Dynamic power distribution mine-used UPS intelligent charging system and method based on output current acquisition

Abstract

The application provides a dynamic power distribution mining UPS intelligent charging system and method based on output current collection, which comprises an input unit, an output unit, a battery management unit, a charging control unit and a man-machine interaction unit. By collecting the input voltage and current of the DC / DC conversion module, the single-path and total load rate are calculated, the charging power is dynamically distributed in combination with the battery state, the mode switching of low-load fast charging, medium-load standard charging, high-load stop charging / maintenance is realized, and the grading early warning and overload protection functions are provided. The application has the beneficial effects of solving the problems of traditional charging, such as ignoring the dynamic change of load, low efficiency, short battery life and the like, guaranteeing the priority of main load power supply, improving the charging efficiency and battery life, and enhancing the intelligence and adaptability of the system.

Description

Technical Field

[0001] This invention belongs to the field of emergency power supply technology in coal mines, and in particular relates to a dynamic power distribution intelligent charging system and method for mining UPS based on output current acquisition. Background Technology

[0002] In underground coal mines, UPS power supplies, which power critical loads such as monitoring substations, sensors, and communication equipment, are of paramount importance. Their built-in backup batteries, typically lithium battery packs, must immediately activate to ensure continuous system power supply in the event of an AC mains power outage. Therefore, ensuring that the backup batteries are always at or near full charge is a fundamental requirement for safe production.

[0003] Traditional mining UPS charging management generally adopts a simplified management model: 1. Constant current-constant voltage charging: The battery is continuously charged when the main power supply is normal, and then switched to float charging state after it is fully charged.

[0004] 2. Simple start-stop control based on voltage threshold: By detecting the battery voltage, charging is started when it is lower than the set threshold, and charging is stopped when the threshold is reached.

[0005] These traditional solutions have the following problems: 1. Ignoring dynamic load changes affects the stability of the main power supply: When the UPS output load is heavy, if it is still charged with a large current, the total input power demand will surge, which may cause the internal power module to overload, resulting in output voltage fluctuations, and thus affecting the power supply quality of critical monitoring equipment.

[0006] 2. Low charging efficiency and shortened battery life: Continuous high-current charging under high load conditions is not only inefficient and generates a lot of heat, but also accelerates the capacity decay and aging process of the battery under the dual effects of high temperature environment and high load stress.

[0007] 3. Lack of intelligent rapid charging mechanism: When the battery is in an undervoltage state due to short-term discharge, and the current load is light after the main power is restored, the traditional solution cannot actively use the system's surplus power for rapid charging, which may cause it to miss the best charging window and affect the reliability of the next backup power.

[0008] 4. Insufficient level of intelligent management: It is unable to adaptively adjust according to real-time power grid conditions, such as off-peak electricity consumption at night and load priorities.

[0009] Therefore, there is an urgent need for a management method that can intelligently sense the load status and dynamically optimize the charging strategy, so as to achieve optimal management of the battery charging process while ensuring the absolute priority and stability of the main load power supply. Summary of the Invention

[0010] In view of this, the present invention aims to propose a smart charging system and method for mining UPS with dynamic power distribution based on output current acquisition, in order to solve the problems of existing technologies such as ignoring dynamic load changes, low charging efficiency and shortened battery life, lack of intelligent fast power replenishment mechanism and insufficient level of intelligent management.

[0011] To achieve the above objectives, the technical solution of the present invention is implemented as follows: In a first aspect, the present invention provides a dynamic power distribution intelligent charging system for mining UPS based on output current acquisition, comprising an input unit connected to an output unit, the output unit being connected to a battery management unit and a charging control unit respectively, and the charging control unit being connected to the battery management unit and a human-machine interaction unit respectively. The input unit includes an input filtering module and an AC / DC conversion module, and the input filtering module is connected to the AC / DC conversion module. The output unit includes a DC / DC conversion module and a remote communication module. The DC / DC conversion module is connected to the AC / DC conversion module, and both the DC / DC conversion module and the remote communication module are connected to the charging control unit. The battery management unit includes a backup battery pack, a battery status monitoring module, and an equalization control module. The backup battery pack is connected to the battery status monitoring module and the equalization control module, respectively. The battery status monitoring module is connected to the charging control unit. The charging control unit includes a load power monitoring module and an intelligent charging decision controller. The load power monitoring module is connected to the DC / DC conversion module, and the intelligent charging decision controller is connected to the load power monitoring module, the battery status monitoring module, the backup battery pack, the remote communication module, and the human-machine interaction unit.

[0012] Furthermore, the DC / DC conversion module is provided with multiple intrinsically safe conversion channels. Each intrinsically safe conversion channel is provided with an input channel and an output channel. Each input channel is provided with a current acquisition module and a voltage acquisition module. The current acquisition module and the voltage acquisition module are both connected to the load power monitoring module.

[0013] Furthermore, the input filtering module is used to filter and purify the input AC power, removing grid noise and transient interference, and providing a high-quality power input foundation for the system. The AC / DC conversion module is used to convert the filtered AC power into stable DC power, providing a reliable basic operating voltage for the various functional circuits inside the UPS host. The DC / DC conversion module is used to achieve electrical isolation and voltage regulation conversion from non-intrinsically safe DC to intrinsically safe DC, providing safe power supply that meets explosion-proof standards for downhole monitoring equipment; The remote communication module is used to establish a data link between the UPS host and the external monitoring network, and to upload operating parameters, early warnings and abnormal information in real time to support remote centralized control and maintenance. Furthermore, the backup battery pack serves as the core of the system's energy storage, and it is immediately activated when the main power grid fails, providing uninterrupted emergency power support for critical underground loads. The battery status monitoring module is used to collect physical quantities of battery voltage, current and temperature in real time, and accurately estimate the remaining power SOC to provide comprehensive feedback on the real-time health status of the battery. The equalization control module evaluates cell differences based on monitoring data and automatically executes equalization charging and discharging strategies to eliminate individual cell inconsistencies and extend the overall cycle life of the battery pack. The load power monitoring module indirectly inversely calculates the output load current and real-time load rate based on the input side parameters and the energy conservation model, thereby realizing safe power sensing under intrinsically safe / non-intrinsically safe isolation conditions.

