Battery pack state monitoring system and method

Abstract

The invention discloses a battery pack state monitoring system and method, and relates to the technical field of battery management. The system comprises a battery pack, a detection board monitoring system and a receiving terminal, a battery pack serves as a detected object, a battery management system (BMS) is arranged in the battery pack, and voltage, current, temperature and SOC and SOH original state data of the battery pack are collected; the detection board monitoring system is an external device independent of the battery pack, and a power supply unit, a data transmission module, a control unit, an alarm module, a pluggable positioning module and an external interface are integrated in the detection board monitoring system. The receiving terminal is a mobile device or a computer equipped with monitoring software, and establishes data interaction with the detection board monitoring system through wired or wireless communication. The standard composite interface is detachably connected with the battery pack, the internal structure of the battery pack does not need to be transformed, plug and play is achieved, the method is suitable for factory-leaving, dispersedly-deployed or movable battery packs, the application scene is expanded, and the deployment flexibility is improved.

Description

Technical Field

[0001] This invention belongs to the field of battery management technology, and in particular relates to a battery pack status monitoring system and method. It is especially suitable for scenarios that require rapid deployment and remote monitoring, such as power battery packs for new energy vehicles, battery packs for energy storage systems, and battery packs for portable devices. It can realize real-time monitoring and abnormal alarm of battery pack voltage, current, temperature, SOC, SOH and other states. Background Technology

[0002] With the widespread application of battery technology in new energy, energy storage and other fields, the safe operation and status monitoring of battery packs have become critical requirements. Existing battery pack status monitoring technologies mainly suffer from the following shortcomings:

[0003] (1) Limitations of wired monitoring: Traditional wired monitoring requires direct connection of the monitoring equipment to the battery pack BMS via a wire harness, which has three major problems: First, the deployment cost is high, the wire harness length needs to be customized according to the installation location of the battery pack, and the wiring process is complicated, especially for distributed energy storage battery packs, the wiring workload is huge; Second, the reliability is poor, the wire harness connection point is easily affected by vibration (such as the driving process of new energy vehicles) and corrosion (such as outdoor energy storage scenarios), resulting in poor contact and interruption of data acquisition; Third, the flexibility is low, it is impossible to quickly modify the battery packs that have been put into use, and if the battery pack needs to be moved (such as portable energy storage power supply), the wired connection will limit its scope of use.

[0004] (2) Deficiencies of infrared camera monitoring: Infrared cameras achieve status judgment by monitoring the surface temperature of the battery pack, but there are obvious deficiencies: First, there are blind spots. When the battery pack is stacked or blocked by the shelf, the camera cannot capture the temperature of the blocked area, resulting in incomplete monitoring. Second, there is a delay in intervention. The infrared camera can only detect the surface temperature. When an abnormal temperature is detected, thermal runaway may have already occurred inside the battery pack. At this time, intervention can no longer prevent the fault from expanding. Third, the function is limited. It can only monitor the temperature and cannot obtain key status data such as voltage, current, and SOC, making it difficult to form a complete status assessment system.

[0005] Currently, there is a lack of solutions on the market that can simultaneously achieve "no need to modify the battery pack", "wireless remote monitoring", "comprehensive monitoring of multiple parameters" and "timely alarm for anomalies". Therefore, there is an urgent need for a new type of monitoring system to fill this technological gap. Summary of the Invention

[0006] The purpose of this invention is to provide a battery pack status monitoring system and method. It can be detachably connected to the battery pack through a standardized composite interface without modifying the internal structure of the battery pack, achieving plug-and-play functionality. It is applicable to battery packs that have already been manufactured, are deployed in a distributed manner, or are in motion. It solves the problems of inconvenient deployment and poor flexibility of existing wired battery pack monitoring, as well as blind spots and delayed intervention in infrared camera monitoring.

[0007] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:

[0008] This invention relates to a battery pack status monitoring system, comprising a battery pack, a detection board monitoring system, and a receiving terminal.

[0009] The battery pack, as the object to be tested, has a built-in battery management system (BMS); the battery management system (BMS) is used to collect the battery pack's voltage, current, temperature, and raw state data of SOC and SOH.

[0010] The detection board monitoring system is an external device independent of the battery pack. It is detachably connected to the battery pack via a standardized composite interface, which simultaneously enables power transmission and data communication. The detection board monitoring system integrates a power supply unit, a data transmission module, a control unit, an alarm module, a pluggable positioning module, and an external interface.

[0011] The receiving terminal is equipped with monitoring software and establishes data interaction with the detection board monitoring system through wired or wireless communication. It is used to process, store, and visualize battery pack status data, battery management system (BMS) information, and alarm information.

[0012] As a preferred technical solution, the power supply unit includes an independent battery and an external power interface, wherein the independent battery is a rechargeable battery; the external power interface supports powering all modules and the battery management system (BMS) of the detection board monitoring system, and also supports charging the independent battery; the data transmission module supports wired communication and various wireless communication protocols (including but not limited to WiFi, 4G / 5G cellular networks, Bluetooth, and LoRa), and has a manual switching function, capable of receiving user switching commands through a human-machine interface to select the communication mode; the positioning module adopts a modular architecture design, which can be specifically presented as a pluggable interface (such as USB or pins) or a fixed onboard integration method according to the overall product design requirements, facilitating flexible configuration and future upgrades. Its positioning technology system does not rely on a single solution, but can integrate multiple positioning technologies (including but not limited to UWB, RFID, satellite positioning, Bluetooth, etc.) or combinations thereof to obtain real-time geographical location information of the battery pack; the external interface supports the expansion of sensors such as smoke sensors and vibration sensors, and also supports program burning through the interface; the alarm module includes a buzzer, LED indicator and remote alarm signal generation unit, used to trigger multi-dimensional alarms when the battery pack is in an abnormal state.

