Lead-acid battery explosion-proof battery box system and control method thereof

Abstract

This invention discloses an explosion-proof battery box system and its control method for lead-acid batteries, belonging to the field of lead-acid battery safety protection technology. The system consists of an explosion-proof battery box body, a flame arrestor, an explosion-proof fan, an explosion-proof display screen, an explosion-proof enclosure, an explosion-proof temperature sensor, an explosion-proof hydrogen concentration sensor, an insulating pad, an explosion-proof insulation resistor, an explosion-proof heating cable, and an automatic control device. The control method includes steps such as heating the explosion-proof heating cable during low-temperature charging, hydrogen discharge during normal-temperature charging, cooling the fan during high-temperature charging, leakage monitoring and shutdown warning, high-temperature discharge control, and automatic switching between multiple battery packs. It realizes multi-dimensional safety monitoring and intelligent automatic control during the use of lead-acid batteries, and has functions such as explosion-proof, temperature control, leakage monitoring, and extended battery life. It is highly controllable, safe and reliable, and has high charging efficiency, and can be widely used in various lead-acid battery application scenarios.

Description

Technical Field

[0001] This invention relates to the field of lead-acid battery safety protection technology, and in particular to an explosion-proof battery box system for lead-acid batteries and its control method. Background Technology

[0002] Lead-acid batteries are widely used in equipment used in explosive or pyrotechnic scenarios due to their low cost, large capacity, mature technology, and stable chemical properties. However, lead-acid batteries are prone to problems such as hydrogen evolution, overheating, and leakage during charging and discharging. Hydrogen accumulation can easily lead to explosions, excessively high temperatures reduce charging efficiency and pose safety hazards, and battery leakage can corrode equipment and cause circuit failures. Existing lead-acid battery boxes only have a simple containment function and lack effective explosion-proof, temperature control, leakage monitoring, and automatic control functions. They cannot monitor and intelligently handle various safety hazards during the use of lead-acid batteries in real time, making it difficult to guarantee the safety and battery life of the equipment. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a lead-acid battery explosion-proof battery box system.

[0004] Another objective of this invention is to provide a control method for an explosion-proof battery box for lead-acid batteries.

[0005] This invention primarily addresses the problems of existing lead-acid battery boxes lacking effective explosion-proof, temperature control, and leakage monitoring functions, resulting in significant safety hazards and low automation.

[0006] The technical solution provided by this invention is: a lead-acid battery explosion-proof battery box system, which is characterized by comprising an explosion-proof battery box body, a flame arrestor, an explosion-proof fan, an explosion-proof display screen, an explosion-proof box, an explosion-proof temperature sensor, an explosion-proof hydrogen concentration sensor, an insulating pad, an explosion-proof insulation resistor, an explosion-proof heating tape, and an automatic control device. An insulating pad is fixedly installed at the bottom of the explosion-proof battery box body, and an explosion-proof insulating resistor is embedded in the center of the insulating pad. An explosion-proof temperature sensor is fixedly installed in the middle of the explosion-proof battery box body. An explosion-proof fan and a flame arrestor are fixedly installed on the top cover of the explosion-proof battery box body. The flame arrestor is snapped and fixed at the ventilation opening of the top cover of the explosion-proof battery box body. The explosion-proof fan is fixed on the top cover of the explosion-proof battery box body and faces the flame arrestor. An explosion-proof hydrogen concentration sensor is fixed under the top cover of the explosion-proof battery box body. An explosion-proof enclosure is provided on one side of the top cover of the explosion-proof battery box body, and an automatic control device is fixed inside the explosion-proof enclosure. An explosion-proof display screen is fixed on the outer surface of the explosion-proof enclosure. The explosion-proof battery box body has an explosion-proof heating cable fixed to its inner wall, and the explosion-proof heating cable is wrapped with an insulating protective layer. The explosion-proof fan, explosion-proof display screen, explosion-proof temperature sensor, explosion-proof hydrogen concentration sensor, explosion-proof insulation resistor, and explosion-proof heating cable are connected to the automatic control device via wiring harnesses; the explosion-proof heating cable has a reserved interface for connection to the lead-acid battery inside the explosion-proof battery box for power supply. The flame arrestor allows air to flow between the inside and outside of the explosion-proof battery box, thus providing ventilation. The explosion-proof fan extracts hydrogen gas from the battery box via the flame arrestor, which also reduces the temperature inside the battery box. The explosion-proof display screen shows the battery's status and fault codes.

