Multi-dimensional safety monitoring system and early warning method for battery pack

Abstract

The invention provides a multi-dimensional safety monitoring system and early warning method for a battery pack, and the system comprises a multi-sensor array which comprises a core parameter sensor which is used for collecting the core parameter data of the battery pack, and the core parameter data comprises the voltage, current and temperature of a single battery; the safety parameter sensor is used for collecting safety parameter data of the battery pack, and the safety parameter data comprises internal air pressure of the battery pack, combustible gas concentration and key electrical connection point temperature; the main controller module is in signal connection with the multi-sensor array and is used for acquiring core parameter data and safety parameter data of the battery pack, performing safety state evaluation based on multi-stage early warning logic, generating a corresponding control instruction and sending the control instruction to the execution protection module; and the execution protection module is connected with the main controller module and is used for receiving the control instruction and executing a corresponding protection action.

Description

Technical Field

[0001] This application relates to a multi-dimensional safety monitoring system and early warning method for a battery pack, belonging to the field of battery management technology. Background Technology

[0002] With the rapid development of new energy technologies, lithium-ion battery packs are widely used due to their high energy density and long cycle life. However, battery packs are susceptible to thermal runaway under abnormal conditions such as overcharging, over-discharging, short circuits, and thermal abuse, which may cause fires or explosions, seriously threatening life and property safety.

[0003] Existing battery management systems (BMS) primarily monitor basic parameters such as individual cell voltage, total voltage, current, and temperature. They lack monitoring of secondary but critical safety parameters such as internal pressure of the battery pack, concentration of combustible gases, and temperature of critical electrical connection points, and there are no corresponding early warnings or real-time monitoring.

[0004] The following limitations exist: 1) Delayed response: Protection is usually triggered only after the voltage or temperature has significantly exceeded the limit, at which point irreversible damage may have already occurred inside the battery.

[0005] 2) Single dimension: Lack of monitoring of secondary but critical safety parameters such as internal pressure of battery pack, temperature of key electrical connection points, and concentration of combustible gas.

[0006] 3) High false alarm rate: Judging solely by thresholds is prone to false alarms due to instantaneous sensor errors or interference, affecting system reliability.

[0007] 4) Lack of predictability: It is impossible to provide early warning before thermal runaway occurs, and the time window reserved for personnel evacuation and emergency response is insufficient.

[0008] Therefore, there is an urgent need for a battery pack safety monitoring system that can provide multi-dimensional, early, and accurate warnings. Summary of the Invention

[0009] In view of at least one of the above technical problems, this application provides a multi-dimensional safety monitoring system and early warning method for battery packs, which realizes early, accurate and multi-level early warning of the safety status of battery packs by fusing data from multiple sensors and performing intelligent analysis.

[0010] To solve the above-mentioned technical problems, the technical solution adopted in this application is: According to a first aspect of this application, a multi-dimensional safety monitoring system for a battery pack is provided, including a main controller module, a multi-sensor array, an execution protection module, and a communication module; The multi-sensor array includes: The core parameter sensor is used to collect core parameter data of the battery pack, including the voltage, current and temperature of the individual battery cells. A safety parameter sensor is used to collect safety parameter data of the battery pack, including internal air pressure, flammable gas concentration and temperature of critical electrical connection points. The main controller module is connected to the multi-sensor array signal to acquire the core parameter data and safety parameter data of the battery pack, and performs safety status assessment based on multi-level early warning logic, generating corresponding control commands to send to the execution protection module; The execution protection module is connected to the main controller module and is used to receive control commands and execute corresponding protection actions.

[0011] In some embodiments, the multi-dimensional safety monitoring system for the battery pack further includes a communication module connected to the main controller module, used to upload system status, warning level, and core parameter data and safety parameter data of the battery pack to the cloud platform to achieve remote monitoring.

[0012] In some embodiments, the execution protection module includes one or more of the following: a main circuit relay, a fire extinguishing device controller, a cooling controller, and an audible and visual alarm.