[0013] As a preferred technical solution, the control unit is configured to perform the following operations:

[0014] After the system completes power-on initialization, it includes clock configuration, peripheral driver loading, and self-test; the self-test detects the power supply unit voltage, data transmission module communication, and positioning module connection status.

[0015] Power the BMS through a standardized composite interface, establish communication, and collect raw BMS data;

[0016] Collect power supply unit voltage / power data, positioning module position data, and external sensor detection data;

[0017] The collected data is preprocessed, and the preprocessed data is evaluated from multiple dimensions. Weights are assigned to each evaluation item, the overall risk score of the battery pack is calculated, and the overall risk score of the battery pack is compared with the risk threshold. If the data is judged to be abnormal, the alarm module is immediately triggered to generate alarm information including the abnormality type, occurrence time, and battery pack ID; if the data is normal, the battery pack status information is updated.

[0018] The control data transmission module sends battery pack status information, BMS information, and alarm information (if any) to the receiving terminal.

[0019] As a preferred technical solution, the monitoring software of the receiving terminal can present data in various forms, including but not limited to digital dashboards, line graphs, and list formats; it provides a visual interface for users to set data acquisition frequency, communication method priority, and positioning module working mode; after receiving alarm information, it triggers terminal pop-up prompts and sound alarms, supports alarm information export and historical alarm record query; it also supports adding / deleting detection board monitoring system devices, and displays the remaining power and communication status of each device's power supply unit.

[0020] As a preferred technical solution, the multi-dimensional assessment includes voltage health assessment, current stress assessment, temperature gradient assessment, SOH decay assessment, external safety assessment, and battery pack consistency assessment. The voltage health assessment is based on individual cell voltage consistency, voltage fluctuation amplitude, and the degree of voltage deviation from the standard value, with a maximum score of 100 points. The current stress assessment is based on current peak value, duration of current exceeding the standard, and charge / discharge current stability, with a maximum score of 100 points. The temperature gradient assessment is based on the maximum internal temperature difference of the battery pack, the rate of temperature change, and the degree of temperature deviation from the safe range, with a maximum score of 100 points. The SOH decay assessment is based on the current SOH value, SOH decay rate, and the matching degree between SOH and cycle number, with a maximum score of 100 points. The external safety assessment is based on smoke concentration, vibration acceleration, and ambient humidity data collected by external sensors, with a maximum score of 100 points. The battery pack consistency assessment is based on individual cell voltage consistency, individual cell temperature consistency, and capacity consistency, with a maximum score of 100 points. The scores from each dimension are weighted and integrated to form the final comprehensive score, with a total score of 100 points.

[0021] As a preferred technical solution, the power supply unit further includes a charging management module and a protection circuit; the charging management module supports charging of independent batteries; the protection circuit includes overvoltage protection, overcurrent protection and short circuit protection, and automatically cuts off the power supply circuit when an abnormal power supply is detected to avoid damage to the internal modules of the detection board monitoring system.

[0022] As a preferred technical solution, the data transmission module supports receiving manual switching commands through a human-machine interface to switch between different communication methods; after the switch is completed, it automatically re-establishes the data connection and resends the key data (including alarm information and battery pack core status data) during the interruption.

[0023] As a preferred technical solution, the positioning module also supports a low-power operating mode; it determines the movement state of the battery pack based on vibration sensor data. In a stationary state, the positioning module enters a low-power mode; when the battery pack begins to move, this mode triggers the positioning module to automatically wake up and return to the normal positioning frequency.

[0024] This invention relates to a battery pack status monitoring method, comprising the following steps:

[0025] Step S1, System Deployment and Startup: Connect the detection board monitoring system to the battery management system (BMS) interface of the battery pack through the standardized composite interface; select independent battery power supply or external power supply. After the system is powered on, the control unit starts the initialization and self-test process. After the self-test is passed, the LED indicator light stays on. If the self-test fails, the red LED flashes and an alarm is triggered by a buzzer.

[0026] Step S2, Data Acquisition and Preprocessing: The control unit sends a data request command to the battery management system (BMS), and the BMS returns raw data of voltage, current, temperature, SOC, and SOH. At the same time, the control unit collects the voltage and power of the power supply unit, the data of the positioning module (if installed), and the smoke concentration / vibration acceleration data of the external sensor (if extended).

[0027] Step S3, Status Judgment and Alarm Trigger: The control unit performs multi-dimensional evaluation of the preprocessed data and assigns weights to each evaluation item to calculate the overall risk score of the battery pack; when it is determined to be high risk, the control unit triggers the alarm module: the buzzer sounds continuously, the red LED flashes, and alarm information is generated at the same time (including the anomaly type, device ID, occurrence time, and anomaly value).