[0007] Furthermore, the battery box contains two or more battery packs. When one battery pack is depleted, the automatic control device automatically switches to another battery pack to increase the device's battery life.

[0008] Furthermore, the insulating pad is used to cover the bottom of the battery; the explosion-proof insulation resistor monitors the resistance of the insulating pad in real time, and assesses whether there is leakage in the battery by the resistance value of the insulating pad; the explosion-proof temperature sensor detects the temperature information of the explosion-proof battery box body and feeds it back to the explosion-proof display screen in real time.

[0009] The present invention discloses a control method for a lead-acid battery explosion-proof battery box system, characterized in that the lead-acid battery explosion-proof battery box body system performs lead-acid battery charging and discharging control, and the specific control method is as follows: Low-temperature charging control: The explosion-proof temperature sensor detects the internal temperature of the explosion-proof battery box and feeds this information back to the automatic control device. When the automatic control device receives the information that the internal temperature of the explosion-proof battery box is too low, it immediately controls the explosion-proof heating cable to be powered on and work to heat up the internal temperature of the explosion-proof battery box. When the explosion-proof temperature sensor detects that the temperature has risen above 0°C, the automatic control device controls the explosion-proof heating cable to be powered off and stop working. Normal temperature charging control: When charging at normal temperature, hydrogen is generated when the battery is overcharged. When the explosion-proof hydrogen concentration sensor detects that the hydrogen concentration is too high, it feeds back the information to the automatic control device. The automatic control device sends a stop charging signal to the charging pile on the one hand, and controls the explosion-proof fan to start on the other hand. The hydrogen is extracted from the battery box through the flame arrestor plate. When the hydrogen concentration drops to a safe range, the explosion-proof fan stops working. High-temperature charging control: The explosion-proof temperature sensor detects the internal temperature of the explosion-proof battery box and feeds it back to the automatic control device. Upon receiving the information that the internal temperature of the explosion-proof battery box is too high, the automatic control device controls the explosion-proof fan to work continuously to cool down the internal temperature of the explosion-proof battery box and ensure the safe charging process. Leakage monitoring and control: When one of the lead-acid batteries leaks electrolyte, the leakage seeps into the insulating pad. The explosion-proof insulation resistor feeds back the abnormal information to the automatic control device. The automatic control device immediately stops the battery from charging and discharging and displays the "battery leakage" fault code on the explosion-proof display screen. Staff can detect and replace the battery in time. Discharge temperature control: During battery discharge, the temperature inside the box rises due to the large current discharge. After the explosion-proof temperature sensor provides feedback, the explosion-proof fan starts to cool down the box. The temperature inside the box drops and the explosion-proof fan works intermittently. When the temperature inside the box rises to 50°C due to equipment failure, the automatic control device immediately stops the battery from discharging to prevent battery damage and safety accidents. Battery pack switching control: The explosion-proof battery box contains two or more sets of lead-acid battery packs of the same capacity. When a set of battery packs is depleted, the automatic control device detects the power signal and automatically cuts off the discharge circuit of that set of battery packs, while simultaneously connecting the discharge circuit of the next set of battery packs, thus achieving uninterrupted switching.