[0013] Correspondingly, the corresponding protection actions include: controlling the main circuit relay to disconnect, activating the fire extinguishing device, activating the cooling of the thermal management system, and activating the audible and visual alarm.

[0014] In some embodiments, the main controller module includes: The data processing unit is used to acquire and preprocess the core parameter data and safety parameter data of the battery pack; The safety status assessment unit has built-in multi-level early warning logic to determine the early warning level based on the core parameter data and safety parameter data of the battery pack; The decision output unit is used to generate corresponding control commands based on the determined warning level.

[0015] According to the second aspect of this application, a multi-dimensional safety warning method for the aforementioned battery pack is provided, including: It can acquire core and safety parameters of the battery pack in real time and monitor open flame or deflagration characteristics. Calculate the rate of change of the corresponding safety parameters based on the data of each safety parameter; The warning level is determined based on the rate of change of safety parameters, core parameter data, absolute values ​​of safety parameter data, and characteristics of open flame or deflagration, using a multi-level warning logic.

[0016] In some embodiments, determining the warning level based on multi-level warning logic includes: If the rate of change of any safety parameter exceeds the corresponding rate of change threshold, and the absolute values ​​of all core parameter data and safety parameter data do not exceed the corresponding second threshold, a level one warning is triggered. A Level 2 warning is triggered when any of the following conditions are met: The absolute value of any core parameter data or security parameter data exceeds the corresponding second threshold but is less than the corresponding third threshold; At least one core parameter data absolute value exceeds the corresponding first threshold, and at least one safety parameter change rate is greater than the corresponding change rate threshold; wherein, the severity of the second threshold is higher than that of the first threshold; A Level 3 warning is triggered when any of the following conditions are met: Open flames or deflagration characteristics were detected; At least two of the core parameter data and safety parameter data have absolute values ​​exceeding the corresponding third threshold, where the severity of the third threshold is higher than that of the second threshold.

[0017] Furthermore, in some embodiments, the multi-dimensional safety warning method for the battery pack further includes: generating corresponding control commands based on the triggered warning level and sending them to the corresponding execution protection module for execution, specifically including: If a Level 1 warning is triggered, an audible and visual alarm will be activated, and light cooling will be initiated. If a Level 2 warning is triggered, audible and visual alarms, enhanced cooling, and power limiting will be implemented. If a Level 3 warning is triggered, the system will activate an audible and visual alarm, disconnect the main circuit relay, and start the fire extinguishing device.

[0018] Furthermore, in the multi-dimensional safety monitoring system for the battery pack, the main controller module includes a processor and a storage medium; The storage medium is used to store instructions; The processor is used to operate according to the instructions to execute the multi-dimensional safety warning method for the battery pack.

[0019] According to a third aspect of this application, this application also provides a new energy device, which is equipped with the above-mentioned multi-dimensional safety monitoring system for the battery pack and uses the above-mentioned multi-dimensional safety early warning method for early warning.

[0020] The beneficial effects achieved by this application are as follows: This application has the following advantages: 1) Early warning: By monitoring thermal runaway precursor parameters such as air pressure and combustible gas concentration and their rate of change, anomalies can be identified before the temperature rises significantly, greatly advancing the warning time.

[0021] 2) Accurate judgment: The multi-parameter fusion judgment logic effectively avoids false alarms caused by single parameter fluctuations and improves the accuracy of early warning.

[0022] 3) Multi-level response: The graded early warning mechanism can match different hazard levels and implement progressive measures from warning to emergency power outage and fire extinguishing, which is both safe and avoids overprotection.

[0023] 4) Information management: Data is uploaded to the cloud through the communication module, which facilitates big data analysis and remote diagnosis, and provides data support for the full life cycle management of battery safety. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of a multi-dimensional safety monitoring system for a battery pack provided in an embodiment of this application. Detailed Implementation

[0025] The present application will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and should not be used to limit the scope of protection of the present application.

