Automatic abnormity early warning device based on multiple parameters

Abstract

The invention relates to an automatic abnormity early warning device based on multiple parameters, which is used for an aging process of a charger and comprises a temperature detection module used for detecting a first temperature parameter and a second temperature parameter of the charger; the electric signal detection module is used for detecting a first voltage signal parameter and a first current signal parameter of the charger; the control module is used for generating a first abnormity early warning signal or a second abnormity early warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter or the first current signal parameter; and the early warning module is used for executing a first early warning operation based on the first abnormal early warning signal or executing a second early warning operation based on the second early warning signal. The abnormal automatic early warning device based on multiple parameters can monitor the multiple parameters, different early warning results are generated based on the monitoring results of the multiple parameters, the correct state of the aged charger can be judged, and missing report and false report are avoided.

Description

Technical Field

[0001] This invention relates to the field of automated monitoring and early warning, and more specifically, to an automatic early warning device for anomalies based on multiple parameters. Background Technology

[0002] In industrial equipment monitoring scenarios, the operating environments of most devices are complex and varied, resulting in low accuracy in early warning of device malfunctions. For example, in charger aging tests, the operating environment is composed of factors such as EMC, temperature, and humidity, and currently, the accuracy of early warnings for operational anomalies in charger aging tests is low. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an automatic early warning device for anomalies based on multiple parameters, which monitors multiple parameters and generates different early warning results based on the monitoring results, and can determine the correct state of an aging charger.

[0004] The technical solution adopted by this invention to solve its technical problem is: constructing an automatic early warning device for abnormalities based on multiple parameters for use in the aging process of a charger, comprising: A temperature detection module is used to detect the first temperature parameter and the second temperature parameter of the charger. The electrical signal detection module is used to detect the first voltage signal parameter and the first current signal parameter of the charger; The control module is used to generate a first abnormality warning signal or a second abnormality warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter, or the first current signal parameter. The early warning module is used to perform a first early warning operation based on the first abnormal early warning signal or to perform a second early warning operation based on the second early warning signal.

[0005] In the multi-parameter-based automatic early warning device for anomalies described in this invention, the generation of a first or second anomaly warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter, or the first current signal parameter includes: When the first temperature parameter is less than the first set temperature, and the second temperature parameter is within the first temperature range, or the first voltage signal parameter is outside the first voltage range, or the first current signal parameter is outside the first current range, the first abnormal warning signal is generated. When the first temperature parameter is greater than or equal to the second set temperature, or the second temperature parameter is greater than the third set temperature, or the first voltage signal parameter is outside the second voltage range, or the second current signal parameter is outside the second current range, the second abnormal warning signal is generated.

[0006] In the multi-parameter-based automatic early warning device for abnormalities described in this invention, the first set temperature, the second set temperature, the third set temperature, the first temperature range, the second temperature range, the first voltage range, the second voltage range, the first current range, and the second current range are based on the power settings of the charger. The second set temperature is greater than or equal to the first set temperature; The first abnormality warning signal includes a first buzzer signal, a first warning light signal, a first text signal, and a first relay signal; the second abnormality warning signal includes a second buzzer signal, a second warning light signal, a second text signal, and a second relay signal. The text signals include temperature-related reminders, voltage-related reminders, and current-related reminders.

[0007] In the multi-parameter-based automatic early warning device for abnormalities described in this invention, the temperature detection module includes an infrared thermal imager and a thermocouple; the infrared thermal imager is aimed at the charger to detect the maximum temperature value in the infrared thermal imaging field of view of the charger; the thermocouple is connected to the air outlet of the charger to detect the temperature value of the charger. The electrical signal detection module includes a voltage detection unit and a current detection unit; the voltage detection unit is used to detect the output voltage of the charger, and the current detection unit is used to detect the output current of the charger.

[0008] In the multi-parameter-based automatic early warning device for abnormalities described in this invention, the temperature detection module is further used to detect a third temperature parameter of the charger. The electrical signal detection module is further used to detect the second voltage signal parameter and the second current signal parameter of the charger.

[0009] In the multi-parameter-based automatic early warning device for anomalies described in this invention, the control module is further configured to: A first power signal parameter is generated based on the first voltage signal parameter and the first current signal parameter; a second power signal parameter is generated based on the second voltage signal parameter and the second current signal parameter; and a percentage parameter is generated based on the first power signal parameter and the second power signal parameter. The first abnormality warning signal or the second abnormality warning signal is generated based on the first temperature parameter, the second temperature parameter, the third temperature parameter, the first power signal parameter, or the percentage parameter. The percentage parameter is equal to the first power signal parameter / (first power signal parameter + second power signal parameter).