[0010] The beneficial effects of this invention are: 1. The structure is reasonable and the components work together to realize multi-dimensional safety monitoring and intelligent control during the use of lead-acid batteries; it integrates real-time monitoring functions for temperature, hydrogen concentration and leakage status, which can promptly detect various safety hazards during the use of lead-acid batteries, avoid problems such as explosion, corrosion and circuit failure, and improve the safety of use; 2. The automatic control device can automatically complete operations such as starting and stopping the explosion-proof heating cable, operating the explosion-proof fan, stopping battery charging and discharging, and switching battery packs based on monitoring data, without manual intervention, reducing operating costs and improving management efficiency; 3. Differentiated temperature control measures are adopted for different charging scenarios. At low temperatures, the explosion-proof heating cable is used to raise the temperature and improve charging efficiency. At high temperatures, the explosion-proof fan is used to cool down and reduce safety hazards. At the same time, hydrogen gas generated by overcharging is discharged in time to further ensure charging safety. 4. The insulating rubber pad can withstand impact and prevent electrolyte corrosion of the explosion-proof battery box body. The explosion-proof insulation resistance can accurately assess the battery leakage through the change of resistance value, so as to realize early detection and early treatment of leakage. 5. Supports the placement of multiple battery packs and enables automatic switching, effectively increasing the device's battery life and making it suitable for usage scenarios with high battery life requirements; 6. The explosion-proof display screen can display the battery status and fault codes in real time, allowing staff to intuitively grasp the equipment's operating status and facilitating subsequent maintenance and troubleshooting; 7. All components meet explosion-proof requirements. The overall system is highly controllable, safe and reliable, and can be widely used in conjunction with various lead-acid batteries, with a wide range of applications. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the axial view structure of the present invention; Figure 3 This is a schematic diagram of the axial view structure of the present invention (showing the flame arrestor and fan mounting structure); Figure 4 yes Figure 1 AA sectional view; Figure 5 This is a partial schematic diagram of the insulating rubber pad and explosion-proof insulating resistor of the present invention; Figure 6 This is a flowchart of the battery charging temperature control process of the present invention; Figure 7 This is a flowchart of the battery charging hydrogen concentration control process of the present invention; Figure 8 This is a flowchart of the battery charging resistor control process of the present invention.

[0012] In the diagram: 1. Explosion-proof box, 2. Explosion-proof battery box body, 3. Explosion-proof fan, 4. Flame arrestor plate, 5. Explosion-proof display screen, 6. Explosion-proof hydrogen concentration sensor, 7. Explosion-proof temperature sensor, 8. Explosion-proof heating tape, 9. Automatic control device, 10. Explosion-proof insulation resistor, 11. Insulating rubber mat. Detailed Implementation

[0013] To better understand and implement this invention, the following detailed description is provided in conjunction with the accompanying drawings.

[0014] like Figure 1 , 2 As shown in Figures 3, 4, and 5, an explosion-proof battery box system for lead-acid batteries includes an explosion-proof battery box body 2, a flame arrestor 4, an explosion-proof fan 3, an explosion-proof display screen 5, an explosion-proof box 1, an explosion-proof temperature sensor 7, an explosion-proof hydrogen concentration sensor 6, an insulating pad 11, an explosion-proof insulation resistor 10, an explosion-proof heating tape 8, and an automatic control device 9. An insulating pad 11 is bonded and fixed to the bottom of the explosion-proof battery box body 2 to cover the bottom of the battery. An explosion-proof insulation resistor 10 is embedded and fixed in the center of the insulating pad 11. An explosion-proof temperature sensor 7 is fixed in the middle of the explosion-proof battery box body 2 by a bracket, with a distance of 5cm from the surface of the battery pack. A flame arrestor 4 is snapped and fixed at the ventilation opening of the top cover of the explosion-proof battery box body 2. An explosion-proof fan 3 is fixed above the cover of the explosion-proof battery box body 2 by bolts and faces the flame arrestor 4. An explosion-proof hydrogen concentration sensor 6 is suspended and fixed below the top cover of the explosion-proof battery box body 2, with a distance of 3cm from the flame arrestor 4. An explosion-proof box 1 is fixed to one side above the top cover of the explosion-proof battery box body 2 by bolts. An automatic control device 9 is integrated and installed inside the explosion-proof box 1. An explosion-proof display screen 5 is embedded on the outer surface of the explosion-proof box 1. An explosion-proof heating cable 8 is wrapped and fixed to the inner wall of the explosion-proof battery box body 2, and the explosion-proof heating cable 8 is wrapped with an insulating protective layer. The explosion-proof fan 3, explosion-proof display screen 5, explosion-proof temperature sensor 7, explosion-proof hydrogen concentration sensor 6, explosion-proof insulation resistor 10, and explosion-proof heating cable 8 are all electrically connected to the automatic control device 9 via waterproof wiring harnesses; the explosion-proof heating cable 8 has a reserved aviation plug interface for connection and power supply to a lead-acid battery; the explosion-proof box 1 adopts an explosion-proof sealed structure, and the circuit board of the internal automatic control device 9 is treated for explosion-proof and moisture-proof properties.