[0026] In the description of this invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0027] In the description of this invention, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0028] like Figure 1 As shown in the figure, this application provides a multi-dimensional safety monitoring system for a battery pack. It includes a main controller module, a multi-sensor array, an execution protection module, and a communication module; The multi-sensor array includes: The core parameter sensor is used to collect core parameter data of the battery pack, including the voltage, current and temperature of the individual battery cells. A safety parameter sensor is used to collect safety parameter data of the battery pack, including internal air pressure, flammable gas concentration and temperature of critical electrical connection points. The main controller module is connected to the multi-sensor array signal to acquire the core parameter data and safety parameter data of the battery pack, and performs safety status assessment based on multi-level early warning logic, generating corresponding control commands to send to the execution protection module; The execution protection module is connected to the main controller module and is used to receive control commands and execute corresponding protection actions.

[0029] It should be noted that the embodiments of this application include combustible gases (such as CO, H2) and key electrical connection points (such as copper busbars, relays).

[0030] In some embodiments, the multi-dimensional safety monitoring system for the battery pack further includes a communication module connected to the main controller module, used to upload system status, warning level, and core parameter data and safety parameter data of the battery pack to the cloud platform to achieve remote monitoring.

[0031] It should be noted that in this embodiment of the application, data is uploaded to the cloud platform through the communication module, which facilitates big data analysis and remote diagnosis, and provides data support for the full life cycle management of battery safety.

[0032] In some embodiments, the execution protection module includes one or more of the following: a main circuit relay, a fire extinguishing device controller, a cooling controller, and an audible and visual alarm.

[0033] Correspondingly, the corresponding protection actions include: controlling the main circuit relay to disconnect, activating the fire extinguishing device, activating the cooling of the thermal management system, and activating the audible and visual alarm.

[0034] In some embodiments, the main controller module includes: The data processing unit is used to acquire and preprocess the core parameter data and safety parameter data of the battery pack; The safety status assessment unit has built-in multi-level early warning logic to determine the early warning level based on the core parameter data and safety parameter data of the battery pack; The decision output unit is used to generate corresponding control commands based on the determined warning level.

[0035] This application embodiment also provides a multi-dimensional safety warning method for the above-mentioned battery pack, including: It can acquire core and safety parameters of the battery pack in real time and monitor open flame or deflagration characteristics. Calculate the rate of change of the corresponding safety parameters based on the data of each safety parameter; The warning level is determined based on the rate of change of safety parameters, core parameter data, absolute values ​​of safety parameter data, and characteristics of open flame or deflagration, using a multi-level warning logic.

[0036] Specifically, the warning level is determined based on a multi-level warning logic, taking into account the rate of change of safety parameters, core parameter data, absolute values ​​of safety parameter data, and characteristics of open flame or deflagration. This includes: If the rate of change of any safety parameter exceeds the corresponding rate of change threshold, and the absolute values ​​of all core parameter data and safety parameter data do not exceed the corresponding second threshold, a level one warning is triggered. A Level 2 warning is triggered when any of the following conditions are met: The absolute value of any core parameter data or security parameter data exceeds the corresponding second threshold but is less than the corresponding third threshold; At least one core parameter data absolute value exceeds the corresponding first threshold, and at least one safety parameter change rate is greater than the corresponding change rate threshold; wherein, the severity of the second threshold is higher than that of the first threshold; A Level 3 warning is triggered when any of the following conditions are met: Open flames or deflagration characteristics were detected; At least two of the core parameter data and safety parameter data have absolute values ​​exceeding the corresponding third threshold, where the severity of the third threshold is higher than that of the second threshold.

[0037] It should be noted that a Level 1 warning (early warning / trend warning) is an early alert to potential risks; for example, a typical scenario: 1. The internal gas pressure of the battery pack increases significantly in a short period of time (indicating that gas may be being generated).

[0038] 2. The concentration of combustible gases (such as CO and H2) inside the battery pack shows a continuous and rapid increasing trend, even though the absolute value of the concentration is still low.

