Sensor device for monitoring corrosion of cold plate of battery

Abstract

The invention relates to a sensor device for monitoring corrosion of a cold plate of a battery. The sensor device comprises a middle mounting unit, a corrosion detection unit and a signal processing and communication module unit, the corrosion detection unit adopts a detection head with a blocked outer end part, the outer layer of the detection head is an anti-corrosion layer for detection, and the inner layer is a substrate layer for detection; the anti-corrosion layer for detection is electrically connected with one end of the first wire; the substrate layer for detection is electrically connected with one end of the second wire; the other ends of the two wires are electrically connected with a potential difference acquisition interface of the signal processing and communication module unit to form a signal acquisition loop; the middle mounting unit is fixedly connected with a base on a water inlet pipeline of the battery cold plate in a sealing manner; the corrosion detection unit extends into the middle part of the water inlet pipeline; and the signal processing and communication module unit is used for properly amplifying the potential difference signal according to the monitored environment variable, comparing the potential difference signal with a preset threshold value, and determining whether to send out an alarm signal or not according to a comparison result. The cold plate corrosion early warning device can sense and give out early warning when the cold plate is corroded.

Description

Technical Field

[0001] This invention relates to the field of thermal pipeline system technology for new energy vehicle batteries, and in particular to a sensor device for monitoring corrosion of battery cold plates. Background Technology

[0002] Currently, most new energy vehicles use liquid cooling systems for thermal management of power batteries to ensure that the batteries operate within a safe temperature range. However, coolant leakage is a frequent problem in liquid cooling systems. Especially when the battery cold plate corrodes or the seal fails, coolant may seep into the battery pack, leading to short circuits, thermal runaway, or even spontaneous combustion of the entire vehicle.

[0003] Current technologies primarily monitor coolant status using pressure or level sensors, but these methods cannot detect whether the cold plate is corroded. The corrosion process is often insidious and slow, and by the time leaks occur, serious safety hazards have already arisen. Therefore, there is a lack of an effective means to detect cold plate corrosion. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes a sensor device for monitoring corrosion of battery cold plates.

[0005] A sensor device for monitoring corrosion of battery cold plates includes a corrosion detection unit, a signal processing and communication module unit, and a central mounting unit. The corrosion detection unit and the signal processing and communication module unit are respectively fixed at both ends of the central mounting unit; The corrosion detection unit adopts a detection head structure with an externally sealed end. The outer layer of the detection head is a detection anti-corrosion layer, the material and thickness of which are the same as those of the inner anti-corrosion layer of the battery cold plate. The inner layer of the detection head is a detection substrate layer, the material and thickness of which are the same as those of the battery cold plate substrate. The detection anti-corrosion layer is electrically connected to one end of the first wire, and the detection substrate layer is electrically connected to one end of the second wire, used to detect the potential difference between the inner and outer layers. The other ends of the first and second wires are electrically connected to the potential difference acquisition interface of the signal processing and communication module unit, forming a signal acquisition loop. The middle mounting unit is sealed and fixedly connected to the base on the battery cold plate inlet pipe. The corrosion detection unit extends into the middle part of the inlet pipe, and the first wire is set directly opposite the coolant impact position. The signal processing and communication module unit is used to receive the potential difference signal monitored by the corrosion detection unit, and to amplify the potential difference signal appropriately according to the monitored environmental variables; to compare the amplified potential difference signal with a preset threshold, and to determine whether it is within the allowable deviation range based on the comparison result, and to confirm whether to issue an alarm signal.

[0006] Furthermore, the middle mounting unit adopts a mounting column structure. The end of the mounting column near the corrosion detection unit adopts a small-diameter cylindrical structure. An external mounting thread is provided on the small-diameter cylindrical structure, and a sealing gasket is fitted at the root of the small-diameter cylindrical structure. The middle mounting unit is installed on the base on the battery cold plate inlet pipe through the external mounting thread and the sealing gasket.

[0007] Furthermore, the inner diameter of the battery cold plate inlet pipe is set to 0.6-0.8 times the equivalent inner diameter of the internal flow channel of the battery cold plate.

[0008] Furthermore, the environmental variables include temperature and humidity.

[0009] Furthermore, the signal processing and communication module unit includes a core control and communication section, a power management section, and a signal acquisition and processing section.

[0010] Furthermore, the core control and communication section includes: Unit A, Unit B, and Unit C; Unit A: Vehicle VCU or Battery BMS, used to receive test results; Unit B: LIN2.1 / CAN2.0 communication module, used to transmit results to Unit A.

[0011] Unit C: The core controller, which uses an MCU, is responsible for data processing and amplification compensation calculation.