[0014] The intelligent charging decision controller integrates real-time load rate and battery status for multi-level threshold comparison, dynamically generates and issues charging current commands, and realizes intelligent power allocation under the premise of prioritizing power supply safety.

[0015] Secondly, based on the same concept, the present invention also provides a smart charging method for a mining UPS with dynamic power distribution based on output current acquisition, comprising the following steps: S1. Set system parameters: In the load power monitoring module, set the DC / DC conversion efficiency ηi and correction factor X for each channel; in the intelligent charging decision controller, set the load rate threshold parameter, charging current parameter, warning parameter and battery status parameter. S2. Collect system status data: The load power monitoring module collects the input voltage Ui and input current Ii of each channel in real time through the current acquisition module and voltage acquisition module; the battery status monitoring module captures the terminal voltage Vbat, charging and discharging current and temperature of the backup battery pack in real time, estimates the current power SOC, and reports Vbat and SOC to the intelligent charging decision controller. S3. Calculate the single-channel load rate A and the total load rate η: Based on the input voltage Ui and input current Ii of each channel, the load power monitoring module calculates the output load current Io using the calculation expression of the output load current. Based on the output load current Io of each channel, it calculates the single-channel load rate A using the single-channel load rate calculation expression. It calculates the total load rate η using the total load rate calculation expression and reports A and η to the intelligent charging decision controller. S4. Based on Vbat and SOC reported by the battery status monitoring module, if the intelligent charging decision controller determines that SOC ≥ SOC full charge threshold or Vbat ≥ float charge voltage threshold, the controller sends a float charge control command to the battery management unit to force the backup battery pack into float charge or idle state; when the battery voltage is lower than the float charge threshold, proceed to the next step. S5. Dynamic power allocation decision based on load rate threshold: The controller compares the real-time total load rate η reported in S3 with the preset first load rate threshold η1 and second load rate threshold η2 in a hierarchical manner, dynamically generates a charging current control command and sends it to the battery management unit. Upon receiving the control command, the battery management unit enters the corresponding charging mode and charges with the set charging current. S6. Graded warning and overload hard cut-off protection execution: While allocating power, the controller compares the single-channel / total channel load rate with the preset safety threshold in real time. Based on the comparison result, it determines whether to execute the full load warning or cut off the charging operation. S7. Status visualization refresh and remote data uplink: The controller drives the human-machine interaction unit through the serial port to refresh the current of each channel, single channel load rate, total load rate, current charging mode and warning / abnormal status in real time; the controller drives the remote communication module through the serial port to upload the running data packets to the downhole monitoring center and the ground dispatch system.

[0016] Furthermore, in step S1, the load rate threshold parameters include a first load rate threshold η1 and a second load rate threshold η2; the charging current parameters include a standard charging current I_standard, a fast charging current I_fast, and a maintenance current I_maintain; the warning parameters include a warning threshold η3 and a warning duration T; and the battery state parameters include a SOC full charge threshold and a float charge voltage threshold.

[0017] Furthermore, in step S5, the controller compares the real-time total load rate η reported in S3 with the preset first load rate threshold η1 and second load rate threshold η2, dynamically generates a charging current control command, and sends it to the battery management unit. Upon receiving the control command, the battery management unit enters the corresponding charging mode and charges with the set charging current, including: If η < η1, the UPS is determined to be in a low-load state and immediately enters fast charging mode. The controller sends a fast charging control command to the battery management unit, and the charging current is set to Ifast. If η1≤η<η2, the UPS is determined to be in a medium load state and immediately enters the standard charging mode. The controller sends a standard charging control command to the battery management unit, and the charging current is set to Istandard. If η≥η2, the UPS is determined to be in a high load state and immediately enters the charging stop / maintenance mode. The controller sends a charging stop / maintenance control command to the battery management unit, and the charging current is set to Imaintain.

[0018] Furthermore, in step S6, while allocating power, the controller compares the single-channel / total channel load rate with the preset safety threshold in real time. Based on the comparison result, it determines whether to execute a full-load warning or cut off charging, including: When the load rate continuously exceeds the warning threshold for a warning duration T, it is determined that the system is about to reach full load, and the controller sends a full load warning message to the human-machine interaction unit. When the load rate climbs to 100%, the controller immediately sends a command to cut off the charging circuit to the battery management unit. The battery management unit cuts off the charging circuit of the corresponding channel, and the controller simultaneously sends a cut-off message to the human-machine interaction unit. Furthermore, in step S3, The expression for calculating the output load current Io is as follows: Io = (Ui × Ii × ηi) ÷ Uo + X; In the formula, Uo represents the output voltage; Ii represents the input current; Ui represents the input voltage; ηi represents the DC / DC conversion efficiency of the output channel; and X is the correction factor.

[0019] The formula for calculating the single-path load rate A is as follows: A = Io ÷ I; In the formula, I is the rated current; The formula for calculating the total load factor η is: η = P_load / P_rated × 100%; In the formula, P_load represents the total load power; P_rated represents the rated output power.

[0020] Compared with existing technologies, the intelligent charging system and method for mining UPS based on dynamic power distribution using output current acquisition described in this invention has the following advantages: (1) Resolve the contradiction between the connection relationship of non-intrinsically safe and intrinsically safe circuits and the explosion-proof requirements: associate non-intrinsically safe inputs and intrinsically safe outputs through data calculation relationship.