[0010] In the multi-parameter-based automatic early warning device for anomalies described in this invention, the generation of the first anomaly warning signal or the second anomaly warning signal based on the first temperature parameter, the second temperature parameter, the third temperature parameter, the first power signal parameter, or the percentage parameter includes: When the first temperature parameter is less than the first set temperature, and the second temperature parameter is within the first temperature range, or the third temperature parameter is within the second temperature range, or the first power signal parameter is within the first power range, or the percentage parameter is within the percentage range, the first abnormal warning signal is generated. When the first temperature parameter is greater than or equal to the second set temperature, or the second temperature parameter is greater than the third set temperature, or the third temperature parameter is greater than the fourth set temperature, or the first power signal parameter is greater than the first power setting parameter, or the percentage parameter is greater than the first set percentage, the second abnormal warning signal is generated.

[0011] In the multi-parameter-based automatic early warning device for anomalies described in this invention, the thermocouple includes a first thermocouple and a second thermocouple. The first thermocouple is installed in the battery pack of the charger to detect the temperature value of the battery pack, and the second thermocouple is installed in the battery management circuit of the charger to detect the temperature value of the management circuit. The electrical signal detection module includes a first voltage detection unit, a second voltage detection unit, a first current detection unit, and a second current detection unit; The first voltage detection unit is used to detect the management circuit voltage of the battery management circuit; the first current detection unit is used to detect the input and output current of the battery management circuit; the second voltage detection unit is used to detect the battery pack voltage of the battery pack; and the second current detection unit is used to detect the input and output current of the battery pack.

[0012] In the multi-parameter-based automatic early warning device for abnormalities described in this invention, the first set temperature, the second set temperature, the third set temperature, the fourth set temperature, the first power setting parameter, the percentage parameter, the first temperature range, the second temperature range, the first power range, and the percentage range are based on the power setting of the charger. The first abnormality warning signal includes a first buzzer signal, a first warning light signal, a first text signal, and a first relay signal; the second abnormality warning signal includes a second buzzer signal, a second warning light signal, a second text signal, and a second relay signal. The second set temperature is greater than or equal to the second set temperature; The text signals include temperature-related reminders, power-related reminders, and consumption-related reminders.

[0013] In the multi-parameter-based automatic early warning device for abnormalities described in this invention, the early warning module includes a buzzer, an early warning light, a communication module, and a relay. The charger and the AC power source are connected via a contactor, and the relay is connected to the control terminal of the contactor. The buzzer emits a first buzzing sound based on the first buzzer signal or emits a second buzzing sound based on the second buzzer signal; The warning light emits light of a first color based on the first warning light signal or emits light of a second color based on the second warning light signal; The communication module is used to send the first text signal or the second text signal; The relay is disconnected based on the first relay signal or closed based on the second relay signal to control the charger to maintain or terminate the aging process.

[0014] The present invention provides a multi-parameter-based automatic anomaly warning device, comprising a temperature detection module, an electrical signal detection module, a control module, and an early warning module. The temperature detection module detects a first temperature parameter and a second temperature parameter of the charger. The electrical signal detection module detects a first voltage signal parameter and a first current signal parameter of the charger. The control module generates a first anomaly warning signal or a second anomaly warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter, or the first current signal parameter. The early warning module performs a first early warning operation based on the first anomaly warning signal or a second early warning operation based on the second early warning signal. Therefore, the multi-parameter-based automatic anomaly warning device of the present invention can monitor multiple parameters and generate different early warning results based on the monitoring results of multiple parameters. This allows it to be judged based on the correct state of an aging charger, avoiding missed and false alarms. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings: Figure 1 This is a schematic diagram of a preferred embodiment of the automatic early warning device for anomalies based on multiple parameters of the present invention. Figure 2 This is a schematic diagram of the control logic for the first minor anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 3 This is a schematic diagram of the control logic for the first severe anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 4This is a schematic diagram of the circuit connection between the multi-parameter-based automatic early warning device for abnormalities and the charger of the present invention; Figure 5 This is a schematic diagram of the control logic for the second minor anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 6 This is a schematic diagram of the control logic for the second severe anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 7 This is another circuit connection diagram of the multi-parameter-based automatic early warning device for abnormalities and the charger of the present invention; Figure 8 This is a schematic diagram of the control logic for the third minor anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 9 This is a schematic diagram of the control logic for the third severe anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0017] Figure 1 This is a schematic block diagram of a preferred embodiment of the multi-parameter-based automatic anomaly early warning device of the present invention. Figure 1 As shown, the multi-parameter-based automatic anomaly warning device of the present invention includes: a temperature detection module 100, an electrical signal detection module 200, a control module 300, and an early warning module 400. The temperature detection module 100 is used to detect a first temperature parameter and a second temperature parameter of the charger. The electrical signal detection module 200 is used to detect a first voltage signal parameter and a first current signal parameter of the charger. The control module 300 is used to generate a first anomaly warning signal or a second anomaly warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter, or the first current signal parameter. The early warning module 400 is used to perform a first early warning operation based on the first anomaly warning signal or a second early warning operation based on the second early warning signal.