[0012] Furthermore, the power management section includes: a D unit, an E unit, an F unit, and a G unit; D Unit: Vehicle battery, providing main power to sensor devices; E Unit: LDO power supply, which steps down the main power supply voltage to the sensor device to +5V, providing power for the operation of the CPU and communication module of the signal processing and communication module unit; Unit F; a constant voltage reference source that provides a +5V reference voltage to provide a reference power supply for the multi-stage operational amplifier circuits of the signal processing and communication module units; G unit; positive and negative voltage power supply, providing +12V / -12V, used to provide operating power for the multi-stage operational amplifier circuit of the signal processing and communication module unit; Furthermore, the signal acquisition and processing section includes: I unit, H unit, J unit, and K unit; Unit I: Potential difference acquisition interface, which acquires the potential difference from the corrosion detection unit; H unit: Potential difference signal processing, completes three-stage amplification and comparison with the set threshold; Unit J: Environmental variable collection, including temperature, humidity, etc.; K-unit: Error compensation unit, which corrects the signal based on environmental variables; L unit: Hardware watchdog, ensuring the normal operation of MCU logic.

[0013] The advantages and positive effects of this invention are as follows: 1. This invention, without altering the existing installation structure of the battery cold plate, sets the corrosion detection point on a pre-set base of the battery cold plate's inlet pipe. Furthermore, the anti-corrosion layer and substrate layer of the corrosion detection unit are identical in material and thickness to the anti-corrosion layer and substrate layer of the battery cold plate, respectively. This ensures that the corrosion condition detected at the point matches the corrosion condition of the battery cold plate during its use. Thus, when corrosion occurs at the detection point, the anti-corrosion layer gradually fails, causing a change in the potential difference between the inner and outer metal surfaces. The corrosion detection unit detects this potential difference in real time and transmits the signal to the signal processing module. The module triggers an alarm when the potential difference reaches a set threshold and uploads the data to the BMS via the communication module, achieving remote early warning.

[0014] 2. This invention can detect and issue an early warning when corrosion occurs in the cold plate, thereby taking maintenance measures in advance to avoid battery thermal runaway and vehicle spontaneous combustion caused by coolant leakage, thus improving the safety and reliability of new energy vehicles. Attached Figure Description

[0015] Figure 1 This is a structural diagram of the sensor device for monitoring corrosion of battery cold plates according to the present invention; Figure 2 yes Figure 1 A magnified view of a section of the corrosion detection unit; Figure 3 This is a schematic diagram of the installation location of the sensor system for monitoring corrosion of battery cold plates according to the present invention; Figure 4 This is a block diagram illustrating the operating principle of the sensor device for monitoring corrosion of battery cold plates according to the present invention. Detailed Implementation

[0016] The structure of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Please refer to the sensor device for monitoring corrosion of battery cold plates. Figures 1-4 The sensor device 1 includes a corrosion detection unit 1-3, a signal processing and communication module unit 1-1, and a central mounting unit 1-2.

[0018] The corrosion detection unit and the signal processing and communication module unit are respectively fixed at both ends of the central mounting unit.

[0019] The corrosion detection unit employs a detection head structure with an externally sealed end. The outer layer of the detection head is a detection anti-corrosion layer 1-3-3, the material and thickness of which are the same as those of the inner anti-corrosion layer of the battery cold plate 3. The inner layer of the detection head is a detection substrate layer 1-3-2, the material and thickness of which are the same as those of the battery cold plate substrate. The detection anti-corrosion layer is electrically connected to one end of the first wire 1-3-4, and the detection substrate layer is electrically connected to one end of the second wire 1-3-1, used to detect the potential difference between the inner and outer layers. The other ends of the first and second wires are electrically connected to the potential difference acquisition interface of the signal processing and communication module unit, forming a signal acquisition loop.

[0020] The signal processing and communication module unit is used to receive the potential difference signal monitored by the corrosion detection unit, and to amplify the potential difference signal appropriately according to the monitored environmental variables; and to compare the amplified potential difference signal with a set threshold, and to determine whether it is within the allowable deviation range based on the comparison result, and to confirm whether to issue an alarm signal.

[0021] The signal processing and communication module unit includes a core control and communication section, a power management section, and a signal acquisition and processing section.

[0022] 1. Core control and communication components, including: Unit A: Vehicle VCU or Battery BMS, receives test results.

[0023] Unit B: LIN2.1 / CAN2.0 communication module, which transmits the results to Unit A.

[0024] Unit C (MCU): The core controller, responsible for data processing and compensation calculations.