[0021] (2) Achieve rapid fault location: By displaying the output current of each channel in real time, maintenance personnel can immediately see which channel has an abnormally increased current on the enclosure panel or remote monitoring interface, which greatly shortens the fault investigation path and time, and improves maintenance efficiency and safety.

[0022] (3) Ensuring power supply safety and priority: The power supply stability of the main load is given the highest priority. Under high load, charging is automatically reduced or stopped, which completely avoids the risk of system overload caused by the superposition of charging power and load power. This is an active safety protection that traditional solutions cannot achieve.

[0023] (4) Optimize charging efficiency and speed: Innovatively bind the load rate range with the charging mode. Quickly replenish power when the system is idle, and pause or slow charge when the system is busy, maximizing the use of the system power margin, significantly shortening the battery recharge time, and improving the overall energy utilization efficiency.

[0024] (5) Effectively extends battery life: It avoids the harsh working conditions of continuous high-current charging of batteries under high load and high temperature system environment, reduces the chemical and thermal stress of batteries, helps to extend the service life of backup battery packs and reduce maintenance costs.

[0025] (6) Enhance system intelligence and adaptability: The method has a clear logic and can customize the parameters of η1, η2 and charging current according to the load characteristics of different mines and the grid conditions. Combined with battery SOC and time strategy, a multi-dimensional adaptive intelligent charging management system is formed. Attached Figure Description

[0026] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the overall architecture as described in an embodiment of the present invention; Figure 2 This is a schematic diagram of the current acquisition module according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the voltage acquisition module according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the load power monitoring process described in an embodiment of the present invention; Figure 5 This is a schematic diagram of the intelligent charging decision-making process according to an embodiment of the present invention. Detailed Implementation

[0027] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0028] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0031] like Figures 1 to 3 As shown, the present invention provides a dynamic power distribution intelligent charging system for mining UPS based on output current acquisition, including an input unit connected to an output unit, the output unit being connected to a battery management unit and a charging control unit, and the charging control unit being connected to the battery management unit and a human-machine interaction unit.

[0032] 1. Input Unit: As the energy inlet of the mining UPS, it includes an input filter module and an AC / DC conversion module, and the input filter module is connected to the AC / DC conversion module.

[0033] The input unit performs two basic and crucial functions: (1) Ensure power quality: The input filtering module is used to filter the input AC power from the mains / mining grid, filter out grid noise and interference signals, ensure the purity and stability of the input power, and provide a qualified power foundation for the subsequent circuits.

[0034] (2) Supply basic working voltage: Using the AC / DC conversion module, the filtered alternating current (AC) is converted into direct current (DC) to provide a stable and normal working voltage for the various functional units inside the UPS host, including the control circuit, monitoring module, output unit, etc., to ensure the continuous and reliable operation of the whole machine.

[0035] 2. Output unit: includes a DC / DC conversion module and a remote communication module. The DC / DC conversion module is connected to the AC / DC conversion module, and both the DC / DC conversion module and the remote communication module are connected to the charging control unit.

[0036] The output unit undertakes two core tasks: supplying power to the downhole load and transmitting system status information. (1) Intrinsically Safe DC Power Supply: The DC / DC converter module performs critical electrical isolation and voltage conversion to convert non-intrinsically safe DC to intrinsically safe DC. Specifically, the DC / DC converter module has multiple intrinsically safe conversion channels. After the non-intrinsically safe DC is intrinsically isolated and converted through the multiple intrinsically safe conversion channels, multiple intrinsically safe DC outputs are distributed to various sub-equipment downhole. The DC / DC converter module also includes a battery charging channel to provide a stable charging voltage for the backup battery pack of the battery management unit.

[0037] It should be noted that each intrinsically safe conversion channel is equipped with an input channel and an output channel. Each input channel is equipped with a current acquisition module and a voltage acquisition module. The current acquisition module and the voltage acquisition module are connected to the load power monitoring module of the charging control unit. The charging control unit collects the input voltage Ui and the input current Ii of each intrinsically safe conversion channel in real time through the current acquisition module and the voltage acquisition module.

[0038] Specifically, the current acquisition module includes chip U2 and resistor R14. One end of resistor R14 is connected to the IN- terminal of U2, and the other end is connected to the IN+ terminal of U2. The OUT terminal of U2 is connected to the load power monitoring module of the charging control unit. The REF and GND terminals of U2 are grounded, and the V+ terminal of U2 is connected to VCC. The voltage acquisition module includes chip U1, resistors R11, R12, and R13. The +IN terminal of U1 is connected to one end of resistor R12 and one end of resistor R13, respectively. The other end of resistor R12 is grounded, and the other end of resistor R13 is connected to VCC. The OUT and -IN terminals of U1 are both connected to one end of resistor R11, and the other end of resistor R11 is connected to the load power monitoring module.

[0039] (2) Remote status communication: Enables network communication between UPS and underground monitoring center and ground dispatch system; uploads local working status, load data, early warning information and abnormal circuit identification in real time, and supports pop-up prompts on the dispatch room screen and remote operation and maintenance.

[0040] 3. Battery Management Unit: This unit includes a backup battery pack, a battery status monitoring module, and a balancing control module. The backup battery pack is connected to both the battery status monitoring module and the balancing control module. The battery status monitoring module is connected to the charging control unit. The backup battery pack serves as the system's energy storage carrier and backup power source; the battery status monitoring module is responsible for real-time data acquisition and power estimation; and the balancing control module is responsible for evaluating and executing charging and discharging strategies.

[0041] Specifically, the battery status monitoring module collects the voltage, current, and temperature of the backup battery pack in real time. Based on the collected voltage, current, and temperature data, the battery charge (SOC) is estimated in real time. The original sampled values ​​and the calculated SOC status are continuously uploaded to the intelligent charging decision controller via serial port.