[0018] In a preferred embodiment of the present invention, when the first temperature parameter is less than the first set temperature and the second temperature parameter is within the first temperature range, or the first voltage signal parameter is outside the first voltage range, or the first current signal parameter is outside the first current range, the first abnormal warning signal is generated; when the first temperature parameter is greater than or equal to the second set temperature, or the second temperature parameter is greater than the third set temperature, or the first voltage signal parameter is outside the second voltage range, or the second current signal parameter is outside the second current range, the second abnormal warning signal is generated.

[0019] In a preferred embodiment of the present invention, the first set temperature, the second set temperature, the third set temperature, the first temperature range, the second temperature range, the first voltage range, the second voltage range, the first current range, and the second current range are set based on the power of the charger. The temperature ranges, voltage ranges, and current ranges corresponding to chargers of the same power can be the same or different. The temperature ranges, voltage ranges, and current ranges corresponding to chargers of different power can also be the same or different, and those skilled in the art can set them according to actual needs.

[0020] In a preferred embodiment of the present invention, the temperature detection module 100 includes, for example, an infrared thermal imager and a thermocouple; the infrared thermal imager is aimed at the charger to detect the maximum temperature value in the infrared thermal imaging field of view of the charger; the thermocouple is connected to the air outlet of the charger to detect the temperature value of the charger; the electrical signal detection module 200 includes a voltage detection unit and a current detection unit; the voltage detection unit is used to detect the output voltage of the charger, and the current detection unit is used to detect the output current of the charger. The temperature detection module 100 and the electrical signal detection module 200 communicate with the control module 300 through a communication port, such as a CAN, RS232, RS485, or USART communication port.

[0021] In a preferred embodiment of the present invention, the control module 300 includes an input / output device memory and a microcontroller. The input / output device is used to input, receive, and / or modify control logic. The memory is used to store the control logic, and the microcontroller is used to execute the control logic. Specifically, it generates a first abnormality warning signal when the first temperature parameter is less than a first set temperature and the second temperature parameter is within a first temperature range, or the first voltage signal parameter is outside a first voltage range, or the first current signal parameter is outside a first current range; and it generates a second abnormality warning signal when the first temperature parameter is greater than or equal to a second set temperature, or the second temperature parameter is greater than a third set temperature, or the first voltage signal parameter is outside a second voltage range, or the second current signal parameter is outside a second current range. Here, the second set temperature can be equal to or greater than the first set temperature. The input / output device may include a screen, buttons, and a communication module, such as an RS485 communication port.

[0022] In a preferred embodiment of the present invention, the warning module 400 includes a buzzer, a warning light, a communication module, and a relay; the charger and the AC power source are connected via a contactor, and the relay is connected to the control terminal of the contactor; the buzzer emits a first buzzing sound based on a first buzzer signal or emits a second buzzing sound based on a second buzzer signal; the warning light emits light of a first color based on a first warning light signal or emits light of a second color based on a second warning light signal; the communication module is used to send the first text signal or the second text signal; the relay opens based on the first relay signal or closes based on the second relay signal to control the charger and the AC power source to disconnect.

[0023] In a preferred embodiment of the present invention, a 40KW charger is aged with an aging output voltage of 1000V and an aging output current of 40A. During this process, the multi-parameter-based automatic abnormality early warning device of the present invention is used to monitor and issue early warnings. Its circuit is as follows: Figure 4 As shown. Figure 2 This is a schematic diagram of the control logic for the first minor anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 3 This is a schematic diagram of the control logic for the first severe anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention. The following is in conjunction with... Figures 2-4 The principle behind it is explained below.

[0024] Here, as Figure 4As shown, the temperature detection module 100 includes an infrared thermal imager and a thermocouple; the infrared thermal imager is aimed at the charger UUT to detect the maximum temperature value in the infrared thermal imaging field of view of the charger UUT; the thermocouple is connected to the air outlet of the charger UUT to detect the temperature value of the charger UUT. In this preferred embodiment, the thermocouple includes thermocouple 1 and thermocouple 2, which can be set at different positions of the air outlet of the charger UUT, such as opposite to each other. The electrical signal detection module 200 includes a voltage detection unit and a current detection unit; the current detection unit is connected to the shunt at the output terminal of the charger UUT to detect the output current of the charger UUT, and the voltage detection unit is connected to the voltage measurement point at the output terminal of the charger UUT to detect the output voltage of the charger UUT. The control module 300 communicates with the controller of the charger UUT via an RS485 terminal.