[0015] The above-mentioned explosion-proof battery box system for lead-acid batteries is used for charging and discharging control of lead-acid batteries, such as... Figure 6 , 7 As shown in Figure 8, the specific control method is as follows: Low-temperature charging control: During outdoor charging in winter, the explosion-proof temperature sensor detects that the internal temperature of the explosion-proof battery box is -5°C and feeds this information back to the automatic control device. The automatic control device immediately controls the explosion-proof heating cable to be powered on to heat the inside of the explosion-proof battery box. When the explosion-proof temperature sensor detects that the temperature has risen to 2°C, the automatic control device controls the explosion-proof heating cable to be powered off and stop working. At this time, the charging pile is started to charge the lead-acid battery, and the charging efficiency is 30% higher than that without heating measures. Normal temperature charging control: When charging at room temperature of 25°C, if the battery is overcharged due to a charging pile malfunction, the explosion-proof hydrogen concentration sensor detects that the hydrogen concentration inside the explosion-proof battery box has reached 20% of the lower explosive limit. The information is immediately fed back to the automatic control device. The automatic control device sends a stop charging signal to the charging pile on the one hand, and controls the explosion-proof fan to start on the other hand. The hydrogen is extracted from the explosion-proof battery box through the flame arrestor. After 5 minutes, the hydrogen concentration drops to a safe range and the explosion-proof fan stops working. High-temperature charging control: When charging outdoors in summer, the explosion-proof temperature sensor detects that the internal temperature of the explosion-proof battery box is 35°C. After feeding back to the automatic control device, the automatic control device controls the explosion-proof fan to work continuously to cool down the internal temperature of the explosion-proof battery box, keeping the internal temperature at around 28°C to ensure the safe charging process. Leakage monitoring and control: One of the lead-acid batteries experienced electrolyte leakage, which seeped into the insulating pad, causing the resistance value monitored by the explosion-proof insulation resistor to drop from 1000MΩ to 50MΩ. The explosion-proof insulation resistor fed back the abnormal information to the automatic control device, which immediately stopped the battery from charging and discharging and displayed the "battery leakage" fault code on the explosion-proof display screen. Staff could then promptly detect and replace the battery. Discharge temperature control: During battery discharge, the temperature inside the box rises to 40°C due to the large current discharge. After the explosion-proof temperature sensor provides feedback, the explosion-proof fan starts to cool down. After the temperature inside the box drops to 30°C, the explosion-proof fan works intermittently. When the temperature inside the box rises to 50°C (threshold) due to equipment failure, the automatic control device immediately controls the battery to stop discharging to prevent battery damage and safety accidents. Battery pack switching control: The explosion-proof battery box contains two sets of lead-acid battery packs of the same capacity. When the first set of battery packs is depleted (remaining power ≤ 5%), the automatic control device detects the power signal and automatically cuts off the discharge circuit of the first set of battery packs while connecting the discharge circuit of the second set of battery packs, achieving uninterrupted switching. The equipment's battery life is doubled compared to a single battery pack.

[0016] The scope of protection of this invention is not limited to the above-described embodiments. All equivalent substitutions or changes made based on the technical solutions and inventive concepts of this invention should be included within the scope of protection of this invention.

Claims

1. A lead-acid battery explosion-proof battery box system, characterized by, It consists of an explosion-proof battery box body, flame arrestor, explosion-proof fan, explosion-proof display screen, explosion-proof box, explosion-proof temperature sensor, explosion-proof hydrogen concentration sensor, insulating pad, explosion-proof insulation resistor, explosion-proof heating cable, and automatic control device; An insulating pad is fixedly installed at the bottom of the explosion-proof battery box body, and an explosion-proof insulating resistor is embedded in the center of the insulating pad. An explosion-proof temperature sensor is fixedly installed in the middle of the explosion-proof battery box body. An explosion-proof fan and a flame arrestor are fixedly installed on the top cover of the explosion-proof battery box body. The flame arrestor is snapped and fixed at the ventilation opening of the top cover of the explosion-proof battery box body. The explosion-proof fan is fixed on the top cover of the explosion-proof battery box body and faces the flame arrestor. An explosion-proof hydrogen concentration sensor is fixed under the top cover of the explosion-proof battery box body. An explosion-proof enclosure is provided on one side of the top cover of the explosion-proof battery box body, and an automatic control device is fixed inside the explosion-proof enclosure. An explosion-proof display screen is fixed on the outer surface of the explosion-proof enclosure. The explosion-proof battery box body has an explosion-proof heating cable fixed to its inner wall, and the explosion-proof heating cable is wrapped with an insulating protective layer. The explosion-proof fan, explosion-proof display screen, explosion-proof temperature sensor, explosion-proof hydrogen concentration sensor, explosion-proof insulation resistor, and explosion-proof heating cable are connected to the automatic control device via wiring harnesses; the explosion-proof heating cable has a reserved interface for connection to the lead-acid battery inside the explosion-proof battery box for power supply. The flame arrestor allows air to flow between the inside and outside of the explosion-proof battery box, thus providing ventilation. The explosion-proof fan extracts hydrogen gas from the battery box via the flame arrestor, which also reduces the temperature inside the battery box. The explosion-proof display screen shows the battery's status and fault codes.