[0042] Specifically, by using the equalization control module to collect real-time information from the battery status monitoring module, the system assesses the consistency of the status of each cell in the battery pack. Based on the assessment results, it automatically decides whether to start the equalization charge and discharge program to eliminate voltage / capacity differences between cells, prevent overcharging or over-discharging of individual cells, and thus effectively extend the overall service life of the backup battery pack.

[0043] Specifically, the battery management unit, as an independent energy storage and status feedback node, is directly controlled by the intelligent charging decision controller and provides it with core status parameters.

[0044] 4. Charging Control Unit: As the core control hub of the system, it includes a load power monitoring module and an intelligent charging decision controller. The load power monitoring module is connected to the current acquisition module and voltage acquisition module of the DC / DC conversion module, respectively. The intelligent charging decision controller is connected to the load power monitoring module, the battery status monitoring module, the backup battery pack, the remote communication module, and the human-machine interaction unit, respectively.

[0045] (1) Load power monitoring is implemented using a load power monitoring module: The input voltage Ui and input current Ii of each channel are collected in real time through the current acquisition module and voltage acquisition module. Based on Ui and Ii, the output load current Io of each channel is calculated. Based on the Io of each channel, the single-channel load rate and the total load rate are calculated. Specifically, in response to the explosion-proof standard that prohibits direct electrical interconnection between intrinsically safe and non-intrinsically safe circuits in coal mines, this module adopts an input-output mapping indirect calculation method to avoid the safety hazards caused by physical direct connection. The calculation principle is as follows: The given expression for the input-output power relationship is: Input power × Conversion efficiency = Output power, that is: Ui×Ii×ηi=Uo×Io; get: Io = (Ui × Ii × ηi) ÷ Uo; Taking into account PCB trace losses, a correction factor X is added, and the final expression for the indirect calculation of the input-output mapping is as follows: Io = (Ui × Ii × ηi) ÷ Uo + X; In the formula, Io represents the output current; Uo represents the output voltage; Ii represents the input current, which is acquired by the current acquisition module; Ui represents the input voltage, which is acquired by the voltage acquisition module; ηi represents the DC / DC conversion efficiency of the output channel; X is the correction factor, which compensates for losses in PCB traces and components.

[0046] Parameter calibration: By performing input-output comparison tests and data fitting on multiple intrinsically safe conversion channels, the specific values ​​of parameters ηi and X are accurately determined.

[0047] Branch load current calculation: Substitute the calibrated parameters into Io=(Ui×Ii×ηi)÷Uo+X to estimate the load current Io of each output channel in real time.

[0048] Branch real-time load rate calculation: Calculate the single-circuit load rate A according to the single-circuit load rate calculation expression A=Io÷I (I is the rated current of the circuit).

[0049] Total load power and total load rate calculation: The current total output load power is obtained by summing the power of each branch in real time, and the real-time total load rate relative to the rated output power of the UPS is calculated as follows: η = P_load / P_rated × 100%; In the formula, η represents the total load factor; P_load represents the total load power; P_rated represents the rated output power.

[0050] (2) Intelligent charging decision controller: As the core computing and command center of the charging control unit, it has a multi-channel high-precision ADC interface and a multi-channel communication interface (serial port / RS485) to meet the high-speed computing and real-time control requirements under complex downhole conditions. The controller is responsible for receiving monitoring data from the front-end load power monitoring module and the battery status monitoring module, performing threshold comparison and logic operations, and outputting precise charging current control commands to the battery management unit to realize adaptive dynamic allocation of charging power.

[0051] Specifically, the data interaction and internal parameter configuration are as follows: The intelligent charging decision controller establishes bidirectional interaction with the load power monitoring module and the battery status monitoring module via serial ports, and presets key decision parameters in non-volatile memory. Specifically, it connects to the load power monitoring module via serial port to receive the calculated total system load rate η and single-channel load rate A in real time; and it connects to the battery status monitoring module via serial port to obtain the current state of charge (SOC) and terminal voltage (Vbat) of the backup battery pack in real time.

[0052] Specifically, the internal storage parameters are as follows: Load rate threshold: First load rate threshold η1: Fast charging / standard charging threshold; Second load rate threshold η2: Standard charging / stop charging threshold.

[0053] Charging current: Standard charging current I_standard; fast charging current I_fast; maintenance current I_maintain.

[0054] It should be noted that all parameters can be customized through the controller's internal program or external communication interface to adapt to the power grid capacity and load characteristics of different mines.

[0055] Specifically, the core decision-making logic and control process are as follows: The controller executes a strict closed-loop logic of "state access priority → load rate range comparison → dynamic mode switching". The specific decision-making process is as follows: First, a pre-entry judgment is made based on the battery status.

[0056] Before distributing any load power, the controller first performs a battery health and charging necessity check: Read Status: Get the current SOC or Vbat of the backup battery pack.

[0057] Full charge protection logic: If the controller determines that the battery is close to full charge (e.g., SOC≥95% or Vbat≥float charging voltage), it will execute the highest priority instruction: regardless of the current load rate range, it will force the exit of the dynamic decision-making process and directly switch to float charging or idle state, completely eliminating the risk of overcharging.

[0058] Access control: The controller can only unlock access and proceed to the subsequent load rate dynamic decision-making process when the battery voltage is lower than the float charge voltage, i.e., when it is indeed necessary to replenish the battery.

[0059] Then, a three-stage dynamic decision-making process is implemented based on the load rate range.

[0060] The controller performs hierarchical comparisons between the real-time total load rate η and preset thresholds η1 and η2, and automatically matches the optimal charging strategy. If the total load rate is in the high load range (η≥η2), then the charging mode is set to stop / maintenance mode: If the system load is deemed heavy and the power supply margin is tight, it is decided to immediately stop charging the backup battery, or strictly limit the charging current to an extremely low maintenance current I_maintain. The purpose is to implement the principle of "absolute priority for main load power supply," ensuring that all available power is prioritized to ensure the stable operation of critical equipment such as monitoring substations and sensors, and preventing system overload.