[0025] In a preferred embodiment of the present invention, the workflow of this device is divided into five stages: "alarm logic input - parameter acquisition - preprocessing - judgment - alarm - interaction", and the specific steps are as follows. Users can set alarm logic via screen and buttons, or transmit alarm logic scripts via remote RS485 port or WIFI; Parameter acquisition stage (real-time ≤100ms): Each sensor (infrared thermal sensor, thermocouple, voltage and current sampling device, etc.) acquires the operating parameters of the target under test at a preset sampling interval (1~60 seconds adjustable); Parameter preprocessing stage: The processor filters (removes spike signals caused by electromagnetic interference) and calibrates (e.g., compensates for temperature values ​​according to thermocouple temperature drift curves, converts actual voltage values ​​according to voltage divider coefficients) the acquired raw data to obtain accurate and effective parameters; The user-preset alarm logic or alarm script is called to perform real-time judgment on the preprocessed parameters: If the parameters are normal: continue to collect data in a loop, and the current parameter value is displayed on the screen in real time; If the parameters are abnormal: trigger an alarm flag, record the time of the abnormality and the current parameter value; Activate the corresponding alarm device according to the abnormality level (minor abnormality / serious abnormality): Minor abnormality (e.g., slight over-temperature): activate the flashing yellow LED + Intermittent short-term buzzer beeping + abnormal command sent via WIFI; severe abnormality (e.g., severe overheating, output voltage 0): LED flashing red light + continuous rapid buzzer beeping + digital control terminal triggering actuator (e.g., power disconnection) + alarm command sent via WIFI. During charger aging tests, various abnormalities may occur, such as: interruption of output current, output voltage returning to zero; sudden increase in output voltage and current (different charger specifications have different output currents); communication interruption; charger explosion and fire (sudden increase in charger outlet temperature, blind spot of infrared thermal imaging probe at the outlet).

[0026] In practical use, point the infrared thermal imaging probe at the charger; connect the thermocouple to the charger's air outlet; connect the current and voltage measurement terminals to the shunt and voltage measurement point at the charger's output, respectively; connect the CAN communication terminal to the CAN communication line of the charger being aged; connect the remote RS485 terminal to the charger controller; connect the output terminal to the contactor control terminal between the AC power source and the charger; and set up abnormal warning logic. Based on the specifications of the charger being aged, such as 40KW or 60KW, set up an abnormal warning logic script (including minor and severe abnormal warning logic): exist Figures 2-3 The meanings of each parameter are as follows: ITMaxTemp represents the maximum temperature value in the infrared thermal imaging field of view; TTemp1 and TTemp2 represent the measured temperature values ​​of thermocouple channels 1 and 2, respectively; V1 and V2 represent the measured values ​​of voltage measurement channels 1 (measuring voltage) and 2 (measuring current), respectively; CANStopDura CAN represents the communication interruption duration; Relay1 represents the output terminal status of the relay, used to control the external contactor; LED1 alarm light status: 0: normal state, green light indication; 1: minor abnormality, yellow light flashing; 2: serious abnormality, red light flashing; Buzz alarm buzzer status: 0: normal state, no sound; 1: minor abnormality, intermittent short-term sounding; 2: serious abnormality, continuous rapid sounding; AlarmStr warning content sent by the communication module: empty: no transmission in normal state. In a preferred embodiment of the present invention, the output voltage and output current can be attenuated by an attenuation circuit before detection. The warning module 400 includes a buzzer, warning light, communication module, and relay. The charger UUT and the AC power source are connected via a contactor, and the relay is connected to the control terminal of the contactor. The control module 300 monitors the 40kW charger UUT using its built-in control logic, and its control process is as follows: Figures 2-3 As shown.

[0027] When the maximum temperature value detected by the infrared thermal imager within its visual range is less than 150°C, a first abnormality warning signal (i.e., a minor abnormality warning signal) is generated if any of the following conditions occur. The warning module 400 is used to execute a first warning operation based on the first abnormality warning signal. The first warning signal and its corresponding first warning operation differ depending on the situation, as detailed below: If the temperature of thermocouple 1 or thermocouple 2 is greater than 100℃ but less than 150℃, it indicates a minor warning situation. A minor abnormality warning signal is generated, the relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, thermocouple temperature too high". Otherwise, it indicates no abnormality.

[0028] If the output voltage is greater than 1010V or less than 900V, it indicates a minor warning situation. A minor abnormality warning signal is generated, the relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, output voltage abnormality". Otherwise, it indicates no abnormality.

[0029] If the output current is greater than 42A or less than 38A, it indicates a minor warning situation, generating a minor abnormality warning signal. The relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, abnormal output current". Otherwise, it indicates no abnormality.

[0030] If any of the following conditions occur, a serious warning situation is indicated, and a second abnormal warning signal (i.e., a serious abnormal warning signal) is generated. The warning module 400 is used to perform a second warning operation based on the second abnormal warning signal, as follows: If the maximum temperature value detected by the infrared thermal imager within the infrared thermal imaging visual range exceeds 150℃, a second abnormal warning signal (i.e., a serious abnormal warning signal) is generated. The relay closes and pulls the switch, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, infrared thermal imaging temperature is too high."

[0031] If the temperature of thermocouple 1 or thermocouple 2 exceeds 160℃, a serious warning situation will occur, generating a serious abnormality warning signal. The relay will close and pull the switch, the indicator light will flash red, the buzzer will sound continuously and rapidly, and the communication module will send a serious warning message: "Serious warning, thermocouple temperature too high".

[0032] If the output voltage is greater than 1100V or less than 800V, it indicates a serious warning situation. A serious abnormality warning signal is generated, the relay closes and pulls the circuit breaker, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, output voltage abnormal."

