Method and system for detecting impact resistance of lead-acid storage battery in heavy load environment

Abstract

The invention belongs to the technical field of storage battery detection, and particularly provides a method and system for detecting the impact resistance of a lead-acid storage battery in a heavy load environment, and the method comprises the steps: carrying out the initial performance parameter detection of a sample; building a heavy-load environment impact simulation device; impact detection parameters are set according to the actual condition of the heavy load environment; starting an impact excitation generation mechanism, and performing impact detection on the sample, including durability detection and instantaneous detection; after the impact detection is finished, taking down the sample from the impact table, and performing appearance inspection on the sample again; performing performance parameter detection on the sample, and recording a detection result; and analyzing the performance parameter change in the sample impact process and the performance parameter after the impact, extracting characteristic indexes, and evaluating the impact resistance of the lead-acid storage battery in the heavy load environment according to the characteristic indexes. According to the invention, through multi-direction impact simulation, multi-parameter dynamic monitoring and intelligent comprehensive evaluation, comprehensive and accurate evaluation of the impact resistance of the storage battery is realized.

Description

Technical Field

[0001] This invention belongs to the field of battery testing technology, specifically, it relates to a method and system for testing the impact resistance of lead-acid batteries under heavy load conditions. Background Technology

[0002] Lead-acid batteries are widely used in heavy-duty equipment such as forklifts, loaders, and heavy trucks due to their advantages of low cost, high reliability, mature technology, and excellent high-current discharge performance. During the actual operation of heavy-duty equipment, batteries must withstand the strong impacts caused by frequent start-stop cycles, road bumps, and sudden load changes. These impacts can directly lead to problems such as deformation of the battery's internal plates, shedding of active materials, and electrolyte leakage. This not only severely reduces the battery's capacity and shortens its lifespan but may also cause safety accidents such as short circuits and fires. Therefore, accurate and comprehensive testing of the impact resistance of lead-acid batteries under heavy-duty environments is a crucial step in ensuring the safe and stable operation of heavy-duty equipment.

[0003] However, existing methods for testing the impact resistance of lead-acid batteries have significant limitations and are difficult to meet the needs of practical applications: 1. Limited assessment dimensions and lack of comprehensiveness: Most existing testing methods only focus on the external damage of the battery after impact, such as shell cracking and leakage, ignoring the changes in the internal structure of the battery during and after the impact (such as plate displacement and diaphragm damage) and the dynamic changes in core performance parameters (such as capacity decay and internal resistance increase). This makes it impossible to comprehensively assess the battery's impact resistance. Some batteries with internal damage but intact appearance may be mistakenly judged as qualified, creating potential safety hazards.

[0004] 2. Incomplete coverage of impact directions and poor adaptability to operating conditions: Batteries in heavy-duty environments are subjected to impacts from multiple directions, including vertical (gravity-induced impacts), horizontal (impacts from sudden changes in the direction of equipment travel), and inclined (compound impacts under complex road conditions). The damage mechanisms and degrees of impacts from different directions vary significantly. However, existing testing methods typically only perform impact tests in a single direction (mostly vertical), lacking differentiated assessments of multi-directional impacts. The test results are disconnected from actual operating conditions and cannot accurately reflect the battery's impact resistance performance in real-world usage scenarios.

[0005] 3. Subjective evaluation methods and low quantification: The evaluation results of existing testing methods mostly rely on manual judgment, lack standardized testing procedures and intelligent evaluation models, making it difficult to accurately quantify the impact resistance of batteries. The judgment results of different testers may vary greatly, resulting in insufficient objectivity and reliability of the test results.

[0006] To address the shortcomings of the existing technologies, this invention proposes a method and system for testing the impact resistance of lead-acid batteries under heavy load conditions. Through multi-directional impact simulation, multi-parameter dynamic monitoring, and intelligent comprehensive evaluation, a comprehensive and accurate assessment of the battery's impact resistance is achieved, thus overcoming the deficiencies of the existing technologies. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a method and system for testing the impact resistance of lead-acid batteries under heavy load conditions. Through multi-directional impact simulation, multi-parameter dynamic monitoring and intelligent comprehensive evaluation, a comprehensive and accurate evaluation of the impact resistance of batteries can be achieved.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a method for testing the impact resistance of lead-acid batteries under heavy load conditions, comprising the following steps: Step 1: Sample preparation: Select the lead-acid battery sample to be tested, perform a visual inspection to ensure that the sample is not obviously damaged; then perform initial performance parameter testing on the sample and record the test results; Step 2: Construction of the simulated heavy-load environment impact device: including the construction of the impact table, sample fixing mechanism, impact excitation generation mechanism and parameter monitoring mechanism; Step 3: Setting impact test parameters: Set the impact test parameters according to the actual conditions of the heavy-duty environment; Step 4: Perform impact testing: Fix the prepared lead-acid battery sample onto the impact stage using the sample fixing mechanism, start the impact excitation mechanism, and perform impact testing on the sample according to the set impact testing parameters; during the testing process, record the changes of various parameters of the sample in real time through the parameter monitoring mechanism. The impact testing includes durability testing and instantaneous testing. Step 5: Performance testing of the sample after impact testing: After the impact test, the sample is removed from the impact table and its appearance is inspected again; then the performance parameters of the sample are tested and the test results are recorded. Step Six: Impact Resistance Assessment: Analyze the changes in performance parameters during and after the impact of the sample, extract characteristic indicators, and assess the impact resistance of the lead-acid battery under heavy load conditions based on these characteristic indicators.