[0028] Step S4, Data Transmission and Reception Processing: The data transmission module sends the battery pack status information (when normal) or status information + alarm information (when abnormal) to the receiving terminal; after receiving the data, the monitoring software of the receiving terminal parses the data, stores it in the local database, and updates the visualization interface; the location information marks the battery pack location on the map plugin;

[0029] Step S5, User Interaction and System Maintenance: Users can view data through the receiving terminal; clicking the "Historical Data" button allows querying data for any time period within the past 3 months, with filtering supported by criteria such as "Voltage Anomaly" and "Temperature Anomaly"; clicking the "Parameter Configuration" button allows adjustment of the data acquisition frequency (e.g., to 200ms / time); when the independent battery power of the detection board monitoring system is ≤20%, the control unit triggers a low battery alarm, prompting the user to charge via the external power interface; if expanded functionality is required, new sensors can be connected via the external interface, and the monitoring software will automatically identify and add corresponding data display items.

[0030] The present invention has the following beneficial effects:

[0031] (1) The detection board monitoring system of the present invention can be detachably connected to the battery pack through a standardized composite interface. It does not require modification of the internal structure of the battery pack, and can be used as a plug-and-play device. It is suitable for battery packs that have been manufactured, deployed in a distributed manner, or moved, which greatly expands the applicable scenarios and improves the deployment flexibility.

[0032] (2) The present invention can simultaneously monitor multiple parameters such as voltage, current, temperature, SOC, SOH, position, smoke, and vibration. Compared with infrared cameras, which can only monitor temperature, the information is more comprehensive and can form a complete battery status assessment system, thus improving the comprehensiveness of monitoring.

[0033] (3) The dual power supply design (independent battery + external power supply) of the present invention ensures that the monitoring system can still work when the battery pack fails, and the interface adopts waterproof connectors to adapt to harsh environments such as outdoors and humidity.

[0034] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0035] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a flowchart of a battery pack status monitoring method according to the present invention;

[0037] Figure 2 This is a schematic diagram of the structure of a battery pack status monitoring system according to the present invention. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0040] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figure 1-2 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0041] Example 1

[0042] Please see Figure 1 As shown, the present invention is a battery pack status monitoring method, comprising the following steps:

[0043] Step S1, System Deployment and Startup: Connect the detection board monitoring system 3 to the battery management system BMS11 interface of the battery pack 1 through the standardized composite interface 2. The insertion and extraction force of the interface should be ≤50N, and there should be no looseness after connection. Select independent battery 311 or external power supply 312 for power supply. After the system is powered on, the control unit 33 starts the initialization and self-test process. After the self-test is passed, the LED indicator light will be constantly lit. If the self-test fails, the red LED will flash and an alarm will be triggered by a buzzer.

[0044] Specifically, after the system is powered on, the control unit 33 performs a self-test procedure:

[0045] Check the voltage of power supply unit 31: If the independent battery voltage is ≥6.5V or the external power supply voltage is ≥12V, the power supply is considered normal.

[0046] Data transmission detection module 32: It determines whether the communication link is normal through a heartbeat mechanism. It periodically sends heartbeat data packets to the monitoring platform. If it receives a confirmation response from the platform within a preset time, it is determined that the communication is normal.

[0047] Detection and positioning module 35: If the module has been installed, send an initialization command, receive the ID information returned by the module, and determine that the module is normal; after the self-test is passed, the green LED indicator light will be constantly on; if the self-test fails (such as insufficient power supply voltage), the red LED will flash at a frequency of 0.5Hz, the buzzer will sound once every 1 second, and at the same time, the self-test failure information will be sent to the receiving terminal 5 through the data transmission module 32.

[0048] Step S2, Data Acquisition and Preprocessing: The control unit 33 sends a data request command to the battery management system BMS11, and the battery management system BMS11 returns raw data of voltage, current, temperature, SOC, and SOH; at the same time, the control unit 33 acquires the voltage of the power supply unit 31 (sampled by ADC, accuracy ≤0.01V), the power (detected by coulomb counter chip), the latitude and longitude / coordinate data of the positioning module 35 (if installed), and the smoke concentration / vibration acceleration data of the external sensor (if extended);

[0049] Specifically, data acquisition: The control unit (33) acquires data at the following frequencies:

[0050] BMS Data: Send the 0x01 command to BMS11, and BMS will return 16 bytes of data (including 4 bytes of voltage, 4 bytes of current, 2 bytes of temperature, 2 bytes of SOC, 2 bytes of SOH, and 2 bytes of checksum), with a sampling frequency of 100ms / time.

[0051] Power supply data: The voltage of power supply unit 31 is sampled by ADC (sampling accuracy 0.01V), and the power of the independent battery is read by coulomb counter chip (model MAX17048) at a sampling frequency of 500ms / time;

[0052] Location data: If a UWB module is installed, a location request command is sent and latitude and longitude data (format: DD.DDDDD°) is received from the module, with a collection frequency of 1 second / time; if an RFID module is installed, the tag ID identified by the reader is read and associated with the preset location information, with a collection frequency of 2 seconds / time.