[0033] If the output current is greater than 42A or less than 38A, it indicates a serious abnormality warning state. A serious abnormality warning signal is generated, the relay closes and pulls the circuit breaker, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, abnormal output current".

[0034] In another preferred embodiment of the present invention, a 60KW charger is aged with an aging output voltage of 1000V and an aging output current of 60A. During this process, the multi-parameter-based automatic abnormality early warning device of the present invention is used to monitor and issue early warnings. Its circuit is as follows: Figure 4As shown. Figure 5 This is a schematic diagram of the control logic for the second minor anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; Figure 6 This is a schematic diagram of the control logic for the second severe anomaly warning of the multi-parameter-based automatic anomaly warning device of the present invention; the following is in conjunction with... Figures 4-6 The principle behind it is explained below.

[0035] When the maximum temperature value detected by the infrared thermal imager within its visual range is less than 180°C, a first abnormality warning signal (i.e., a minor abnormality warning signal) is generated if any of the following conditions occur. The warning module 400 is used to execute a first warning operation based on the first abnormality warning signal. The first warning signal and its corresponding first warning operation differ depending on the situation, as detailed below: If the temperature of thermocouple 1 or thermocouple 2 is greater than 100℃ but less than 180℃, it indicates a minor warning situation. A minor abnormality warning signal is generated, the relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, thermocouple temperature too high". Otherwise, it indicates no abnormality.

[0036] If the output voltage is greater than 1010V or less than 900V, it indicates a minor warning situation. A minor abnormality warning signal is generated, the relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, output voltage abnormality". Otherwise, it indicates no abnormality.

[0037] If the output current is greater than 62A or less than 58A, it indicates a minor warning situation, generating a minor abnormality warning signal. The relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, abnormal output current". Otherwise, it indicates no abnormality.

[0038] If any of the following situations occur, a serious warning situation is indicated, and a second abnormal warning signal (i.e., a serious abnormal warning signal) is generated. The warning module 400 is used to perform a second warning operation based on the second abnormal warning signal, as follows.

[0039] If the maximum temperature value detected by the infrared thermal imager within the infrared thermal imaging visual range is greater than or equal to 200℃, it indicates a serious warning situation. A serious abnormality warning signal is generated, the relay closes and pulls the switch, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, infrared thermal imaging temperature is too high".

[0040] If the temperature of thermocouple 1 or thermocouple 2 exceeds 160℃, a serious warning situation will occur, generating a serious abnormality warning signal. The relay will close and pull the switch, the indicator light will flash red, the buzzer will sound continuously and rapidly, and the communication module will send a serious warning message: "Serious warning, thermocouple temperature too high".

[0041] If the output voltage is greater than 1100V or less than 800V, it indicates a serious warning situation. A serious abnormality warning signal is generated, the relay closes and pulls the circuit breaker, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, output voltage abnormal."

[0042] If the output current is greater than 65A or less than 55A, it indicates a serious abnormality warning state. A serious abnormality warning signal is generated, the relay closes and pulls the circuit breaker, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, abnormal output current".

[0043] The multi-parameter-based automatic anomaly warning device of this invention can monitor multiple parameters and generate different warning results based on the monitoring results of multiple parameters. Therefore, it can be used to determine the correct state of an aging charger, avoiding missed and false alarms. Furthermore, different parameters can be set for chargers of different power levels, thus adapting to chargers of different power levels and having a wide range of applications.

[0044] In a further preferred embodiment of the present invention, the temperature detection module 100 is further used to detect a third temperature parameter of the charger; the electrical signal detection module 200 is further used to detect a second voltage signal parameter and a second current signal parameter of the charger.

[0045] The control module is further configured to: generate a first power signal parameter based on the first voltage signal parameter and the first current signal parameter; generate a second power signal parameter based on the second voltage signal parameter and the second current signal parameter; generate a percentage parameter based on the first power signal parameter and the second power signal parameter; and generate a first abnormality warning signal or a second abnormality warning signal based on the first temperature parameter, the second temperature parameter, the third temperature parameter, the first power signal parameter, or the percentage parameter; wherein the percentage parameter = the first power signal parameter / (the first power signal parameter + the second power signal parameter).

[0046] In a preferred embodiment of the present invention, when the first temperature parameter is less than the first set temperature and the second temperature parameter is within the first temperature range, or the third temperature parameter is within the second temperature range, or the first power signal parameter is within the first power range, or the percentage parameter is within the percentage range, the first abnormal warning signal is generated; when the first temperature parameter is greater than or equal to the second set temperature, or the second temperature parameter is greater than the third set temperature, or the third temperature parameter is greater than the fourth set temperature, or the first power signal parameter is greater than the first power setting parameter, or the percentage parameter is greater than the first set percentage, the second abnormal warning signal is generated.