2. A lead-acid battery explosion-proof battery box system according to claim 1, characterized in that, The battery box contains two or more battery packs. When one battery pack is depleted, the automatic control device automatically switches to another battery pack to increase the device's battery life.

3. A lead-acid battery explosion-proof battery box system according to claim 1, characterized in that, The insulating pad is used to cover the bottom of the battery; the explosion-proof insulation resistor monitors the resistance of the insulating pad in real time, and assesses whether there is leakage in the battery by the resistance value of the insulating pad; the explosion-proof temperature sensor detects the temperature information of the explosion-proof battery box body and feeds it back to the explosion-proof display screen in real time.

4. A control method of the lead-acid battery explosion-proof battery case system according to claim 1 or 2 or 3, characterized by, The explosion-proof battery box system for lead-acid batteries controls the charging and discharging of lead-acid batteries. The specific control methods are as follows: Low-temperature charging control: The explosion-proof temperature sensor detects the internal temperature of the explosion-proof battery box and feeds this information back to the automatic control device. When the automatic control device receives the information that the internal temperature of the explosion-proof battery box is too low, it immediately controls the explosion-proof heating cable to be powered on and work to heat up the internal temperature of the explosion-proof battery box. When the explosion-proof temperature sensor detects that the temperature has risen above 0°C, the automatic control device controls the explosion-proof heating cable to be powered off and stop working. Normal temperature charging control: When charging at normal temperature, hydrogen is generated when the battery is overcharged. When the explosion-proof hydrogen concentration sensor detects that the hydrogen concentration is too high, it feeds back the information to the automatic control device. The automatic control device sends a stop charging signal to the charging pile on the one hand, and controls the explosion-proof fan to start on the other hand. The hydrogen is extracted from the battery box through the flame arrestor plate. When the hydrogen concentration drops to a safe range, the explosion-proof fan stops working. High-temperature charging control: The explosion-proof temperature sensor detects the internal temperature of the explosion-proof battery box and feeds it back to the automatic control device. Upon receiving the information that the internal temperature of the explosion-proof battery box is too high, the automatic control device controls the explosion-proof fan to work continuously to cool down the internal temperature of the explosion-proof battery box and ensure the safe charging process. Leakage monitoring and control: When one of the lead-acid batteries leaks electrolyte, the leakage seeps into the insulating pad. The explosion-proof insulation resistor feeds back the abnormal information to the automatic control device. The automatic control device immediately stops the battery from charging and discharging and displays the "battery leakage" fault code on the explosion-proof display screen. Staff can detect and replace the battery in time. Discharge temperature control: During battery discharge, the temperature inside the box rises due to the large current discharge. After the explosion-proof temperature sensor provides feedback, the explosion-proof fan starts to cool down the box. The temperature inside the box drops and the explosion-proof fan works intermittently. When the temperature inside the box rises to 50°C due to equipment failure, the automatic control device immediately stops the battery from discharging to prevent battery damage and safety accidents. Battery pack switching control: The explosion-proof battery box contains two or more sets of lead-acid battery packs of the same capacity. When a set of battery packs is depleted, the automatic control device detects the power signal and automatically cuts off the discharge circuit of that set of battery packs, while simultaneously connecting the discharge circuit of the next set of battery packs, thus achieving uninterrupted switching.

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