[0053] Sensor data: If an external smoke sensor is connected, the smoke concentration (unit: %obs / m) is read through the I2C interface, with a sampling frequency of 1 second / time; if an external vibration sensor is connected, the level signal is read (high level indicates excessive vibration), with a sampling frequency of 200ms / time.

[0054] Data preprocessing includes filtering, outlier removal, and format conversion;

[0055] During filtering, the Kalman filter algorithm is used for voltage, current, and temperature data. The filtering formula is: Prediction equation: Update equation: ;in, It is a state vector (voltage / current / temperature). Here is the state transition matrix. For the control matrix, To control the quantity, For Kalman gain, Let covariance matrix be the variance matrix. For the observation matrix, To observe noise covariance.

[0056] Calculate the mean of the past 10 data collections. with standard deviation If the current data exceeds If a value is found to be out of range, it is replaced with the previous valid data.

[0057] Encapsulate all the data, as shown in the example below: {"device_id":"BMS-2025-001","collect_time":"2025-05-20 14:30:00","voltage":3.65,"current":1.2,"temperature":25.5,"soc":85,"soh":92,"power_remaining":75,"location":"30.123456,120.654321","smoke_concentration":0.05,"vibration_status":"normal"}.

[0058] Step S3, Status Judgment and Alarm Trigger: The control unit 33 performs multi-dimensional evaluation of the preprocessed data and assigns weights to each evaluation item to calculate the overall risk score of the battery pack; and compares the overall risk score of the battery pack with the risk threshold. When it is determined to be high risk, the control unit 33 triggers the alarm module 34: the buzzer sounds continuously, the red LED flashes, and alarm information is generated at the same time (including the anomaly type, device ID, occurrence time, and anomaly value).

[0059] Specifically, the multi-dimensional assessment includes voltage health assessment, current stress assessment, temperature gradient assessment, SOH degradation assessment, external safety assessment, and battery pack consistency assessment.

[0060] Voltage health assessment is based on the consistency of individual cell voltage, the magnitude of voltage fluctuation, and the degree of voltage deviation from the standard value (3.2V-3.7V / cell), with a full score of 100 points. 100 points are awarded when the maximum difference in individual cell voltage is ≤0.1V and no voltage exceeds the standard value. 10 points are deducted for every 0.05V increase in the maximum difference in individual cell voltage, and 20 points are deducted for every 0.1V exceeding the standard value when an individual cell voltage is detected.

[0061] The current stress assessment is based on the peak current, the duration of current exceeding the limit, and the stability of the charging and discharging current, with a full score of 100 points. Among them, 100 points are awarded when the peak current is ≤1.2 times the rated current, there is no operation exceeding the rated current for more than 3 seconds, and the current fluctuation coefficient is ≤5%. 15 points are deducted for every 0.1 times the rated current exceeded by the peak current, 5 points are deducted for every additional second of continuous overcurrent, and 3 points are deducted for every 1% increase in the current fluctuation coefficient.

[0062] The temperature gradient assessment is based on the maximum temperature difference inside the battery pack, the rate of temperature change, and the degree of temperature deviation from the safe range (-10℃-55℃), with a full score of 100 points. A score of 100 points is awarded when the maximum temperature difference is ≤5℃, the rate of temperature change is ≤2℃ / min, and the temperature does not exceed the safe range. 8 points are deducted for every 1℃ increase in the maximum temperature difference, 10 points are deducted for every 0.5℃ / min increase in the rate of temperature change, and 12 points are deducted for every 1℃ increase in the temperature beyond the safe range.

[0063] SOH decay assessment is based on the current SOH value, SOH decay rate, and the matching degree between SOH and the number of cycles, with a full score of 100 points. 100 points are awarded when SOH ≥ 90%, decay rate ≤ 2% / year, and fitting error with the number of cycles ≤ 3%. 15 points are deducted for every 5% decrease in SOH, 10 points are deducted for every 0.5% / year increase in decay rate, and 5 points are deducted for every 1% increase in fitting error.

[0064] External safety assessment is based on data collected from external sensors, including smoke concentration, vibration acceleration, and ambient humidity, with a maximum score of 100 points. Specifically, smoke concentration <0.05%obs / m and vibration acceleration <0.05%obs / m are considered high safety data points. 100 points are awarded when the ambient humidity is <60%RH; 10 points are deducted for every 0.01%obs / m increase in smoke concentration; and points are deducted for every vibration acceleration exceeding [a certain threshold]. Deduct 8 points; deduct 3 points for every 5% RH exceeding the ambient humidity.

[0065] Battery pack consistency assessment is based on scores for individual cell voltage consistency, individual cell temperature consistency, and capacity consistency, with a maximum score of 100 points; among which, voltage consistency variance... Temperature uniformity variance And capacity consistency variance A score of 100 is achieved when the voltage consistency variance increases by 100%. Deduct 5 points for each increase in temperature consistency variance. Deduct 6 points; for every increase in capacity consistency variance... 4 points deducted.

[0066] Weights were assigned to the above six detection and evaluation modules, with a total weight of 100%. Among them, the voltage health detection module had a weight of 25%, the current pressure detection module had a weight of 18%, the temperature gradient detection module had a weight of 20%, the SOH degradation assessment module had a weight of 15%, the external safety detection module had a weight of 12%, and the battery pack consistency analysis module had a weight of 10%.