[0047] In a preferred embodiment of the present invention, the temperature detection module includes an infrared thermal imager, a first thermocouple, and a second thermocouple; the infrared thermal imager is aligned with the charger to detect the maximum temperature value in the infrared thermal imaging field of view of the charger; the first thermocouple is disposed in the battery pack of the charger to detect the battery pack temperature value, and the second thermocouple is disposed in the battery management circuit of the charger to detect the management circuit temperature value; the electrical signal detection module includes a first voltage detection unit, a second voltage detection unit, a first current detection unit, and a second current detection unit; the first voltage detection unit is used to detect the management circuit voltage of the battery management circuit; the first current detection unit is used to detect the input and output current of the battery management circuit; the second voltage detection unit is used to detect the battery pack voltage of the battery pack; and the second current detection unit is used to detect the input and output current of the battery pack.

[0048] The first set temperature, the second set temperature, the third set temperature, the fourth set temperature, the first power setting parameter, the percentage parameter, the first temperature range, the second temperature range, the first power range, and the percentage range are based on the power setting of the charger; the first abnormal warning signal includes a first buzzer signal, a first warning light signal, a first text signal, and a first relay signal; the second abnormal warning signal includes a second buzzer signal, a second warning light signal, a second text signal, and a second relay signal; the second set temperature is greater than or equal to the second set temperature; the text signal includes temperature-related reminder text, power-related reminder text, and consumption-related reminder text.

[0049] The warning module includes a buzzer, a warning light, a communication module, and a relay; the charger and the AC power source are connected via a contactor, and the relay is connected to the control terminal of the contactor; the buzzer emits a first buzzing sound based on a first buzzer signal or a second buzzing sound based on a second buzzer signal; the warning light emits light of a first color based on a first warning light signal or emits light of a second color based on a second warning light signal; the communication module is used to send the first text signal or the second text signal; the relay opens based on the first relay signal or closes based on the second relay signal to control the charger to maintain or end the aging process.

[0050] Figure 7 This is another circuit connection diagram of the multi-parameter-based automatic anomaly warning device and the charger of the present invention. Figure 7 In the preferred embodiment shown, during the aging test of the charger, the charge and discharge limit test of the Battery Management System (BMS) can be performed. During the BMS charge and discharge limit test, various abnormalities may occur, such as: abnormal over-power heating and fire of the battery management circuit; and overheating and fire of the battery pack.

[0051] Therefore, in this preferred embodiment, the temperature detection module includes an infrared thermal imager, a first thermocouple, and a second thermocouple; the infrared thermal imager is aligned with the charger to detect the maximum temperature value in the infrared thermal imaging field of view of the charger; the first thermocouple is disposed in the battery pack of the charger to detect the battery pack temperature value, and the second thermocouple is disposed in the battery management circuit of the charger to detect the management circuit temperature value; the electrical signal detection module includes a first voltage detection unit, a second voltage detection unit, a first current detection unit, and a second current detection unit; the first voltage detection unit is used to detect the management circuit voltage of the battery management circuit; the first current detection unit is used to detect the input and output current of the battery management circuit; the second voltage detection unit is used to detect the battery pack voltage of the battery pack; and the second current detection unit is used to detect the input and output current of the battery pack.

[0052] like Figure 7As shown, during testing, the BMS charge / discharge limit test circuit is connected; the infrared thermal imaging probe is aimed at the charger's BMS, and the thermocouple is connected to the charger's battery pack and battery management circuit; the first voltage detection unit, the second voltage detection unit, the first current detection unit, and the second current detection unit are respectively connected to the voltage measurement point of the tested BMS, the current measurement point of the BMS (Hall current transmitter), the voltage measurement point of the battery pack, and the current measurement point of the battery pack (Hall current transmitter); the relay output terminal is connected to the contactor control terminal between the BMS charge / discharge tester and the charger's BMS; the magnitude and direction of the BMS voltage, BMS current, battery pack voltage, and battery pack current during the BMS charge / discharge process are related to the BMS charge / discharge state. Using a single parameter greater than or less than the boundary value is no longer sufficient to accurately predict anomalies. The control module 300 uses its built-in control logic to monitor the charger UUT, and its control process is as follows: Figures 8-9 As shown.

[0053] exist Figure 7 In the diagram, ITMaxTemp represents the maximum temperature value within the infrared thermal imaging field of view; TTemp1, TTemp2, and TTemp3 represent the measured temperature values ​​of thermocouple channels 1 (internal temperature of the battery pack), 2 (internal temperature of the battery pack), and 3 (internal temperature of the battery management circuit). V1, V2, V3, and V4 represent the measured values ​​of voltage measurement channels 1 (measuring BMS voltage), 2 (measuring BMS current), 3 (measuring battery pack voltage), and 4 (measuring battery pack current). Relay1 indicates the status of the relay 1 output terminal, used to control external contactors. The LED1 alarm light status is: 0: normal state, green light indicating; 1: minor abnormality, yellow light flashing; 2: serious abnormality, red light flashing; the Buzz alarm buzzer status is: 0: normal state, no sound; 1: minor abnormality, intermittent short sound; 2: serious abnormality, continuous rapid sound; AlarmStr represents the warning content sent by the communication module, empty: no message sent in normal state.