[0009] In the preferred embodiment, the initial performance parameters in step one include battery capacity and internal resistance.

[0010] In a preferred embodiment, in step three, the impact detection parameters include the impact acceleration range, the impact duration range, the impact number range, and the impact direction, which includes the vertical direction, the horizontal direction, and the inclined direction.

[0011] In the preferred embodiment, in step four, the parameter monitoring mechanism records the sample's capacity, internal resistance, temperature, instantaneous discharge current, and output voltage data in real time during the impact process.

[0012] In the preferred embodiment, the specific operation of the durability test in step four includes: setting impact test parameters, impacting three lead-acid battery samples from the vertical, horizontal and inclined directions respectively, and recording the capacity change data, internal resistance change data and battery surface temperature change data of each sample during the impact in different directions.

[0013] In the preferred embodiment, the specific operation of instantaneous detection in step four includes: setting impact detection parameters, impacting three lead-acid battery samples from the vertical, horizontal and inclined directions respectively, and recording the instantaneous discharge current and output voltage drop of each sample at the moment of impact in different directions.

[0014] In a preferred embodiment, in step five, the performance parameters of the sample after testing include battery capacity and internal resistance, and the testing method is consistent with the testing method for the initial performance parameters in step one.

[0015] In the preferred embodiment, step six, the impact resistance assessment includes durable impact testing and analysis and instantaneous impact testing and analysis. The lead-acid battery is deemed to have qualified impact resistance under heavy load only if both the durable impact test and the instantaneous impact test are qualified; if any test item fails, the overall impact resistance is deemed unqualified.

[0016] In a preferred embodiment, the durability impact testing and analysis includes the following sub-steps: S1. Obtain the capacity and internal resistance of the lead-acid battery at the end of the durability test process in different impact directions. Compare the capacity and internal resistance of the lead-acid battery at the end with the initial data to obtain the capacity decay and internal resistance increase. Compare them with the rated capacity decay and rated internal resistance increase set by the system respectively. If either the capacity decay or the internal resistance increase is greater than or equal to the rated capacity decay and rated internal resistance increase set by the system, the sample is determined to be unqualified in the durability test in the corresponding impact direction. S2. For samples that pass the test in step S1, acquire data on capacity changes over time, internal resistance changes over time, and battery surface temperature changes over time during the durability test in the current impact direction. Construct potential non-compliance indicators for durability impact to further determine whether the lead-acid battery passes the durability impact test in the current direction. If the test result in any impact direction is non-compliant, the lead-acid battery is assessed as non-compliant in the durability impact test in that direction. If the test results in all directions are compliant, proceed to the comprehensive durability impact assessment.

[0017] In the preferred embodiment, the formula for calculating the potential non-compliance index of durability impact in step S2 is as follows: ; In the formula, i The values ​​1, 2, or 3 represent the current impact direction as vertical, horizontal, and inclined, respectively. This represents the change in capacity over time during the current impact-direction durability test. This represents the function of internal resistance changing with time during the durability test in the current impact direction. This represents the change in battery surface temperature over time during the durability test in the current impact direction. , and These represent the standard functions of capacity change over time, internal resistance change over time, and battery surface temperature change over time during the durability test in the current impact direction, as set by the system. and These represent the weighting coefficients corresponding to capacitance and internal resistance, respectively. This is the penalty coefficient for temperature changes. , and These represent the capacitance, internal resistance, and temperature reference values, respectively. This indicates the potential non-compliance index of durability impact in the current impact direction. , These represent the start and end times of the durability test in the current impact direction.

[0018] In the preferred embodiment, in step S2, the... Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the lead-acid battery fails the durability impact test in the current direction.

[0019] In the preferred embodiment, the operation method for the comprehensive durability impact assessment is as follows: The formula for calculating the comprehensive failure index coefficient of durability impact is as follows: ; In the formula, The coefficient for comprehensive failure index of durability impact is denoted as follows: Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the durability impact test of the lead-acid battery is unqualified.