[0061] If the total load rate is in the medium load range (η1≤η<η2), then the charging mode is set to standard charging mode: The system load is deemed moderate, with some power supply margin, and standard charging mode is enabled, outputting the set current I_standard. The aim is to balance charging speed with the stability of power supply to the main load, achieving a dynamic balance in power distribution.

[0062] If the total load rate is in the low load range (η<η1), then the charging mode is set to fast charging mode: If the system load is determined to be light and the power supply margin is sufficient, fast charging mode is activated, outputting a large current I_fast. The purpose is to fully utilize the system's idle power window, quickly restoring the battery to full charge during periods of low load, minimizing recharge time, and improving the reliability of the next power backup.

[0063] Finally, the controller executes the optimal charging strategy and feeds back the status through the following path: Execute the optimal charging strategy: convert the decision result into a charging current control command, send it to the charging management unit, accurately adjust the charging current, and achieve smooth and seamless switching between modes.

[0064] Status synchronization and early warning linkage: The current charging mode, load rate, and battery status are refreshed in real time to the screen of the human-machine interface unit via serial port. When the load rate triggers the early warning threshold or the battery status is abnormal, the controller uploads the alarm code and abnormal circuit information to the underground monitoring center through the remote communication module, supporting pop-up prompts on the dispatch room's large screen, realizing a closed-loop remote operation and maintenance system.

[0065] 5. Human-Computer Interaction Unit The human-machine interface (HMI) unit connects to the intelligent charging decision controller of the charging control unit via a serial port, receiving and refreshing system operation data. Through the HMI unit, the abstract electrical parameters and calculation results within the controller are transformed into real-time data that maintenance personnel can directly read. Based on a dynamic refresh mechanism, the system initializes the display upon power-up, continuously scrolling and refreshing data throughout the control cycle to ensure that the screen information remains synchronized with the actual electrical conditions underground at the millisecond level. Specific displayed data includes: (1) Branch operation parameters: Real-time display of the current output current value of each output circuit, such as A, B and C, and its corresponding real-time load rate of a single circuit.

[0066] (2) System global parameters: Real-time total load current and system total load rate are refreshed synchronously, which intuitively reflects the overall power occupancy of the UPS.

[0067] (3) Charging and battery status: Displays the current charging mode, such as fast charging / standard charging / stop charging / float charging, battery SOC estimate and voltage status, so that maintenance personnel can keep track of the backup power health.

[0068] Based on the human-computer interaction unit, an early warning prompt and abnormal interaction mechanism are set up as follows: (1) Full load warning interaction: When the single-channel or total load rate continuously exceeds the preset warning threshold (such as 90%) and reaches the anti-interference delay, the controller immediately sends a full load warning message to the human-machine interaction unit.

[0069] The corresponding circuit area on the screen is highlighted or flashed to indicate the warning circuit number, such as "C circuit load rate 96%", reminding maintenance personnel to check the load equipment in a timely manner to prevent the operating condition from deteriorating further.

[0070] (2) Abnormal overload interaction: If the load rate climbs to 100%, the screen immediately switches to an abnormal status prompt and locks the display of fault circuit information, such as "C-way load rate 100%".

[0071] In conjunction with the automatic disconnection action of the battery management unit, the screen clearly indicates the fault isolation result, realizing a closed-loop interaction of "alarm-power-off-location" and eliminating blind troubleshooting.

[0072] (3) Information retention and traceability: Warnings and abnormal statuses are kept locked on the screen until the load falls back to the safe range or is manually reset, ensuring that the underground inspection personnel can know the historical fault points at a glance.

[0073] After the charging control unit completes the load rate calculation, mode decision and threshold comparison, it pushes the structured status message (including current value, load rate, mode identifier and alarm code) to the human-machine interaction unit through the serial port at regular intervals. The warning / abnormal information displayed on the screen will be synchronously packaged and uploaded to the underground monitoring center and the large screen in the dispatch room through the remote communication module to achieve ground-to-ground linkage. After the key system parameters, such as η1, η2, warning value, charging current, etc., are set through the controller's internal program or external communication interface, the screen of the human-machine interaction unit serves as the real-time display window after the parameters take effect, ensuring that the configuration results are visible and verifiable.

[0074] Based on the aforementioned intelligent charging system for mining UPS, such as Figures 4 to 5 As shown, the present invention also provides a smart charging method for a mining UPS with dynamic power distribution, comprising the following steps: S1. Set system parameters: In the load power monitoring module, set the DC / DC conversion efficiency ηi and correction factor X for each channel; in the intelligent charging decision controller, set the load rate threshold parameter, charging current parameter, warning parameter, and battery status parameter; the load rate threshold parameter includes a first load rate threshold η1 and a second load rate threshold η2; the charging current parameter includes the standard charging current I_standard, the fast charging current I_fast, and the maintenance current I_maintain; the warning parameter includes the warning threshold η3 and the warning duration T; the battery status parameter includes the SOC full charge threshold and the float charge voltage threshold. Wherein, 0 < η1 < η2 < 100%, preferably, η1 is set between 50% and 70%, and η2 is set between 80% and 90%.

[0075] S2. Acquire system status data: The load power monitoring module acquires the input voltage Ui and input current Ii of each channel in real time through the current acquisition module and voltage acquisition module of the output unit; the battery status monitoring module captures the terminal voltage Vbat, charging and discharging current and temperature of the backup battery pack in real time, estimates the current power SOC, and reports Vbat and SOC to the intelligent charging decision controller.