[0067] Calculate the overall risk score of the battery pack: Overall score = Voltage health test score × 25% + Current stress test score × 18% + Temperature gradient test score × 20% + State of Health (SOH) degradation assessment score × 15% + External safety test score × 12% + Battery pack consistency analysis score × 10%;

[0068] Preset total score risk thresholds: High-risk threshold ≤ 69 points, Medium-risk threshold ≤ 69 points. The score is ≥90 points for low-risk threshold; if the total score is ≤69 points, the emergency alarm of alarm module 34 will be triggered immediately .... If the total score is ≥90, the battery pack status is determined to be normal, and only the status information of battery pack 1 is updated.

[0069] Step S4, Data Transmission and Reception Processing: The data transmission module 32 sends the status information of battery pack 1 (when normal) or status information + alarm information (when abnormal) to the receiving terminal 5; after receiving the data, the monitoring software 51 of the receiving terminal 5 parses the data, stores it in the local database (supports SQLite), and updates the visualization interface; real-time data is displayed on the dashboard, historical data is displayed in a line graph (1 hour / 24 hours / 7 days time dimension can be selected), and the location information is marked on the map plugin to indicate the location of battery pack 1;

[0070] Specifically, when sending data, the data transmission module 32 sends data according to the following rules:

[0071] Normal state: Status data is sent once every 1 second, using UDP protocol (5G / 4G / WiFi) or Bluetooth Low Energy (BLE) protocol (Bluetooth).

[0072] Abnormal state: After the alarm is triggered, send alarm information 3 times consecutively (100ms interval) to ensure that receiving terminal 5 receives it;

[0073] When receiving data, the monitoring software 51 of the receiving terminal 5 listens to the designated port (UDP port 5005) in real time, and performs the following operations after receiving the data:

[0074] Data parsing: Verify the validity of the data format. If the format is incorrect, discard the data; if the format is correct, extract the data from each field.

[0075] Data storage: The parsed data is stored in a local database (SQLite for mobile devices and MySQL for computers), and indexed by device ID and collection time to support fast querying;

[0076] Interface update: Real-time updates of digital dashboard values ​​and colors (red for anomalies), updates of trend chart lines (adding new data points), and refreshes the location of battery pack 1 on the map;

[0077] Alarm prompt: If the data contains the "alarm_type" field, a pop-up prompt and sound alarm will be triggered. The pop-up will display "Device ID: BMS-2025-001, Anomaly type: Overvoltage, Occurrence time: 2025-05-20 14:30:00". After the user clicks "Confirm", the pop-up will close and the alarm status will be marked as "Processed".

[0078] Step S5, User Interaction and System Maintenance: Users can view data through receiving terminal 5; clicking the "Historical Data" button allows querying data for any time period within the past 3 months, and supports filtering by conditions such as "voltage anomaly" and "temperature anomaly"; clicking the "Parameter Configuration" button allows adjustment of the data acquisition frequency (e.g., adjusting to 200ms / time); when the independent battery 311 of the detection board monitoring system 3 has a charge level ≤20%, the control unit 33 triggers a low battery alarm, prompting the user to charge via the external power interface 312; if expanded functionality is required, a new sensor can be connected via the external interface 36, and the monitoring software 51 will automatically identify and add corresponding data display items.

[0079] Specifically, when users view and operate the system, they open the monitoring software 51, which displays the real-time data dashboard by default. Clicking "Switch Device" allows them to view the status of multiple battery packs. Clicking "Historical Data" allows them to select the device ID and time range (e.g., 2025-11-19 00:00 to 2025-11-20 00:00), and the software generates and exports an Excel report. Users then enter the "Parameter Configuration" interface, modify the data acquisition frequency (e.g., adjust it to 200ms / time), and click "Save." The configuration command is then sent to the detection board monitoring system 3 via a wireless link, and the control unit 33 stores the new threshold in Flash memory, which takes effect immediately.

[0080] When the independent battery power is ≤20%, the monitoring software 51 displays "Low power prompt". The user connects a 12V power supply through the external power interface 312. The power supply unit 31 automatically switches to external power supply and charges the independent battery. After charging is completed (power ≥95%), the software displays "Charging complete".

[0081] Module replacement: If the positioning module 35 fails, the user can directly remove the old module and insert the new module. The control unit 33 will automatically recognize the new module and initialize it without reprogramming.

[0082] Program upgrade: If the firmware of the control unit 33 needs to be updated, the user can send the new firmware (.bin format) to the data transmission module 32 via the wireless link through the "Firmware Upgrade" function of the receiving terminal 5. After receiving the firmware, the control unit 33 will perform IAP (In-Application Programming) upgrade. During the upgrade process, the red LED will flash. After the upgrade is completed, the system will automatically restart.

[0083] Example 2

[0084] See Figure 2 As shown, the present invention is a battery pack status monitoring system, which can be used to execute the method content of Embodiment 1 of the present invention, including: battery pack 1, detection board monitoring system 3 and receiving terminal 5;

[0085] Battery pack 1, as the object under test, has a built-in battery management system BMS11; the battery management system BMS11 is used to collect the voltage, current, temperature and raw state data of battery pack 1, such as SOC and SOH.