[0020] In the preferred embodiment, the instantaneous impact detection and analysis includes the following sub-steps: S1, the instantaneous discharge current of each sample in each impact direction. and the magnitude of output voltage drop Each parameter is compared with its corresponding independent threshold. If any parameter exceeds the corresponding independent threshold, the sample is deemed to have failed the instantaneous impact test in that impact direction. S2, if the instantaneous discharge current in all directions and the magnitude of output voltage drop If none of them exceed the corresponding independent threshold, then proceed to the instantaneous impact comprehensive assessment.

[0021] In the preferred embodiment, the operation method for the instantaneous impact comprehensive assessment is as follows: Construct a calculation model for the comprehensive non-compliance index coefficient of instantaneous impact, the expression of which is: ; in, and These represent the instantaneous discharge current and the output voltage drop amplitude detected instantaneously in the current impact direction, respectively. and These are the weighting coefficients for current and voltage, respectively; The calculated B is compared with the set corresponding threshold. If B is greater than or equal to the threshold, the instantaneous impact test of the lead-acid battery is deemed unqualified.

[0022] This invention also provides a testing system for the impact resistance of lead-acid batteries under heavy load conditions, used to perform the above-described testing method for the impact resistance of lead-acid batteries under heavy load conditions, including: A simulated heavy-duty environmental impact device includes an impact platform, a sample fixing mechanism, an impact excitation mechanism, and a parameter monitoring mechanism. The sample fixing mechanism is mounted on the impact platform and is used to fix the lead-acid battery sample to be tested. The impact excitation mechanism is used to apply vertical, horizontal, or inclined impacts to the sample according to preset parameters. The parameter monitoring mechanism is used to collect data on the sample's capacity change over time, internal resistance change over time, battery surface temperature change over time, instantaneous discharge current, and output voltage drop in real time during the impact process, and transmit the collected data to the evaluation module. The evaluation module is used to analyze the changes in performance parameters during the impact process and the performance parameters after the impact, extract characteristic indicators, and evaluate the impact resistance of lead-acid batteries under heavy load conditions based on the characteristic indicators.

[0023] The present invention provides a method and system for testing the impact resistance of lead-acid batteries under heavy load conditions, which has the following beneficial effects: 1. By collecting multi-dimensional parameters, simulating dynamic impacts, and using a comprehensive evaluation model, the state of lead-acid batteries under durability and instantaneous impacts can be accurately quantified. By simulating the complex impact conditions of heavy-load environments and combining comprehensive parameter monitoring and analysis, the impact resistance of lead-acid batteries can be accurately and comprehensively evaluated, and the test results are closer to actual usage conditions.

[0024] 2. Set the impact acceleration, duration, number of impacts, and multi-directional impacts according to the actual working conditions of heavy-duty equipment. Multi-directional impact simulation includes three impact directions: vertical, horizontal, and inclined, covering various impact types that may occur in real working conditions. Then, through independent testing in different directions, identify the weak points in the battery structure.

[0025] 3. Durability testing simulates long-term repeated impacts, while instantaneous testing simulates sudden, severe impacts, recording multi-dimensional parameters for each. The combination of durability and instantaneous testing reflects the battery's resistance to impact degradation over long-term use, while instantaneous testing reflects its ability to withstand sudden, severe impacts. This combination provides comprehensive coverage of both long-term performance and sudden operating conditions. The recording of multi-dimensional parameters fully captures the impact on the battery's internal structure and performance, avoiding the one-sided focus on appearance found in existing technologies.

[0026] 4. First, non-compliant directions are quickly screened using thresholds, then cumulative damage is calculated, and finally, overall performance is evaluated using a comprehensive model combining geometric mean and harmonic mean, reinforcing the weakest link effect. The grading judgment logic improves detection efficiency, quickly screening out obviously non-compliant batteries and avoiding unnecessary subsequent calculations; the integral calculation of cumulative damage quantifies the dynamic damage during the impact process, reflecting the battery's true impact resistance more accurately than static comparisons; the comprehensive evaluation model uses geometric mean to reflect multi-directional synergistic effects and harmonic mean to reinforce the weakest link effect, overcoming the limitations of single-directional evaluation or subjective judgment in existing technologies, ensuring the accuracy and objectivity of the evaluation results. Attached Figure Description

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0028] 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 for illustrative purposes only and are not intended to limit the invention.

[0029] Example 1: A method for testing the impact resistance of lead-acid batteries under heavy load conditions, such as... Figure 1As shown, it includes the following steps: Step 1: Sample Preparation Select lead-acid battery samples to be tested and conduct a visual inspection to ensure that the samples are free from obvious initial damage such as cracks, leaks, and deformation. Then, perform initial performance parameter tests on the samples, including battery capacity and internal resistance, and record the test results in detail as a benchmark for subsequent performance comparison.