[0054] When the maximum temperature value detected by the infrared thermal imager within its visual range is less than 70°C, a first abnormality warning signal (i.e., a minor abnormality warning signal) is generated if any of the following conditions occur. The warning module 400 is used to execute a first warning operation based on the first abnormality warning signal. The first warning signal and its corresponding first warning operation differ depending on the specific situation, as detailed below: If the temperature of thermocouple 1 or thermocouple 2 inside the battery pack is greater than 55℃ but less than 60℃, a minor abnormality warning signal is generated. The relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, battery pack temperature is too high". Otherwise, it indicates that there is no abnormality.

[0055] If the temperature of thermocouple 3 in the battery management circuit is greater than 60℃ but less than 75℃, a minor abnormality warning signal is generated. The relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "Minor warning, battery management circuit temperature is too high". Otherwise, it indicates that there is no abnormality.

[0056] Based on BMS voltage, BMS input and output current, and battery pack voltage; calculate BMS input and output power and battery pack input and output power based on battery pack input and output current; calculate the power consumed by the battery management circuit based on BMS input and output power and battery pack input and output power; and then calculate the percentage of power consumed by the battery management circuit relative to the input and output power based on the power consumed by the battery management circuit.

[0057] If the BMS input / output power is greater than 970W but less than 990W, a minor abnormality warning signal is generated, the relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "minor warning, BMS charging / discharging power is too high". Otherwise, it indicates that there is no abnormality.

[0058] If the power consumption of the battery management circuit accounts for more than 5% but less than 10% of the input and output power, a minor abnormality warning signal is generated. The relay disconnects, the indicator light flashes yellow, the buzzer sounds intermittently for a short time, and the communication module sends a minor warning message, such as "Minor warning, battery management circuit is consuming too much power." Otherwise, it indicates that there is no abnormality.

[0059] If any of the following situations occur, a serious warning situation is indicated, and a second abnormal warning signal (i.e., a serious abnormal warning signal) is generated. The warning module 400 is used to perform a second warning operation based on the second abnormal warning signal, as follows.

[0060] If the maximum temperature value detected by the infrared thermal imager within the infrared thermal imaging visual range is greater than or equal to 70℃, it indicates a serious warning situation. A serious abnormality warning signal is generated, the relay closes and pulls the switch, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, BMS temperature too high".

[0061] If the temperature of thermocouple 1 or thermocouple 2 inside the battery pack is greater than or equal to 60°C, it indicates a serious warning situation. A serious abnormality warning signal is generated, the relay closes and pulls the switch, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, battery pack temperature too high".

[0062] If the temperature of thermocouple 3 in the battery management circuit exceeds 7560℃, it indicates a serious warning situation, generating a serious abnormality warning signal. The relay closes and pulls the switch, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, battery management circuit temperature is too high".

[0063] If the BMS input / output power is greater than or equal to 990W, it indicates a serious warning situation, generating a serious abnormality warning signal. The relay closes and pulls the switch, the indicator light flashes red, the buzzer sounds continuously and rapidly, and the communication module sends a serious warning message: "Serious warning, BMS charging and discharging power is too high".

[0064] If the power consumed by the battery management circuit accounts for more than or equal to 10% of the input and output power, a serious warning situation will occur. A serious abnormality warning signal will be generated, the relay will close and pull the switch, the indicator light will flash red, the buzzer will sound continuously and rapidly, and the communication module will send a serious warning message: "Serious warning, battery management circuit is consuming too much power."

[0065] The multi-parameter-based automatic anomaly warning device of this invention can monitor multiple parameters and generate different warning results based on the monitoring results of multiple parameters. Therefore, it can be used to determine the correct state of an aging charger, avoiding missed and false alarms. Furthermore, different parameters can be set for chargers of different power levels, thus adapting to chargers of different power levels and having a wide range of applications.

[0066] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-parameter-based automatic early warning device for the aging process of a charger, characterized in that, include: A temperature detection module is used to detect the first temperature parameter and the second temperature parameter of the charger. The electrical signal detection module is used to detect the first voltage signal parameter and the first current signal parameter of the charger; The control module is used to generate a first abnormality warning signal or a second abnormality warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter, or the first current signal parameter. The early warning module is used to perform a first early warning operation based on the first abnormal early warning signal or to perform a second early warning operation based on the second early warning signal.

2. The automatic anomaly early warning device based on multiple parameters according to claim 1, characterized in that, The generation of a first or second abnormality warning signal based on the first temperature parameter, the second temperature parameter, the first voltage signal parameter, or the first current signal parameter includes: When the first temperature parameter is less than the first set temperature, and the second temperature parameter is within the first temperature range, or the first voltage signal parameter is outside the first voltage range, or the first current signal parameter is outside the first current range, the first abnormal warning signal is generated. When the first temperature parameter is greater than or equal to the second set temperature, or the second temperature parameter is greater than the third set temperature, or the first voltage signal parameter is outside the second voltage range, or the second current signal parameter is outside the second current range, the second abnormal warning signal is generated.