[0076] S3. Calculate the single-channel load rate and total load rate: Based on the input voltage Ui and input current Ii of each channel, the load power monitoring module calculates the output load current Io using the calculation expression of the output load current. Based on the output load current Io of each channel, the single-channel load rate A is calculated using the single-channel load rate calculation expression. The total load rate η is calculated using the total load rate calculation expression. A and η are then reported to the intelligent charging decision controller.

[0077] S4. Based on the Vbat and SOC reported by the battery state monitoring module, if the intelligent charging decision controller determines that SOC ≥ 95% or Vbat ≥ float charge voltage threshold, the controller sends a float charge control command to the battery management unit, forcing the backup battery pack into float charge or idle state. At this time, regardless of the total load rate η, the subsequent decision-making process is terminated, completely avoiding the risk of overcharging. The controller only unlocks the charging permission and executes the next step when the battery voltage is lower than the float charge threshold, i.e., when the backup battery really needs to be charged. This establishes a control bottom line that prioritizes battery chemical safety over charging speed.

[0078] S5. Dynamic power allocation decision based on load rate threshold: The controller compares the real-time total load rate η reported by S3 with the first load rate threshold η1 (fast charging / standard charging threshold) and the second load rate threshold η2 (standard charging / stop charging threshold) preset in the internal non-volatile memory, and dynamically generates charging current control commands.

[0079] If η < η1, the UPS is determined to be in a low-load state, the system load is light, and the power supply margin is sufficient. It immediately enters the fast charging mode, that is, the controller sends a fast charging control command to the battery management unit. At this time, the battery is charged with a fast charging current I_fast greater than I_standard, such as 0.3C-0.5C. This mode can make full use of the surplus power and quickly restore the battery to a full charge state during the off-peak period. If η1≤η<η2, the UPS is determined to be in a medium load state, with a moderate system load and some power supply margin. It immediately enters standard charging mode, where the controller sends a standard charging control command to the battery management unit. At this time, the battery is charged using the set standard charging current I_standard, such as 0.1C-0.2C. This mode balances charging speed with the stability of the main load power supply. If η≥η2, the UPS is determined to be under high load, the system is heavily loaded, and the power supply margin is tight. It immediately enters the stop charging / maintenance mode, that is, the controller sends a stop charging / maintenance control command to the battery management unit. At this time, the charging of the backup battery pack is stopped, or the charging current is limited to a very low maintenance current I_maintain, such as 0.05C, where C is the battery capacity, to ensure that all available power is prioritized to ensure the stable operation of critical monitoring loads.

[0080] S6. Graded early warning and overload hard cut-off protection execution: While allocating power, the controller compares the single-path / total path load rate with the preset safety threshold in real time.

[0081] When the load rate continuously exceeds the warning threshold for a warning duration T (e.g., 3-5 seconds), it is determined that the system is about to be fully loaded, and the controller sends a full load warning message to the human-machine interaction unit. If the load rate climbs to 100%, the controller immediately sends a cut-off command to the battery management unit, thereby cutting off the charging circuit of the corresponding channel to prevent the power module from being damaged by thermal overload. At the same time, it sends a cut-off message to the human-machine interaction unit.

[0082] S7. Status Visualization Refresh and Remote Data Upload: The serial port drives the human-machine interaction unit to refresh the current value, single-channel load rate, total load rate η, current charging mode, and warning / abnormal status of each channel (A / B / C) in real time, realizing one-click visualization of the underground site; at the same time, the operation data packet is uploaded to the underground monitoring center and the ground dispatch system through the remote communication module of the output unit, supporting large screen pop-up prompts and historical data traceability, and building a dual-track operation and maintenance closed loop of local monitoring combined with remote centralized control.

[0083] Example 1: A mining UPS with a rated output power of 90W provides 3 intrinsically safe DC outputs and external communication via RS485. Its backup battery is a 19.2V / 10Ah lithium iron phosphate battery pack.

[0084] System setup: An intelligent charging decision controller based on ARM Cortex-M core. The controller reads data from the load power monitoring module and the battery status monitoring module through the serial port, and sends status information to the LCD screen of the human-machine interaction unit through the serial port.

[0085] Parameter settings: Configured via the controller's internal program or external communication interface. The single-path and total-path load warning threshold η3 = 90%, and the warning duration T is set to 3 seconds.

[0086] First load rate threshold η1=20%, second load rate threshold η2=70%; standard charging current I_standard=1A(0.1C), fast charging current I_fast=3A(0.3C), maintenance current I_maintain=0.5A.

[0087] The LCD screen displays the single-channel current Io = (Ui × Ii × ηi) ÷ Uo + X, with parameter settings Ui = 24V, ηi = 88%, and X = 0.01. The work process is as follows: (1) After the system is powered on, the LCD screen displays the current and single-channel load rate of each channel (channel A, channel B, channel C), as well as the total current and total load rate. The current mentioned below is Ii. The single-channel current Io is calculated by substituting the measured Ii into the expression Io=(Ui×Ii×ηi)÷Uo+X before being displayed on the LCD screen.

[0088] (2) All three loads are 0.2A, and the measured real-time single-channel load rate is 18% (<η3), with a total load rate η=16% (<η1). The controller immediately sends a fast charging control command to the battery management unit to fast charge the battery with a high current of 3A. At this time, the total input power of the system is approximately 14W of load + 72W of charging = 86W, which is far lower than the rated output power of 90W, making it safe and efficient.

[0089] (3) When the load on both B and C channels slowly increases from 0.2A to 0.9A, the real-time single-channel load rate is measured to be 80%, and the total load rate η rises to 53%, which is between η1 and η2. The controller detects that the threshold has been crossed and immediately sends a standard charging control command to the battery management unit to switch the charging current from 3A to 1A standard charging. At this time, the total input power of the system is approximately 48W of load + 24W of charging = 72W, which is lower than the rated output power of 90W, leaving more power margin for load fluctuations.