[0030] Step 2: Construction of the simulated heavy-load environment impact device A simulated heavy-duty environmental impact device was constructed, which includes an impact platform, a sample fixing mechanism, an impact excitation generating mechanism, and a parameter monitoring mechanism. The functions and selection of each component are as follows: Impact table: Used to provide a stable impact bearing foundation, the XYZ-500 electromagnetic impact table is selected, and its impact acceleration adjustment range is 10-200g to meet the simulation requirements of different impact intensities in heavy-load environments.

[0031] Sample fixing mechanism: Set on the impact stage, it is used to firmly fix the lead-acid battery sample to be tested, so as to avoid the sample displacement during the impact process from affecting the test accuracy. The fixing method can be adjusted according to the installation method of the battery in the actual heavy-duty equipment.

[0032] It adopts customized anti-slip clamps to adapt to heavy-duty lead-acid batteries of different specifications, and the fixing pressure is adjustable to avoid damage to the sample surface.

[0033] Impact excitation mechanism: used to apply impacts of different directions and intensities to the sample according to preset parameters. The ABC-200 multi-directional impact exciter is selected, which can realize impact output in vertical, horizontal and inclined (0-60° adjustable) directions. The impact duration can be adjusted from 1 to 100ms.

[0034] Parameter monitoring mechanism: Used to collect various performance parameters of the sample in real time during the impact process, including DEF-300 high-precision capacity tester (measurement accuracy ±0.5%), GHI-100 micro internal resistance tester (measurement range 0.01mΩ-100mΩ), JKL-05 contact temperature sensor (measurement range -20℃-150℃, accuracy ±0.3℃), and MNO-200 high-speed current and voltage acquisition instrument (sampling frequency 1MHz, current measurement range 0-2000A, voltage measurement range 0-100V). Each device communicates with the evaluation module through a data bus to realize the real-time transmission and storage of parameters.

[0035] Step 3: Setting Impact Testing Parameters Based on the actual conditions of heavy-duty environments, such as frequent start-stop of forklifts and heavy trucks driving on bumpy roads, set impact detection parameters.

[0036] The impact detection parameters include the impact acceleration range, impact duration range, impact number range, and impact direction, which includes vertical, horizontal, and inclined directions.

[0037] In this embodiment, it specifically includes: Impact acceleration range: 50-150g, corresponding to moderate to severe impact intensity in heavy-duty environments; Impact duration range: 10-50ms, matching the instantaneous characteristics of impacts from heavy-duty equipment; Impact frequency range: 1000-5000 times, simulating the actual impact frequency of a battery over 1-2 years; Impact direction: Vertical direction, corresponding to the up-and-down bumping impact of the equipment; Horizontal direction, corresponding to the acceleration / deceleration impact of the equipment; Inclined direction, set the inclination angle to 30°, corresponding to the side tilting impact of the equipment or the combined impact of complex road conditions.

[0038] Step 4: Conduct impact testing The prepared lead-acid battery sample is fixed on the impact stage using a sample fixing mechanism. The impact excitation mechanism is activated, and the sample is subjected to impact testing according to the set impact testing parameters. During the testing process, the parameter monitoring mechanism records the changes of various parameters of the sample in real time. The impact testing includes durability testing and instantaneous testing. The specific operation is as follows: Durability testing: Set impact test parameters and impact three lead-acid battery samples from vertical, horizontal and inclined directions respectively. Record the capacity change over time, internal resistance change over time and battery surface temperature change over time for each sample during the impact in different directions.

[0039] In this embodiment, the impact acceleration was set to 80g, the impact duration to 30ms, and the number of impacts to 3000. Three lead-acid battery samples were impacted from the vertical, horizontal, and inclined (30°) directions, respectively. Each direction corresponds to one sample to ensure a single variable. The capacity, internal resistance, and surface temperature of each sample were recorded in real time during the impact process. The data sampling interval was 1s.

[0040] Instantaneous detection: Set the impact detection parameters and impact three lead-acid battery samples from the vertical, horizontal and inclined directions respectively. Record the instantaneous discharge current and output voltage drop of each sample at the moment of impact in different directions.

[0041] In this embodiment, the impact acceleration was set to 120g, the impact duration to 10ms, and the number of impacts to 1. A sudden strong impact was simulated. Three lead-acid battery samples were impacted from the vertical direction, the horizontal direction, and the inclined direction (30°) respectively. The samples were different individuals from the same batch as the durability test samples. The instantaneous discharge current and output voltage drop of each sample at the moment of impact (within 0-10ms after the impact) were recorded in real time.