[0039] 3. The temperature rise rate of critical electrical connection points is abnormal, exceeding the temperature rise curve during normal charging and discharging.

[0040] 4. Abnormal absolute rate of decrease in internal air pressure of the battery pack (indicating possible leakage, leading to seal failure).

[0041] The purpose of Level 1 warning is to identify "abnormal signs" and provide early warnings before the battery condition deteriorates significantly. By monitoring thermal runaway precursor parameters and their rate of change, such as internal air pressure, combustible gas concentration, and temperature of key electrical connection points, abnormalities can be identified before the temperature rises significantly, greatly advancing the warning time.

[0042] It should be noted that this is a Level 2 warning (moderate warning / threshold cross-warning); an example, a typical scenario: 1. The voltage of a single battery cell reaches the overcharge / over-discharge threshold.

[0043] 2. The battery module temperature exceeds the normal operating range.

[0044] 3. The absolute temperature of critical electrical connection points is too high.

[0045] 4. The absolute value of the combustible gas concentration reaches the warning level.

[0046] The purpose of a Level 2 warning is to confirm that the battery is in an unsafe state and requires immediate inspection or intervention.

[0047] It should be noted that the three-level warning (emergency warning / thermal runaway warning) is triggered, for example, in a typical scenario, when any of the following conditions are met, indicating that thermal runaway is about to occur or has already occurred: 1. Multiple core parameters are severely out of range (e.g., the temperature of multiple individual cells rises sharply and exceeds the dangerous threshold).

[0048] 2. Multiple safety parameters are severely exceeded (such as a sharp increase in internal air pressure accompanied by an explosion in the concentration of combustible gas).

[0049] 3. The combination of core parameters and safety parameters is severely exceeded (such as battery temperature runaway and the detection of open flame characteristic signals - which can be obtained through ultraviolet or flame sensors, or the air pressure instantaneously exceeds the limit).

[0050] 4. The system detected open flame or deflagration characteristics.

[0051] The purpose of a Level 3 warning is to declare that the battery pack has entered an emergency state, requiring the immediate implementation of the highest level of protective measures and an urgent notification for personnel to evacuate.

[0052] In some embodiments, the rate of change of safety parameters includes the rate of change of internal air pressure in the battery pack, the rate of change of combustible gas concentration, and the rate of change of temperature at critical electrical connection points.

[0053] In some embodiments, the multi-dimensional safety warning method for the battery pack further includes: generating corresponding control commands based on the triggered warning level and sending them to the corresponding execution protection module for execution, specifically including: If a Level 1 warning is triggered, an audible and visual alarm will be activated, and light cooling will be initiated. If a Level 2 warning is triggered, audible and visual alarms, enhanced cooling, and power limiting will be implemented. If a Level 3 warning is triggered, the system will activate an audible and visual alarm, disconnect the main circuit relay, and start the fire extinguishing device.

[0054] It should be noted that the multi-level response and graded early warning mechanism in this application embodiment can match different hazard levels and implement progressive measures, from audible and visual alarms to mild cooling, strong cooling and power limiting, to controlling the main circuit relay to disconnect emergency power and start fire extinguishing devices, which is both safe and avoids over-protection.

[0055] This application embodiment also provides a new energy device, which is equipped with the above-mentioned multi-dimensional safety monitoring system for the battery pack and uses the above-mentioned multi-dimensional safety early warning method for early warning.

[0056] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0057] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0058] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0059] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0060] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A multi-dimensional safety monitoring system for a battery pack, characterized in that, It includes a main controller module, a multi-sensor array, an execution protection module, and a communication module; The multi-sensor array includes: The core parameter sensor is used to collect core parameter data of the battery pack, including the voltage, current and temperature of the individual battery cells. A safety parameter sensor is used to collect safety parameter data of the battery pack, including internal air pressure, flammable gas concentration and temperature of critical electrical connection points. The main controller module is connected to the multi-sensor array signal to acquire the core parameter data and safety parameter data of the battery pack, and performs safety status assessment based on multi-level early warning logic, generating corresponding control commands to send to the execution protection module; The execution protection module is connected to the main controller module and is used to receive control commands and execute corresponding protection actions.