[0025] 2. Power Management Section D Unit: Vehicle battery, providing main power to sensor devices, with a voltage range of 12V-48V; E Unit: LDO power supply, which steps down the main power supply voltage to the sensor device to +5V, providing power for the operation of the CPU and communication module of the signal processing and communication module unit; Unit F; a constant voltage reference source that provides a +5V reference voltage to provide a reference power supply for the multi-stage operational amplifier circuits of the signal processing and communication module units; G unit; positive and negative voltage power supply, providing +12V / -12V, used to provide operating power for the multi-stage operational amplifier circuit of the signal processing and communication module unit.

[0026] 3. Signal Acquisition and Processing Section Unit I: Potential difference acquisition interface, which acquires the potential difference from the corrosion detection unit.

[0027] H unit: Potential difference signal processing, completes three-stage amplification and comparison with the set threshold.

[0028] Unit J: Environmental variable collection, including temperature, humidity, etc.

[0029] K-unit: Error compensation unit, which corrects the signal based on environmental variables, mainly controlling the amplification factor of the potential difference.

[0030] L unit: Hardware watchdog, ensuring the normal operation of MCU logic.

[0031] The middle mounting unit adopts a mounting column structure. The end of the mounting column near the corrosion detection unit adopts a small-diameter cylindrical structure. An external mounting thread is provided on the small-diameter cylindrical column, and a sealing gasket is fitted at the root of the small-diameter cylindrical column.

[0032] The middle mounting unit is mounted on the base 4 of the battery cold plate inlet pipe 5 via external mounting threads and sealing gasket 2. The corrosion detection unit extends into the middle part of the inlet pipe, and the first wire is positioned directly opposite the coolant impact position.

[0033] Furthermore, to enable early warning capabilities for corrosion detection, the detection pipeline on the inlet side is designed with an equivalent inner diameter smaller than the size of the internal flow channel of the battery cold plate, specifically 0.6 to 0.8 times the equivalent inner diameter of the cold plate flow channel. According to the fluid continuity equation, under the same volumetric flow rate conditions, the coolant velocity in the detection pipeline with the smaller inner diameter will inevitably be higher than the velocity in the internal flow channel of the cold plate. This increased velocity will exacerbate the electrochemical corrosion rate at that location, causing the corrosion level detected by the corrosion detection units 1–3 at that location to rise before the actual corrosion level inside the cold plate. When the corrosion detection unit triggers an early warning, the actual corrosion level inside the battery cold plate remains within a controllable range, thus enabling early prediction and preventing more severe corrosion failure inside the cold plate.

[0034] The corrosion detection process using the sensor device of this invention for monitoring battery cold plate corrosion is as follows: 1. Power Initialization The system is powered by power supply D, and the step-down and reference voltage, positive and negative voltage power supply are completed by units E, F and G.

[0035] 2. Perform signal acquisition Unit I obtains the potential difference signal from the corrosion detection unit.

[0036] The H unit performs three-stage amplification and comparison processing on the signal, and outputs a preliminary detection value.

[0037] 3. Environmental Data Acquisition Unit J collects environmental variables, including temperature and humidity, and transmits them to the MCU.

[0038] 4. Data Processing and Compensation The MCU compares the potential difference data with the threshold set in the ROM reference database.

[0039] Based on environmental variables, the MCU calculates compensation data and applies it to the H unit via the K unit to correct the deviation.

[0040] 5. Result Output The MCU generates the final detection results.

[0041] Transmitted to Unit A (VCU / BMS) via Unit B (LIN / CAN communication).

[0042] 6. System monitoring The L-unit hardware watchdog provides real-time monitoring to ensure the normal operation of the MCU logic.

[0043] Installation and maintenance of the sensor device for monitoring battery cold plate corrosion according to this invention: Sensor installation: A threaded mounting hole is pre-drilled on the base of the inlet pipeline. The sensor is fixed by threads and a sealing ring. The corrosion detection unit is flush with the middle of the pipe wall. After installation, a sealing test is performed. Specifically, the pressure is 0.3MPa. If there is no leakage, the sealing test is passed.

[0044] Regular maintenance: Calibrate the initial potential difference U0 every 6 months, clean the deposits on the sensor detection end annually, and check the wire connection status.

[0045] The sensor device of this invention needs to have high sensitivity, resistance to coolant environment, and anti-electromagnetic interference capability, specifically: This invention employs multi-stage low-noise amplification and a stable reference source, combined with a dynamic compensation mechanism for environmental data, enabling the sensor to accurately capture early, weak corrosion signals and significantly improve detection sensitivity.

[0046] Through a sealed structure and potting protection of the electronic components, the sensor can operate stably for a long time in corrosive media such as ethylene glycol coolant, ensuring that the structure and signal are not affected by coolant corrosion.

[0047] By employing mechanisms such as shielded wiring, analog filtering, isolated power supply, EMC-optimized board layout, software filtering, and hardware watchdog timers, the sensor's anti-interference capability is enhanced, enabling it to maintain reliable data and stable operation even in the vehicle's strong electromagnetic environment.