[0086] The detection board monitoring system 3 is an external device independent of the battery pack 1. It is detachably connected to the battery pack 1 through a standardized composite interface 2. The standardized composite interface 2 realizes both power transmission and data communication functions. The detection board monitoring system 3 integrates a power supply unit 31, a data transmission module 32, a control unit 33, an alarm module 34, a pluggable positioning module 35, and an external interface 36.

[0087] The receiving terminal 5 is a mobile device or computer equipped with monitoring software 51. It establishes data interaction with the detection board monitoring system 3 through wireless communication, and is used to process, store and visualize the status data of battery pack 1, information of battery management system BMS11 and alarm information.

[0088] The power supply unit 31 includes an independent battery 311 and an external power interface 312. The independent battery 311 is a rechargeable battery with a capacity of not less than 5000mAh. The external power interface 312 supports 12V-24V DC power supply and is used to power all internal modules of the detection board monitoring system 3 and the battery management system BMS11 of the battery pack 1. The data transmission module 32 supports at least two of the communication methods of WiFi, 4G, and 5G and has the function of automatically switching communication links. The positioning module 35 adopts a pluggable USB interface design and supports GPS, UWB, or RFID positioning technology to obtain the real-time geographical location information of the battery pack 1. The external interface 36 is a standard GPIO interface, which supports the expansion of smoke sensors and vibration sensors, and also supports program burning through this interface. The alarm module 34 includes a buzzer, LED indicator and remote alarm signal generation unit, which is used to trigger multi-dimensional alarms when the battery pack 1 is in an abnormal state.

[0089] Control unit 33 employs a 32-bit ARM Cortex-M4 core processor; control unit 33 is configured to perform the following operations:

[0090] After the system completes power-on initialization, it includes clock configuration, peripheral driver loading, and self-test; the self-test checks the voltage of the power supply unit 31, the communication link of the data transmission module 32, and the connection status of the positioning module 35.

[0091] The BMS11 is powered and communicated via a 5V DC voltage output through the standardized composite interface 2, with a communication rate of no less than 1Mbps.

[0092] Raw data from BMS11 is collected at a frequency of 100ms / time, and voltage / power data of power supply unit 31, position data of positioning module 35 and detection data of external sensors are collected at a frequency of 500ms / time.

[0093] The collected data is preprocessed, including data filtering (using the Kalman filter algorithm) and outlier removal (based on 3D model). Guidelines) and data format conversion (convert to JSON format);

[0094] The preprocessed data is compared with preset thresholds (which can be configured via the receiving terminal 5). The preset thresholds include the upper limit of voltage (≥3.7V / unit), the lower limit of voltage (≤2.5V / unit), the upper limit of temperature (≥60℃), the lower limit of temperature (≤-20℃), and the vibration acceleration threshold (≥50m / s²).

[0095] If the data is abnormal, the alarm module 34 is immediately triggered to generate alarm information including the type of abnormality, the time of occurrence, and the battery pack ID; if the data is normal, the status information of battery pack 1 is updated.

[0096] The control data transmission module 32 sends the battery pack 1 status information, BMS 11 information and alarm information to the receiving terminal 5 at a frequency of 1 second / time.

[0097] The monitoring software of receiving terminal 5 presents data in the form of digital dashboards, line graphs, and lists; it provides a visual interface for users to set data acquisition frequency, communication method priority, and positioning module 35 working mode; after receiving alarm information, it triggers terminal pop-up prompts and sound alarms, supports alarm information export and historical alarm record query; it also supports adding / deleting detection board monitoring system 3 devices, and displays the remaining power and communication status of each device's power supply unit 31.

[0098] The standardized composite interface 2 uses a waterproof connector and integrates power supply, communication and signal grounding functions. The standardized composite interface 2 has a plug-in life of ≥1000 cycles and a plug-in force of ≤50N.

[0099] The power supply unit 31 also includes a charging management module and a protection circuit. The charging management module uses a MAX1879 chip, which supports constant current and constant voltage charging of the independent battery 311. The charging current can be adjusted in the range of 0.5A-2A, and the charging cut-off voltage is 4.2V / cell. The protection circuit includes overvoltage protection (threshold is the upper limit of the external power supply voltage +2V), overcurrent protection (threshold is 3A) and short circuit protection. When an abnormal power supply is detected, the power supply circuit is automatically cut off to avoid damage to the internal modules of the detection board monitoring system 3.

[0100] The data transmission module 32 supports receiving manual switching commands through the human-machine interface and switching between different communication methods; the data transmission interruption time during the switching process is ≤100ms, and after the switching is completed, the data connection is automatically re-established and the key data during the interruption (including alarm information and battery pack core status data) is resent.

[0101] The positioning module 35 also supports a low-power operating mode. When the battery pack 1 is stationary (vibration acceleration ≤ 0.1 m / s² detected by the vibration sensor for 5 minutes), the positioning module 35 automatically enters the low-power mode, the positioning frequency decreases from 1 s / time to 10 s / time, and the current consumption decreases from 10 mA to 2 mA. When the battery pack 1 is detected to resume movement (vibration acceleration > 0.1 m / s²), the positioning module 35 automatically wakes up and resumes the normal positioning frequency.

