one of the range, the highest voltage, the lowest voltage and the average voltage of the cell voltages of all the monomers in the energy storage PACK package is calculated.

9. The energy storage PACK single pack convenient charging equalization system according to claim 1, characterized in that, Further comprising a human-computer interaction interface, the human-computer interaction interface is electrically connected with the battery management module, and is used for real-time display of the battery state parameter.

10. A method for energy storage PACK single package convenient charging equalization, applied to the energy storage PACK single package convenient charging equalization system of claims 1-9, characterized in that, The method comprises: Through the power conversion module, the accessed alternating current is converted into adjustable direct current; Through the battery management module and the energy storage PACK package, a communication connection is established, and the battery state parameter of the energy storage PACK package is collected; Based on the battery state parameter, a control signal is generated; According to the control signal, the power distribution module turns on or turns off the charging circuit; The charging circuit is formed by connecting the power conversion module and the energy storage PACK package in series through the power distribution module.

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