[0042] The core of this embodiment, based on the above technical solution, lies in quantifying the impact resistance of lead-acid batteries under heavy load conditions by combining multi-directional impact testing (vertical, horizontal, and tilted) with durability and instantaneous detection. The impact from different directions significantly affects the battery's internal structure (plates, electrolyte, separator), requiring independent testing to identify weak points. Simultaneously, electrochemical performance degradation is considered, and parameters such as capacity decay, internal resistance increase, and temperature change reflect irreversible damage caused by the impact.

[0043] Step 5: Performance testing of samples after impact testing After the impact test, the sample is removed from the impact platform and its appearance is inspected again to record any damage such as shell cracking, leakage, deformation, or loose terminals. Then, the sample is tested for performance parameters, including battery capacity and internal resistance, using a standardized testing method that is exactly the same as in step one. The test results are recorded to ensure comparability with the initial performance parameters.

[0044] Step Six: Impact Resistance Assessment The changes in performance parameters during and after the impact of the sample were analyzed, characteristic indicators were extracted, and the impact resistance of lead-acid batteries under heavy load was evaluated based on the characteristic indicators.

[0045] Impact resistance assessment includes durability testing and analysis of lead-acid batteries and performance evaluation of lead-acid batteries under instantaneous impact.

[0046] (a) Durability testing and analysis Includes the following sub-steps: S1. Obtain the capacity and internal resistance of the lead-acid battery at the end of the durability test process in different impact directions. Compare the capacity and internal resistance of the lead-acid battery at the end with the initial data to obtain the capacity decay and internal resistance increase. Compare these with the capacity decay threshold and internal resistance increase threshold set by the system. If either the capacity decay or the internal resistance increase is greater than or equal to the rated capacity decay and rated internal resistance increase set by the system, it indicates that the lead-acid battery fails the durability impact test in the current direction.

[0047] Specifically, the capacity decay ΔQ = initial capacity - capacity after impact, the internal resistance increase ΔR = internal resistance after impact - initial internal resistance, the capacity decay threshold ΔQ0 = 8% × initial capacity, and the internal resistance increase threshold ΔR0 = 50% × initial internal resistance, are set according to the heavy-duty battery industry standards and actual usage requirements.

[0048] If any parameter exceeds the standard ΔQ≥ΔQ0 or ΔR≥ΔR0, the sample is directly judged to be unqualified in the durability test in the corresponding impact direction, and batteries with significantly degraded performance are quickly screened out.

[0049] S2. For samples that pass the test in step S1, acquire data on capacity changes over time, internal resistance changes over time, and battery surface temperature changes over time during the durability test in the current impact direction. Construct potential non-compliance indicators for durability impact to further determine whether the lead-acid battery passes the durability impact test in the current direction. If the test result in any impact direction is non-compliant, the lead-acid battery is assessed as non-compliant in the durability impact test in that direction. If the test results in all directions are compliant, proceed to the comprehensive durability impact assessment.

[0050] Specifically, this includes: acquiring data on capacity changes over time, internal resistance changes over time, and battery surface temperature changes over time during the durability test in the current impact direction; constructing a calculation model for potential non-compliance indicators during durability impact, with the expression being: ; In the formula, i The values ​​1, 2, or 3 represent the current impact direction as vertical, horizontal, and inclined, respectively. This represents the change in capacity over time during the current impact-direction durability test. This represents the function of internal resistance changing with time during the durability test in the current impact direction. This represents the change in battery surface temperature over time during the durability test in the current impact direction. , and These represent the standard functions of capacity change over time, internal resistance change over time, and battery surface temperature change over time during the durability test in the current impact direction, as set by the system. and These represent the weighting coefficients corresponding to capacitance and internal resistance, respectively. This is the penalty coefficient for temperature changes. , and These represent the capacitance, internal resistance, and temperature reference values, respectively. This indicates the potential non-compliance index of durability under the current impact direction.

[0051] The product of the capacity / internal resistance sum and the temperature term directly triggers a failure when the temperature is abnormal, reflecting the safety veto logic.

[0052] Will Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the lead-acid battery fails the durability impact test in the current direction.

[0053] Comprehensive Durability Impact Assessment: Calculate the comprehensive failure index coefficient for durability impact. The calculation formula is as follows: ; In the formula, The coefficient for comprehensive failure index of durability impact is denoted as follows: Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the durability impact test of the lead-acid battery is unqualified. i =1 corresponds to the vertical direction. i =2 corresponds to the horizontal direction. i =3 corresponds to the tilt direction; It is the geometric mean of the three-directional damage quantification values, reflecting the synergistic damage effect of multi-directional impacts. At the same time, by taking the cube root to balance the order of magnitude, it avoids the difficulty in setting the threshold due to excessively large product. It is the harmonic mean of the damage quantification values ​​in three directions, which is sensitive to the minimum value and can enhance the weakest link effect, preventing minor damage in one direction from being masked by the excellent performance in other directions.