3. The automatic anomaly early warning device based on multiple parameters according to claim 2, characterized in that, The first set temperature, the second set temperature, the third set temperature, the first temperature range, the second temperature range, the first voltage range, the second voltage range, the first current range, and the second current range are based on the power settings of the charger; The second set temperature is greater than or equal to the first set temperature; The first abnormality warning signal includes a first buzzer signal, a first warning light signal, a first text signal, and a first relay signal; the second abnormality warning signal includes a second buzzer signal, a second warning light signal, a second text signal, and a second relay signal. The text signals include temperature-related reminders, voltage-related reminders, and current-related reminders.

4. The automatic anomaly early warning device based on multiple parameters according to any one of claims 1 to 3, characterized in that, The temperature detection module includes an infrared thermal imager and a thermocouple; the infrared thermal imager is aimed at the charger to detect the maximum temperature value in the infrared thermal imaging field of view of the charger. The thermocouple is connected to the air outlet of the charger to detect the temperature value of the charger; The electrical signal detection module includes a voltage detection unit and a current detection unit; the voltage detection unit is used to detect the output voltage of the charger, and the current detection unit is used to detect the output current of the charger.

5. The automatic anomaly early warning device based on multiple parameters according to claim 1, characterized in that, The temperature detection module is further used to detect a third temperature parameter of the charger; The electrical signal detection module is further used to detect the second voltage signal parameter and the second current signal parameter of the charger.

6. The automatic anomaly early warning device based on multiple parameters according to claim 5, characterized in that, The control module is further used for: A first power signal parameter is generated based on the first voltage signal parameter and the first current signal parameter; a second power signal parameter is generated based on the second voltage signal parameter and the second current signal parameter; and a percentage parameter is generated based on the first power signal parameter and the second power signal parameter. The first abnormality warning signal or the second abnormality warning signal is generated based on the first temperature parameter, the second temperature parameter, the third temperature parameter, the first power signal parameter, or the percentage parameter. The percentage parameter is equal to the first power signal parameter / (first power signal parameter + second power signal parameter).

7. The automatic anomaly early warning device based on multiple parameters according to claim 6, characterized in that, The process of generating the first or second abnormality warning signal based on the first temperature parameter, the second temperature parameter, the third temperature parameter, the first power signal parameter, or the percentage parameter includes: When the first temperature parameter is less than the first set temperature, and the second temperature parameter is within the first temperature range, or the third temperature parameter is within the second temperature range, or the first power signal parameter is within the first power range, or the percentage parameter is within the percentage range, the first abnormal warning signal is generated. When the first temperature parameter is greater than or equal to the second set temperature, or the second temperature parameter is greater than the third set temperature, or the third temperature parameter is greater than the fourth set temperature, or the first power signal parameter is greater than the first power setting parameter, or the percentage parameter is greater than the first set percentage, the second abnormal warning signal is generated.

8. The automatic anomaly early warning device based on multiple parameters according to claim 4, characterized in that, The thermocouple includes a first thermocouple and a second thermocouple; The first thermocouple is installed in the battery pack of the charger to detect the temperature value of the battery pack, and the second thermocouple is installed in the battery management circuit of the charger to detect the temperature value of the management circuit. The electrical signal detection module includes a first voltage detection unit, a second voltage detection unit, a first current detection unit, and a second current detection unit; The first voltage detection unit is used to detect the management circuit voltage of the battery management circuit; The first current detection unit is used to detect the input and output current of the battery management circuit; the second voltage detection unit is used to detect the battery pack voltage of the battery pack; the second current detection unit is used to detect the input and output current of the battery pack.

9. The automatic anomaly early warning device based on multiple parameters according to claim 7, characterized in that, The first set temperature, the second set temperature, the third set temperature, the fourth set temperature, the first power setting parameter, the percentage parameter, the first temperature range, the second temperature range, the first power range, and the percentage range are based on the power setting of the charger; The first abnormality warning signal includes a first buzzer signal, a first warning light signal, a first text signal, and a first relay signal; the second abnormality warning signal includes a second buzzer signal, a second warning light signal, a second text signal, and a second relay signal. The second set temperature is greater than or equal to the second set temperature; The text signals include temperature-related reminders, power-related reminders, and consumption-related reminders.

10. The automatic anomaly early warning device based on multiple parameters according to claim 2, 3, or 9, characterized in that, The early warning module includes a buzzer, a warning light, a communication module, and a relay; The charger and the AC power source are connected via a contactor, and the relay is connected to the control terminal of the contactor. The buzzer emits a first buzzing sound based on the first buzzer signal or emits a second buzzing sound based on the second buzzer signal; The warning light emits light of a first color based on the first warning light signal or emits light of a second color based on the second warning light signal; The communication module is used to send the first text signal or the second text signal; The relay is disconnected based on the first relay signal or closed based on the second relay signal to control the charger to maintain or terminate the aging process.

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