[0048] In summary, through the aforementioned amplification technology, the coolant-resistant structural packaging scheme, and the anti-electromagnetic interference design combining hardware and software, the corrosion monitoring sensor of this invention can operate stably for a long time under complex vehicle operating conditions, ensuring that corrosion signals are captured in advance and accurately, and guaranteeing that the detection output is not affected by coolant composition, electromagnetic interference, and environmental fluctuations, thereby achieving reliable early warning of battery cold plate corrosion status.

[0049] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A sensor device for monitoring corrosion of battery cold plates, characterized in that: Includes a corrosion detection unit, a signal processing and communication module unit, and a central mounting unit; The corrosion detection unit and the signal processing and communication module unit are respectively fixed at both ends of the central mounting unit; The corrosion detection unit adopts a detection head structure with an externally sealed end. The outer layer of the detection head is a detection anti-corrosion layer, the material and thickness of which are the same as those of the inner anti-corrosion layer of the battery cold plate. The inner layer of the detection head is a detection substrate layer, the material and thickness of which are the same as those of the battery cold plate substrate. The detection anti-corrosion layer is electrically connected to one end of the first wire, and the detection substrate layer is electrically connected to one end of the second wire, used to detect the potential difference between the inner and outer layers. The other ends of the first and second wires are electrically connected to the potential difference acquisition interface of the signal processing and communication module unit, forming a signal acquisition loop. The middle mounting unit is sealed and fixedly connected to the base on the battery cold plate inlet pipe. The corrosion detection unit extends into the middle part of the inlet pipe, and the first wire is set directly opposite the coolant impact position. The signal processing and communication module unit is used to receive the potential difference signal monitored by the corrosion detection unit, and to amplify the potential difference signal appropriately according to the monitored environmental variables; to compare the amplified potential difference signal with a preset threshold, and to determine whether it is within the allowable deviation range based on the comparison result, and to confirm whether to issue an alarm signal.

2. The sensor device for monitoring corrosion of battery cold plates according to claim 1, characterized in that: The middle mounting unit adopts a mounting column structure. The end of the mounting column near the corrosion detection unit adopts a small-diameter cylindrical structure. An external mounting thread is provided on the small-diameter cylindrical structure, and a sealing gasket is fitted at the root of the small-diameter cylindrical structure. The middle mounting unit is installed on the base on the battery cold plate inlet pipe through the external mounting thread and the sealing gasket.

3. The sensor device for monitoring corrosion of battery cold plates according to claim 1, characterized in that: The inner diameter of the inlet pipe of the battery cold plate is set to 0.6-0.8 times the equivalent inner diameter of the internal flow channel of the battery cold plate.

4. The sensor device for monitoring corrosion of battery cold plates according to claim 1, characterized in that: The environmental variables include temperature and humidity.

5. The sensor device for monitoring battery cold plate corrosion according to claim 1, characterized in that: The signal processing and communication module unit includes a core control and communication section, a power management section, and a signal acquisition and processing section.

6. The sensor device for monitoring battery cold plate corrosion according to claim 5, characterized in that: The core control and communication section includes: Unit A, Unit B, and Unit C; Unit A: Vehicle VCU or Battery BMS, used to receive test results; Unit B: LIN2.1 / CAN2.0 communication module, used to transmit results to Unit A; Unit C: The core controller, which uses an MCU, is responsible for data processing and amplification compensation calculation.

7. The sensor device for monitoring battery cold plate corrosion according to claim 5, characterized in that: The power management section includes: D unit, E unit, F unit and G unit; D Unit: Vehicle battery, providing main power to sensor devices; E Unit: LDO power supply, which steps down the main power supply voltage to the sensor device to +5V, providing power for the operation of the CPU and communication module of the signal processing and communication module unit; Unit F; a constant voltage reference source that provides a +5V reference voltage to provide a reference power supply for the multi-stage operational amplifier circuits of the signal processing and communication module units; G unit; positive and negative voltage power supply, providing +12V / -12V, used to provide operating power for the multi-stage operational amplifier circuit of the signal processing and communication module unit.

8. The sensor device for monitoring corrosion of battery cold plates according to claim 5, characterized in that: The signal acquisition and processing section includes: I unit, H unit, J unit, and K unit; Unit I: Potential difference acquisition interface, which acquires the potential difference from the corrosion detection unit; H unit: Potential difference signal processing, completes three-stage amplification and comparison with the set threshold; Unit J: Environmental variable collection, including temperature and humidity; K-unit: Error compensation unit, which corrects the signal based on environmental variables; L unit: Hardware watchdog, ensuring the normal operation of MCU logic.

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