[0054] The calculated C is compared with the comprehensive threshold C0 set by the system. If C≥C0, the durability impact test of the lead-acid battery is deemed unqualified; if C<C0, the durability impact test is deemed qualified. In this embodiment, C0 is calibrated to 30 according to the heavy-duty battery application scenario.

[0055] The calculated C is compared with the set corresponding threshold. If C is greater than or equal to the threshold, the durability impact test of the lead-acid battery is deemed unqualified.

[0056] Through the above technical solution, this embodiment focuses on data analysis and comprehensive evaluation of durability testing. It achieves precise quantitative evaluation through multi-level judgment logic and mathematical models. First, it compares the capacity decay and internal resistance increase before and after the impact with preset thresholds. If any parameter exceeds the standard, the direction is judged as unqualified, quickly identifying batteries with significant performance degradation in specific impact directions (vertical, horizontal, inclined). Then, for batteries that pass the initial judgment, it further quantifies their cumulative damage during continuous impact, calculating the degree of deviation of capacity, internal resistance, and temperature from standard values ​​over time through integration, reflecting the dynamic degradation of the battery. Finally, based on... The comparison results determine whether to proceed to the overall comprehensive evaluation. Failure in any direction means the lead-acid battery fails the durability impact test in that direction; success in all directions means it proceeds to the comprehensive calculation, which is then performed using the formula... Calculate the comprehensive failure index coefficient for durability impact, and then... Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the durability impact test of the lead-acid battery has failed. In the formula, Three directions The product of these terms reflects the synergistic effect, while the square root is used to balance the order of magnitude, preventing the product from becoming too large and making threshold setting difficult. The harmonized average core term is sensitive to the minimum value, thus amplifying the weakest link effect.

[0057] (II) Performance evaluation under instantaneous impact The estimation includes the following sub-steps: S1, the instantaneous discharge current of each sample in each impact direction. and the magnitude of output voltage drop Each parameter is compared with its corresponding independent threshold. If any parameter exceeds the corresponding independent threshold, the sample is deemed to have failed the instantaneous impact test in that impact direction.

[0058] In this implementation, the instantaneous discharge current threshold I0 = 1500A and the output voltage drop threshold ΔU0 = 0.8V are set according to the requirements of heavy-duty equipment for the instantaneous power supply stability of the battery. If either parameter exceeds the corresponding independent threshold (I... i ≥I0 or ΔU i If the instantaneous impact test result is greater than or equal to ΔU0, then the sample is directly deemed to have failed the instantaneous impact test in that impact direction.

[0059] S2, if the instantaneous discharge current in all directions and the magnitude of output voltage drop If none of the values ​​exceed the corresponding independent threshold, then proceed to the instantaneous impact comprehensive assessment. The operation steps are as follows: The formula for calculating the instantaneous impact comprehensive index is as follows: ; Wherein, γ is the weighting coefficient of instantaneous discharge current, γ=0.6, because instantaneous current is crucial for power supply during equipment startup; δ is the weighting coefficient of output voltage drop, δ=0.4, because voltage stability affects the operating accuracy of the equipment; the calculated B is compared with the set corresponding threshold. If B is greater than or equal to the threshold, the instantaneous impact test of the lead-acid battery is deemed unqualified.

[0060] It is the product of the three weighted indices. The geometric mean is used to eliminate the dimensionality effect of the product. To harmonize the average and amplify the weakest link effect, the calculated B is compared with the system-set comprehensive threshold B0. If B ≥ B0, the instantaneous impact test of the lead-acid battery is deemed unqualified; if B < B0, the instantaneous impact test is deemed qualified. In this embodiment, the comprehensive threshold B0 is calibrated to 800 based on the instantaneous power supply requirements of heavy-duty equipment.

[0061] The lead-acid battery is deemed to have qualified impact resistance under heavy load only if both the durability impact test and the instantaneous impact test are qualified; if either test item fails, the overall impact resistance is deemed to be unqualified.