[0090] (4) Scenario 1: Road A slowly increases from 0.2A to 0.9A; Scenario 2: C-channel power is increased to 1.05A, with a single-channel load rate of 93%. Scenario 3: C-channel failure increases the voltage to 1.13A, with a single-channel load rate of 100%.

[0091] In scenario one, when the measured real-time total current rises to approximately 2.7A and the total load rate is 72% (>η2), the controller sends a stop charging / maintenance control command to the battery management unit, the charging current switches to Imaintain, and power is preferentially provided to the sub-devices; In scenario two, the controller immediately sends a single-channel full-load warning message to the human-machine interface unit, and the display screen and remote communication prompt the full-load warning. In scenario three, the controller immediately sends a cut-off command to the battery management unit to cut off the power supply circuit of the corresponding channel, and at the same time sends a cut-off message to the human-machine interaction unit, with the display screen and remote communication indicating an abnormality.

[0092] (5) After receiving the abnormal information, the maintenance personnel came to the power supply box and immediately saw that the current of circuit C was abnormal and the load rate had reached 100%. They immediately notified the relevant personnel to check the load of circuit C, thus resolving the potential problem before the system crashed due to overload.

[0093] (6) At the same time, the early warning information and abnormal circuit information are uploaded to the underground monitoring center by the remote communication module and a pop-up notification is displayed on the large screen in the dispatch room.

[0094] The beneficial effects of this invention are: (1) Resolve the contradiction between the connection relationship of non-intrinsically safe and intrinsically safe circuits and the explosion-proof requirements: associate non-intrinsically safe inputs and intrinsically safe outputs through data calculation relationship.

[0095] (2) Achieve rapid fault location: By displaying the output current of each channel in real time, maintenance personnel can immediately see which channel has an abnormally increased current on the enclosure panel or remote monitoring interface, which greatly shortens the fault investigation path and time, and improves maintenance efficiency and safety.

[0096] (3) Ensuring power supply safety and priority: The power supply stability of the main load is given the highest priority. Under high load, charging is automatically reduced or stopped, which completely avoids the risk of system overload caused by the superposition of charging power and load power. This is an active safety protection that traditional solutions cannot achieve.

[0097] (4) Optimize charging efficiency and speed: Innovatively bind the load rate range with the charging mode. When the system is idle, i.e., under low load, it quickly replenishes the battery, and when the system is busy, i.e. under high load, it pauses or slows down the charging, maximizing the use of the system's power margin, significantly shortening the battery recharge time, and improving the overall energy utilization efficiency.

[0098] (5) Effectively extends battery life: It avoids the harsh working conditions of continuous high-current charging of batteries under high load and high temperature system environment, reduces the chemical and thermal stress of batteries, helps to extend the service life of backup battery packs and reduce maintenance costs.

[0099] (6) Enhance system intelligence and adaptability: The method has a clear logic and can customize the parameters of η1, η2 and charging current according to the load characteristics of different mines and the grid conditions. Combined with battery SOC and time strategy, a multi-dimensional adaptive intelligent charging management system is formed.

[0100] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A smart charging system for mining UPS with dynamic power distribution based on output current acquisition, characterized in that: It includes an input unit connected to an output unit, the output unit being connected to a battery management unit and a charging control unit, and the charging control unit being connected to a battery management unit and a human-machine interface unit. The input unit includes an input filtering module and an AC / DC conversion module, and the input filtering module is connected to the AC / DC conversion module. The output unit includes a DC / DC conversion module and a remote communication module. The DC / DC conversion module is connected to the AC / DC conversion module, and both the DC / DC conversion module and the remote communication module are connected to the charging control unit. The battery management unit includes a backup battery pack, a battery status monitoring module, and an equalization control module. The backup battery pack is connected to the battery status monitoring module and the equalization control module, respectively. The battery status monitoring module is connected to the charging control unit. The charging control unit includes a load power monitoring module and an intelligent charging decision controller. The load power monitoring module is connected to the DC / DC conversion module, and the intelligent charging decision controller is connected to the load power monitoring module, the battery status monitoring module, the backup battery pack, the remote communication module, and the human-machine interaction unit.

2. The intelligent charging system for mining UPS based on dynamic power distribution with output current acquisition as described in claim 1, characterized in that: The DC / DC conversion module is equipped with multiple intrinsically safe conversion channels. Each intrinsically safe conversion channel has an input channel and an output channel. Each input channel is equipped with a current acquisition module and a voltage acquisition module. The current acquisition module and the voltage acquisition module are both connected to the load power monitoring module.

3. The intelligent charging system for mining UPS based on dynamic power distribution with output current acquisition as described in claim 1, characterized in that: The input filtering module is used to filter and purify the input AC power, remove grid noise and transient interference, and provide a high-quality power input foundation for the system. The AC / DC conversion module is used to convert the filtered AC power into stable DC power, providing a reliable basic operating voltage for the various functional circuits inside the UPS host. The DC / DC conversion module is used to achieve electrical isolation and voltage regulation conversion from non-intrinsically safe DC to intrinsically safe DC, providing safe power supply that meets explosion-proof standards for downhole monitoring equipment; The remote communication module is used to establish a data link between the UPS host and the external monitoring network, and to upload operating parameters, early warnings and abnormal information in real time to support remote centralized control and maintenance.