[0102] Example 3: Monitoring of Power Battery Packs for New Energy Vehicles

[0103] A new energy vehicle manufacturer needs to conduct long-term condition monitoring of the power battery packs after they leave the factory. These battery packs are distributed in warehouse vehicles or vehicles that have been sold but are parked. In order to achieve effective after-sales management, it is necessary to promptly detect safety hazards such as battery performance degradation and thermal runaway.

[0104] System Configuration:

[0105] Battery Pack 1: Lithium iron phosphate battery pack (100Ah, 3.2V / cell, 16 series, total voltage 51.2V), built-in BMS11 (model BMS-2023-A).

[0106] Detection board monitoring system 3: equipped with 5G data transmission module (SIM8200EA-M2), UWB positioning module (DW1000), and external vibration sensor (SW-420).

[0107] Receiving terminal 5: An industrial computer (Windows 10 system) is used, with monitoring software 51 installed, and deployed in the vehicle manufacturer's after-sales center. Implementation process:

[0108] Deployment: Before the car leaves the factory, the detection board monitoring system 3 is connected to the battery pack 1BMS interface through the standardized composite interface 2 and powered by an external power source (the car's 12V battery);

[0109] Monitoring: During vehicle operation, the detection board monitoring system 3 collects BMS data every 100ms, collects vibration sensor data every 200ms (monitoring vibration during driving), and sends data to the after-sales center receiving terminal 5 via 5G link every second.

[0110] Abnormal Handling: When a car collision occurs, if the vibration sensor detects an acceleration ≥50m / s², the control unit 33 will trigger a vibration abnormality alarm. The alarm information will be transmitted to the receiving terminal 5 within 1 second, and the after-sales center will immediately contact the car owner to arrange for repair.

[0111] Results: Through this system, automakers can remotely and centrally monitor the battery packs of 1,000 new energy vehicles. The time to detect faults has been shortened from "24 hours after user feedback" to "1 second after the anomaly occurs", and the incidence of thermal runaway accidents has been reduced by 90%.

[0112] Example 4: Monitoring of Battery Packs in Energy Storage Power Stations

[0113] Application Scenario: An energy storage power station comprises 100 energy storage battery packs (distributed across 20 energy storage cabinets). Monitoring of battery pack temperature and state of charge (SOC) is required to prevent overheating and overcharging. System Configuration:

[0114] Battery Pack 1: Lithium-ion battery pack (200Ah, 3.7V / cell, 24 series, total voltage 88.8V), built-in BMS11 (model BMS-2023-B).

[0115] Detection board monitoring system 3: equipped with WiFi data transmission module (ESP8266), RFID positioning module (RC522), and external smoke sensor (MQ-2);

[0116] Receiving terminal 5: A smartphone (Android 13 system) is used; each power plant maintenance personnel is equipped with one. Implementation process:

[0117] Deployment: Install a detection board monitoring system 3 on each energy storage battery pack, powered by an external power supply (12V DC power supply of the energy storage cabinet), and connect the WiFi module to the power station's local area network;

[0118] Monitoring: Maintenance personnel can monitor the temperature (normal range 0-45℃) and SOC (normal range) of each battery pack in real time via a mobile app. ), the RFID module locates the energy storage cabinet number where the battery pack is located;

[0119] Anomaly Handling: When the temperature of a battery pack rises to 55℃ (exceeding the preset threshold of 50℃), the detection board monitoring system 3 triggers a temperature anomaly alarm, and the APP pops up a notification. The maintenance personnel immediately go to the corresponding energy storage cabinet and find that the cooling fan is faulty. After replacing the fan, the temperature returns to normal.

[0120] Results: The power station achieved unattended monitoring of the battery pack status, reduced the number of maintenance personnel from 5 to 2, shortened the anomaly handling time from 30 minutes to 5 minutes, and improved the operating efficiency of the energy storage system by 15%.

[0121] It is worth noting that the various units included in the above system embodiments are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of each functional unit are only for easy differentiation and are not used to limit the scope of protection of the present invention.

[0122] Furthermore, those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware, and the corresponding program can be stored in a computer-readable storage medium.

[0123] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A battery pack status monitoring system, comprising a battery pack (1), a detection board monitoring system (3), and a receiving terminal (5), characterized in that: The battery pack (1) is the object to be tested and has a built-in battery management system (BMS) (11); the battery management system (BMS) (11) is used to collect the voltage, current, temperature and SOC and SOH raw state data of the battery pack (1); The detection board monitoring system (3) is an external device independent of the battery pack (1). It is detachably connected to the battery pack (1) through a standardized composite interface (2). The standardized composite interface (2) simultaneously realizes power transmission and data communication functions. The detection board monitoring system (3) integrates a power supply unit (31), a data transmission module (32), a control unit (33), an alarm module (34), a pluggable positioning module (35), and an external interface (36). The receiving terminal (5) establishes a connection with the detection board monitoring system (3) through wired or wireless communication and completes data interaction. It is used to process, store and visualize the status data of the battery pack (1), the information of the battery management system (BMS) (11) and alarm information.