2. The multi-dimensional safety monitoring system for a battery pack according to claim 1, characterized in that, It also includes a communication module, which connects to the main controller module, and is used to upload system status, warning level, and core and safety parameter data of the battery pack to the cloud platform to achieve remote monitoring.

3. The multi-dimensional safety monitoring system for a battery pack according to claim 1, characterized in that, The execution protection module includes one or more of the following: main circuit relay, fire extinguishing device controller, cooling controller, and audible and visual alarm.

4. The multi-dimensional safety monitoring system for a battery pack according to claim 3, characterized in that, The corresponding protective actions include: controlling the main circuit relay to disconnect, activating the fire extinguishing device, activating the cooling of the thermal management system, and activating the audible and visual alarm.

5. The multi-dimensional safety monitoring system for a battery pack according to claim 1, characterized in that, The main controller module includes: The data processing unit is used to acquire and preprocess the core parameter data and safety parameter data of the battery pack; The safety status assessment unit has built-in multi-level early warning logic to determine the early warning level based on the core parameter data and safety parameter data of the battery pack; The decision output unit is used to generate corresponding control commands based on the determined warning level.

6. A multi-dimensional safety early warning method for battery packs, characterized in that, Based on the multi-dimensional safety monitoring system for the battery pack according to any one of claims 1-5, the method includes: It can acquire core and safety parameters of the battery pack in real time and monitor open flame or deflagration characteristics. Calculate the rate of change of the corresponding safety parameters based on the data of each safety parameter; The warning level is determined based on the rate of change of safety parameters, core parameter data, absolute values ​​of safety parameter data, and characteristics of open flame or deflagration, using a multi-level warning logic.

7. The multi-dimensional safety early warning method for battery packs according to claim 6, characterized in that, Based on the rate of change of safety parameters, core parameter data, absolute values ​​of safety parameter data, and characteristics of open flame or deflagration, the warning level is determined according to a multi-level warning logic, including: If the rate of change of any safety parameter exceeds the corresponding rate of change threshold, and the absolute values ​​of all core parameter data and safety parameter data do not exceed the corresponding second threshold, a level one warning is triggered. A Level 2 warning is triggered when any of the following conditions are met: The absolute value of any core parameter data or security parameter data exceeds the corresponding second threshold but is less than the corresponding third threshold; At least one core parameter data absolute value exceeds the corresponding first threshold, and at least one safety parameter change rate is greater than the corresponding change rate threshold; wherein, the severity of the second threshold is higher than that of the first threshold; A Level 3 warning is triggered when any of the following conditions are met: Open flames or deflagration characteristics were detected; At least two of the core parameter data and safety parameter data have absolute values ​​exceeding the corresponding third threshold, where the severity of the third threshold is higher than that of the second threshold.

8. The multi-dimensional safety early warning method for battery packs according to claim 7, characterized in that, Also includes: Based on the triggered warning level, corresponding control commands are generated and sent to the corresponding execution protection module for execution, specifically including: If a Level 1 warning is triggered, an audible and visual alarm will be activated, and light cooling will be initiated. If a Level 2 warning is triggered, audible and visual alarms, enhanced cooling, and power limiting will be implemented. If a Level 3 warning is triggered, the system will activate an audible and visual alarm, disconnect the main circuit relay, and start the fire extinguishing device.

9. The multi-dimensional safety monitoring system for a battery pack according to any one of claims 1-5, characterized in that, The main controller module includes a processor and a storage medium; The storage medium is used to store instructions; The processor is configured to operate according to the instructions to execute the multi-dimensional safety warning method for the battery pack according to any one of claims 6-8.

10. A new energy device, characterized in that, The new energy equipment is equipped with a multi-dimensional safety monitoring system for the battery pack as described in any one of claims 1-5 and 9, and uses a multi-dimensional safety early warning method as described in any one of claims 6-8 for early warning.

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