4. The intelligent charging system for mining UPS based on dynamic power distribution with output current acquisition as described in claim 1, characterized in that: The backup battery pack serves as the core of the system's energy storage and is immediately activated when the main power grid fails, providing uninterrupted emergency power support for critical underground loads. The battery status monitoring module is used to collect physical quantities of battery voltage, current and temperature in real time, and accurately estimate the remaining power SOC to provide comprehensive feedback on the real-time health status of the battery. The equalization control module evaluates cell differences based on monitoring data and automatically executes equalization charging and discharging strategies to eliminate individual cell inconsistencies and extend the overall cycle life of the battery pack. The load power monitoring module indirectly inversely calculates the output load current and real-time load rate based on the input side parameters and the energy conservation model, thereby realizing safe power sensing under intrinsically safe / non-intrinsically safe isolation conditions. The intelligent charging decision controller integrates real-time load rate and battery status for multi-level threshold comparison, dynamically generates and issues charging current commands, and realizes intelligent power allocation under the premise of prioritizing power supply safety.

5. A method for intelligent charging of a mining UPS based on dynamic power distribution using output current acquisition, applied to the intelligent charging system for a mining UPS based on dynamic power distribution using output current acquisition as described in any one of claims 1-4, characterized in that: Includes the following steps: S1. Set system parameters: In the load power monitoring module, set the DC / DC conversion efficiency ηi and correction factor X for each channel; In the intelligent charging decision controller, load rate threshold parameters, charging current parameters, early warning parameters, and battery status parameters are set; S2. Collect system status data: The load power monitoring module collects the input voltage Ui and input current Ii of each channel in real time through the current acquisition module and voltage acquisition module; the battery status monitoring module captures the terminal voltage Vbat, charging and discharging current and temperature of the backup battery pack in real time, estimates the current power SOC, and reports Vbat and SOC to the intelligent charging decision controller. S3. Calculate the single-channel load rate A and the total load rate η: Based on the input voltage Ui and input current Ii of each channel, the load power monitoring module calculates the output load current Io using the calculation expression of the output load current. Based on the output load current Io of each channel, it calculates the single-channel load rate A using the single-channel load rate calculation expression. It calculates the total load rate η using the total load rate calculation expression and reports A and η to the intelligent charging decision controller. S4. Based on Vbat and SOC reported by the battery status monitoring module, if the intelligent charging decision controller determines that SOC ≥ SOC full charge threshold or Vbat ≥ float charge voltage threshold, the controller sends a float charge control command to the battery management unit to force the backup battery pack into float charge or idle state; when the battery voltage is lower than the float charge threshold, proceed to the next step. S5. Dynamic power allocation decision based on load rate threshold: The controller compares the real-time total load rate η reported in S3 with the preset first load rate threshold η1 and second load rate threshold η2 in a hierarchical manner, dynamically generates a charging current control command and sends it to the battery management unit. Upon receiving the control command, the battery management unit enters the corresponding charging mode and charges with the set charging current. S6. Graded warning and overload hard cut-off protection execution: While allocating power, the controller compares the single-channel / total channel load rate with the preset safety threshold in real time. Based on the comparison result, it determines whether to execute the full load warning or cut off the charging operation. S7. Status visualization refresh and remote data uplink: The controller drives the human-machine interaction unit through the serial port to refresh the current of each channel, single channel load rate, total load rate, current charging mode and warning / abnormal status in real time; the controller drives the remote communication module through the serial port to upload the running data packets to the downhole monitoring center and the ground dispatch system.

6. The intelligent charging method for mining UPS based on dynamic power distribution using output current acquisition as described in claim 5, characterized in that: In step S1, the load rate threshold parameters include a first load rate threshold η1 and a second load rate threshold η2; the charging current parameters include the standard charging current I_standard, the fast charging current I_fast, and the maintenance current I_maintain. The warning parameters include the warning threshold η3 and the warning duration T; the battery status parameters include the SOC full charge threshold and the float charge voltage threshold.

7. The intelligent charging method for mining UPS based on dynamic power distribution using output current acquisition as described in claim 5, characterized in that: In step S5, the controller compares the real-time total load rate η reported in S3 with the preset first load rate threshold η1 and second load rate threshold η2, dynamically generates a charging current control command, and sends it to the battery management unit. Upon receiving the control command, the battery management unit enters the corresponding charging mode and charges with the set charging current, including: If η < η1, the UPS is determined to be in a low-load state and immediately enters fast charging mode. The controller sends a fast charging control command to the battery management unit, and the charging current is set to Ifast. If η1≤η<η2, the UPS is determined to be in a medium load state and immediately enters the standard charging mode. The controller sends a standard charging control command to the battery management unit, and the charging current is set to Istandard. If η≥η2, the UPS is determined to be in a high load state and immediately enters the charging stop / maintenance mode. The controller sends a charging stop / maintenance control command to the battery management unit, and the charging current is set to Imaintain.

8. The intelligent charging method for mining UPS based on dynamic power distribution using output current acquisition as described in claim 5, characterized in that: In step S6, while allocating power, the controller compares the single-channel / total channel load rate with the preset safety threshold in real time. Based on the comparison result, it determines whether to execute a full-load warning or cut off charging, including: When the load rate continuously exceeds the warning threshold for a warning duration T, it is determined that the system is about to reach full load, and the controller sends a full load warning message to the human-machine interaction unit. When the load rate climbs to 100%, the controller immediately sends a command to cut off the charging circuit to the battery management unit. The battery management unit cuts off the charging circuit of the corresponding channel, and the controller simultaneously sends a cut-off message to the human-machine interaction unit.

9. The intelligent charging method for mining UPS based on dynamic power distribution using output current acquisition as described in claim 5, characterized in that: In step S3, The expression for calculating the output load current Io is as follows: Io = (Ui × Ii × ηi) ÷ Uo + X; In the formula, Uo represents the output voltage; Ii represents the input current; Ui represents the input voltage; ηi represents the DC / DC conversion efficiency of the output channel; and X is the correction factor. The formula for calculating the single-path load rate A is as follows: A = Io ÷ I; In the formula, I is the rated current; The formula for calculating the total load factor η is: η = P_load / P_rated × 100%; In the formula, P_load represents the total load power; P_rated represents the rated output power.

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