2. The battery pack status monitoring system according to claim 1, characterized in that, The power supply unit (31) includes an independent battery (311) and an external power interface (312). The independent battery (311) is a rechargeable battery that can be disassembled and replaced. The external power interface (312) can power all modules inside the detection board monitoring system (3) and the battery management system (BMS) (11) of the battery pack (1), and can also charge the independent battery (311). The data transmission module (32) supports wired communication and multiple wireless communication protocols, and has a manual switching function. It can receive the user's switching command through the human-machine interface to select the communication mode. The positioning module (35) adopts a pluggable USB interface or a fixed onboard integrated design, and supports GPS, UWB or RFID positioning technology to obtain the real-time geographical location information of the battery pack (1). The external interface (36) supports the expansion of smoke sensors and vibration sensors, and can also support program burning through the interface. The alarm module (34) includes a buzzer, LED indicator and remote alarm signal generation unit, which is used to trigger multi-dimensional alarms when the battery pack (1) is in an abnormal state.

3. The battery pack status monitoring system according to claim 1, characterized in that, The control unit (33) is configured to perform the following operations: After the system completes power-on initialization, it includes clock configuration, peripheral driver loading and self-test; the self-test detects the voltage of the power supply unit (31), the communication of the data transmission module (32) and the connection status of the positioning module (35); it supplies power to the battery management system (BMS) (11) through the standardized composite interface (2), collects the original data of the battery management system (BMS) (11), and collects the voltage / power data of the power supply unit (31), the position data of the positioning module (35) and the detection data of the external sensor; The collected data is preprocessed, including data filtering, outlier removal, and data format conversion. The preprocessed data is evaluated in multiple dimensions, and weights are assigned to each evaluation item. The overall risk score of the battery pack is calculated and compared with the risk threshold. If the data is determined to be high risk, the alarm module (34) is immediately triggered to generate alarm information including the abnormality type, occurrence time, and battery pack ID. If the data is normal, the status information of the battery pack (1) is updated. The control data transmission module (32) sends the battery pack (1) status information, battery management system (BMS) (11) information and alarm information to the receiving terminal (5).

4. The battery pack status monitoring system according to claim 3, characterized in that, The monitoring software of the receiving terminal (5) presents data in the form of digital dashboard, line graph, and list; it provides a visual interface for users to set the data acquisition frequency, communication method priority and positioning module (35) working mode; after receiving alarm information, it triggers terminal pop-up prompts and sound alarms, supports alarm information export and historical alarm record query; at the same time, it supports adding / deleting detection board monitoring system (3) devices, and displays the remaining power and communication status of the power supply unit (31) of each device.

5. A battery pack status monitoring system according to claim 4, characterized in that, The power supply unit (31) also includes a charging management module and a protection circuit; the charging management module supports charging of the independent battery (311); the protection circuit includes overvoltage protection, overcurrent protection and short circuit protection, and automatically cuts off the power supply circuit when an abnormal power supply is detected to avoid damage to the internal modules of the detection board monitoring system (3).

6. The battery pack status monitoring system according to claim 3, characterized in that, The data transmission module (32) supports receiving manual switching instructions through the human-machine interface, switching between different communication methods, and automatically re-establishing the data connection and resending the key data during the interruption after the switching is completed.

7. A battery pack status monitoring system according to claim 3, characterized in that, The positioning module (35) also supports a low-power working mode; it judges the motion state of the battery pack (1) based on the vibration sensor data; when stationary, the positioning module (35) will enter a low-power mode; when the battery pack starts to move, this state will trigger the positioning module to automatically wake up and return to the normal positioning frequency.

8. A battery pack status monitoring method based on the system of any one of claims 1-7, characterized in that, Includes the following steps: Step S1, System Deployment and Startup: Connect the detection board monitoring system (3) to the battery management system (BMS) (11) of the battery pack (1) through the standardized composite interface (2); select independent battery (311) power supply or external power supply (312) power supply. After the system is powered on, the control unit (33) starts the initialization and self-test process. After the self-test is passed, the LED indicator light stays on. If the self-test fails, the red LED flashes and an alarm is triggered by a buzzer. Step S2, Data Acquisition and Preprocessing: The control unit (33) sends a data request command to the battery management system (BMS) (11), and the battery management system (BMS) (11) returns the original data of voltage, current, temperature, SOC, and SOH; at the same time, the control unit (33) collects the voltage and power of the power supply unit (31), the data of the positioning module (35), and the smoke concentration / vibration acceleration data of the external sensor; Step S3, Status Judgment and Alarm Trigger: The control unit (33) performs multi-dimensional evaluation on the preprocessed data, assigns weights to each evaluation item, and calculates the overall risk score of the battery pack; When a high risk is determined, the control unit (33) triggers the alarm module (34): the buzzer sounds continuously, the red LED flashes, and an alarm message is generated at the same time; Step S4, Data transmission and reception processing: The data transmission module (32) sends the status information or alarm information of the battery pack (1) to the receiving terminal (5); After receiving the data, the monitoring software (51) of the receiving terminal (5) parses the data, stores it in the local database, and updates the visualization interface; The location information marks the location of the battery pack (1) on the map plugin; Step S5, User Interaction and System Maintenance: The user can view the data through the receiving terminal (5); Click the "Historical Data" button to query data for any time period within the past 3 months; Click the "Parameter Configuration" button to adjust the data acquisition frequency; When the independent battery (311) of the detection board monitoring system (3) has a power level ≤20%, the control unit (33) triggers a low power alarm, prompting the user to charge through the external power interface (312).

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