[0062] Through the above technical solution, this embodiment addresses the performance evaluation of lead-acid batteries under instantaneous impact (sudden load). By quantifying the instantaneous discharge current and voltage drop amplitude, combined with a nonlinear comprehensive model, it determines whether the battery meets the requirements of high dynamic load. The instantaneous discharge current reflects the rapid response capability of the battery plate active materials and electrolyte, while the voltage drop amplitude characterizes internal resistance and polarization effects, directly related to the power supply stability of the equipment. If either direction... or If the independent threshold is exceeded, it is directly judged as unqualified. If all directions are qualified, it is judged as unqualified by formula. Calculate the instantaneous impact comprehensive index to further evaluate the overall performance, Compared with the corresponding threshold set by the system, if If the instantaneous impact test result is greater than or equal to the corresponding threshold set by the system, it indicates that the lead-acid battery has failed the instantaneous impact test. In the formula, It is a weighted combination of current and voltage. The product of three-way weighted indices Geometric mean eliminates the dimensionality effect of consecutive products. The harmonized average core term is sensitive to the minimum value, thus amplifying the weakest link effect.

[0063] Example 2: This embodiment provides a testing system for the impact resistance of lead-acid batteries under heavy load conditions, used to execute the testing method for the impact resistance of lead-acid batteries under heavy load conditions described in Embodiment 1, including: A simulated heavy-duty environmental impact device includes an impact platform, a sample fixing mechanism, an impact excitation mechanism, and a parameter monitoring mechanism. The sample fixing mechanism is mounted on the impact platform and is used to fix the lead-acid battery sample to be tested. The impact excitation mechanism is used to apply vertical, horizontal, or inclined impacts to the sample according to preset parameters. The parameter monitoring mechanism is used to collect data on the sample's capacity change over time, internal resistance change over time, battery surface temperature change over time, instantaneous discharge current, and output voltage drop in real time during the impact process, and transmit the collected data to the evaluation module. The evaluation module is used to analyze the changes in performance parameters during the impact process and the performance parameters after the impact, extract characteristic indicators, and evaluate the impact resistance of lead-acid batteries under heavy load conditions based on the characteristic indicators.

[0064] It adopts an industrial control computer equipped with an Intel Core i7 processor, 16GB of memory, and a 1TB solid-state drive. It has built-in dedicated evaluation software to receive data transmitted by parameter monitoring agencies, perform calculation logic for durability testing and analysis and instantaneous impact performance evaluation, and output evaluation results.

[0065] Those skilled in the art will readily understand that the above description is merely 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 scope of protection of the present invention.

Claims

1. A method for testing the impact resistance of lead-acid batteries under heavy load conditions, characterized in that, Includes the following steps: Step 1: Sample preparation: Select the lead-acid battery sample to be tested and perform a visual inspection to ensure that the sample is not obviously damaged; Then, the initial performance parameters of the sample were tested, and the test results were recorded. Step 2: Construction of the simulated heavy-load environment impact device: including the construction of the impact table, sample fixing mechanism, impact excitation generation mechanism and parameter monitoring mechanism; Step 3: Setting impact test parameters: Set the impact test parameters according to the actual conditions of the heavy-duty environment; Step 4: Perform impact testing: Fix the prepared lead-acid battery sample onto the impact stage using the sample fixing mechanism, start the impact excitation mechanism, and perform impact testing on the sample according to the set impact testing parameters; during the testing process, record the changes of various parameters of the sample in real time through the parameter monitoring mechanism. The impact testing includes durability testing and instantaneous testing. Step 5: Performance testing of the sample after impact testing: After the impact test, the sample is removed from the impact table and its appearance is inspected again; then the performance parameters of the sample are tested and the test results are recorded. Step Six: Impact Resistance Assessment: Analyze the changes in performance parameters during and after the impact of the sample, extract characteristic indicators, and assess the impact resistance of the lead-acid battery under heavy load conditions based on these characteristic indicators.

2. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step one, the initial performance parameters include battery capacity and internal resistance.

3. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step three, the impact detection parameters include the impact acceleration range, impact duration range, impact number range, and impact direction, including vertical, horizontal, and inclined directions.

4. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step four, the parameter monitoring mechanism records the sample's capacity, internal resistance, temperature, instantaneous discharge current, and output voltage data in real time during the impact process.

5. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step four, the specific operations of the durability test include: setting impact test parameters, impacting three lead-acid battery samples from the vertical, horizontal and inclined directions respectively, and recording the capacity change data, internal resistance change data and battery surface temperature change data of each sample during the impact in different directions.

6. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step four, the specific operation of instantaneous detection includes: setting impact detection parameters, impacting three lead-acid battery samples from the vertical, horizontal and inclined directions respectively, and recording the instantaneous discharge current and output voltage drop of each sample at the moment of impact in different directions.

7. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step five, the performance parameters of the sample after testing include battery capacity and internal resistance, and the testing method is the same as that used for the initial performance parameters in step one.

8. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 1, characterized in that, In step six, the impact resistance assessment includes durable impact testing and analysis and instantaneous impact testing and analysis. The lead-acid battery is deemed to have qualified impact resistance under heavy load only if both the durable impact test and the instantaneous impact test are qualified. If any test item fails, the overall impact resistance is deemed unqualified.

9. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 8, characterized in that, The durability impact testing and analysis includes the following sub-steps: S1. Obtain the capacity and internal resistance of the lead-acid battery at the end of the durability test process in different impact directions. Compare the capacity and internal resistance of the lead-acid battery at the end with the initial data to obtain the capacity decay and internal resistance increase. Compare them with the rated capacity decay and rated internal resistance increase set by the system respectively. If either the capacity decay or the internal resistance increase is greater than or equal to the rated capacity decay and rated internal resistance increase set by the system, the sample is determined to be unqualified in the durability test in the corresponding impact direction. S2. For samples that pass the test in step S1, acquire data on capacity changes over time, internal resistance changes over time, and battery surface temperature changes over time during the durability test in the current impact direction. Construct potential non-compliance indicators for durability impact to further determine whether the lead-acid battery passes the durability impact test in the current direction. If the test result in any impact direction is non-compliant, the lead-acid battery is assessed as non-compliant in the durability impact test in that direction. If the test results in all directions are compliant, proceed to the comprehensive durability impact assessment.

10. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 9, characterized in that, In step S2, the formula for calculating the potential non-compliance index of durability impact is: ； In the formula, i The values ​​1, 2, or 3 represent the current impact direction as vertical, horizontal, and inclined, respectively. This represents the change in capacity over time during the current impact-direction durability test. This represents the function of internal resistance changing with time during the durability test in the current impact direction. This represents the change in battery surface temperature over time during the durability test in the current impact direction. , and These represent the standard functions of capacity change over time, internal resistance change over time, and battery surface temperature change over time during the durability test in the current impact direction, as set by the system. and These represent the weighting coefficients corresponding to capacitance and internal resistance, respectively. This is the penalty coefficient for temperature changes. , and These represent the capacitance, internal resistance, and temperature reference values, respectively. This indicates the potential non-compliance index of durability impact in the current impact direction. , These represent the start and end times of the durability test in the current impact direction.

11. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 10, characterized in that, In step S2, Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the lead-acid battery fails the durability impact test in the current direction.

12. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 10, characterized in that, The operational method for the comprehensive durability impact assessment is as follows: The formula for calculating the comprehensive failure index coefficient of durability impact is as follows: ； In the formula, The coefficient for comprehensive failure index of durability impact is denoted as follows: Compared with the corresponding threshold set by the system, if If the value is greater than or equal to the corresponding threshold set by the system, it indicates that the durability impact test of the lead-acid battery is unqualified.

13. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 8, characterized in that, The instantaneous impact detection and analysis includes the following sub-steps: S1, the instantaneous discharge current of each sample in each impact direction. and the magnitude of output voltage drop Each parameter is compared with its corresponding independent threshold. If any parameter exceeds the corresponding independent threshold, the sample is deemed to have failed the instantaneous impact test in that impact direction. S2, if the instantaneous discharge current in all directions and the magnitude of output voltage drop If none of them exceed the corresponding independent threshold, then proceed to the instantaneous impact comprehensive assessment.

14. The method for testing the impact resistance of a lead-acid battery under heavy load conditions according to claim 13, characterized in that, The operational method for the comprehensive assessment of instantaneous impact is as follows: Construct a calculation model for the comprehensive non-compliance index coefficient of instantaneous impact, the expression of which is: ； in, and These represent the instantaneous discharge current and the output voltage drop amplitude detected instantaneously in the current impact direction, respectively. and These are the weighting coefficients for current and voltage, respectively; The calculated B is compared with the set corresponding threshold. If B is greater than or equal to the threshold, the instantaneous impact test of the lead-acid battery is deemed unqualified.

15. A testing system for the impact resistance of lead-acid batteries under heavy load conditions, characterized in that, A method for testing the impact resistance of lead-acid batteries under heavy load conditions as described in any one of claims 1 to 14, comprising: A simulated heavy-duty environmental impact device includes an impact platform, a sample fixing mechanism, an impact excitation mechanism, and a parameter monitoring mechanism. The sample fixing mechanism is mounted on the impact platform and is used to fix the lead-acid battery sample to be tested. The impact excitation mechanism is used to apply vertical, horizontal, or inclined impacts to the sample according to preset parameters. The parameter monitoring mechanism is used to collect data on the sample's capacity change over time, internal resistance change over time, battery surface temperature change over time, instantaneous discharge current, and output voltage drop in real time during the impact process, and transmit the collected data to the evaluation module. The evaluation module is used to analyze the changes in performance parameters during the impact process and the performance parameters after the impact, extract characteristic indicators, and evaluate the impact resistance of lead-acid batteries under heavy load conditions based on the characteristic indicators.

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