A multifunctional energy storage battery monitoring and repairing device

Abstract

This invention discloses a multifunctional energy storage battery monitoring and repair device, comprising a battery module A and a controller module B connected via a multi-core data cable. Battery module A has a built-in startup module to achieve physical-level safety interlocking: when the data cable is not connected or the controller is not started, the battery has no voltage output, eliminating the risk of short circuits. Battery module A includes an AFE acquisition unit, a first MCU main control unit, an active high-voltage equalization unit, a soft-start protection unit, and an address code identification unit. Active high-voltage equalization uses the highest cell voltage as a reference to replenish low-voltage cells; the soft-start protection uses a timing sequence of relay closing first, followed by a delay and then MOSFET conduction to avoid arcing; the address code enables precise positioning of individual cells. Controller module B includes a second MCU main control unit, a bidirectional inverter, a 485 communication unit, an interaction unit, and a power output unit, supporting wide voltage input and multiple output specifications. Status is displayed on a screen, and remote operation and maintenance are achieved through 485 communication. This invention solves the problems of low equalization efficiency, short relay life, inconvenient operation and maintenance, and safety hazards, and is suitable for residential, commercial, industrial, and off-grid power storage scenarios.

Description

Technical Field

[0001] This invention belongs to the field of energy storage battery management technology, specifically relating to a modularly designed multifunctional energy storage battery monitoring and repair device. This device integrates battery status monitoring, remote monitoring, multiple electrical protections, and active balancing repair functions, and can be widely used in residential energy storage, industrial and commercial energy storage, and off-grid wind and solar power generation scenarios. Background Technology

[0002] With the widespread application of energy storage technology, lithium battery packs are prone to inconsistencies in cell voltage, capacity, and internal resistance during long-term operation due to factors such as cell manufacturing tolerances, environmental temperature differences, and inconsistent self-discharge. These problems can lead to a decrease in the overall usable capacity of the battery pack, limited charging and discharging power, and overcharging or over-discharging of some cells, thereby significantly shortening the battery pack's lifespan.

[0003] Existing battery management systems mostly employ passive balancing, which achieves voltage balance by discharging high-voltage cells through resistors. This balancing method has low current and low efficiency, and cannot solve the capacity deficiency problem of low-voltage cells, resulting in limited repair effectiveness. Furthermore, the direct switching of relays in the battery charging and discharging circuit under load generates strong electric arcs, leading to contact erosion, a sharp decline in relay lifespan, and even safety hazards such as poor contact and overheating.

[0004] Furthermore, existing energy storage batteries generally lack individual identification labels. When a large number of batteries are used in parallel in an energy storage cabinet, if a battery fails, maintenance personnel have difficulty quickly locating the problem, resulting in extremely low maintenance efficiency. In addition, there is a lack of physical interlocking mechanism between the battery and the controller. When the controller is not connected or is not powered on, the positive and negative terminals of the battery directly output to the outside, posing a risk of short circuit and accidental electric shock.

[0005] Therefore, developing a multifunctional energy storage battery monitoring and repair device that combines active equalization repair, relay protection, safety interlocking, and remote operation and maintenance capabilities is the key to solving the above-mentioned technical problems. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies, such as low efficiency in cell consistency repair, short relay life, inconvenience in large-scale operation and maintenance, and safety risks of bare batteries, and to provide a modular, multifunctional energy storage battery monitoring and repair device. This device utilizes technologies such as active high-level balancing, soft-start protection, physical safety interlocking, and address code identification to achieve accurate battery status monitoring, active repair, multiple protections, and remote operation and maintenance, thereby improving the reliability, safety, and lifespan of the battery pack.

[0007] To achieve the above objectives, this invention provides a multifunctional energy storage battery monitoring and repair device, which consists of two parts: a battery module A and a controller module B. The two are connected via a multi-core data cable for power supply, communication, and control. The device employs a physical-level safety interlock design: when the data cable is not connected, and the controller module B is not powered on or not started, the positive and negative terminals of battery module A have no external voltage output; only when the data cable is properly connected and the controller module B has started will the positive and negative terminals of battery module A supply power. This design eliminates the risk of short circuits in the bare battery from the outset.

[0008] Battery module A includes a cell pack, an AFE acquisition unit, a first MCU main control unit, an active altitude tracking equalization unit, a soft-start protection unit, and an address code identification unit. Among them: The cell pack supports multiple cells in series and can be adapted to cells with various chemical systems.

[0009] The AFE acquisition unit is used to collect real-time data on the voltage, total charge / discharge current, and battery pack temperature of each cell string.

[0010] The first MCU main control unit calculates the state of charge, state of energy, and health status values ​​based on the data obtained by the acquisition unit using a built-in algorithm, and transmits them to the controller module B via a multi-core data line.

[0011] The active voltage balancing unit has a built-in independent balancing power supply and relay array. Its balancing logic is as follows: using the highest cell voltage in the current cell group as a reference value, it quickly replenishes the voltage of cells with voltages lower than the reference voltage, actively reducing the voltage difference between cells.

[0012] The soft-start protection unit consists of a relay and a MOSFET that work together, connected in series in the power supply circuit of the battery pack. Its control logic is as follows: when the system starts, the relay is fully closed first. After a preset delay time to allow the contacts to stabilize, the MOSFET is then driven to conduct and output load current, thereby preventing the relay from arcing under load.

[0013] The address code identification unit is used to store a unique address code, which is equivalent to an electronic ID card, making it easy to accurately locate individual batteries in large-scale energy storage systems.

[0014] Battery module A also has a start-up module that controls the on / off state of the positive and negative terminals. This start-up module is driven by the control signal from controller module B.

[0015] Controller module B includes a second MCU main control unit, a bidirectional inverter, a 485 communication unit, an interaction unit, and a power supply output unit. Among them: The second MCU main control unit receives the status data transmitted by battery module A, controls the working status of the bidirectional inverter and DC-DC module, and realizes charging and discharging strategy management.

[0016] Bidirectional inverters enable bidirectional conversion of electrical energy, supporting both charging and discharging operating modes.

[0017] The 485 communication unit is used to remotely transmit battery status data, enabling remote monitoring and maintenance.

[0018] The interactive unit includes an LCD screen and maintenance buttons. The screen displays the overall status of the battery pack, the voltage of each cell, and the voltage difference in real time; the maintenance buttons are used to trigger the active high-voltage equalization repair process.

[0019] The power output unit supports wide voltage AC input and can output AC and DC power of various specifications to adapt to various load scenarios.

[0020] In addition, controller module B may also include a DC-DC module, a backup battery module, and a fan control module to ensure stable system operation.

[0021] A method for monitoring and repairing multi-energy storage batteries includes the following steps: S1. Battery module A and controller module B communicate and handshake through a multi-core data cable. The startup module performs hardware safety interlock verification. If the connection is abnormal or the controller is not started, the battery module will not output external voltage. The S2 and AFE acquisition units collect battery current, individual cell voltage, temperature, and power parameters around the clock and upload them to the first MCU main control unit. S3. The first MCU main control unit calculates, generates, and updates the core status parameters of SOC, SOE, and SOH in real time, and stores the health change data of individual units and the entire group. S4. After receiving the local or remote equalization operation and maintenance start command, pause the charger output, so that the battery pack enters the static voltage regulation state, eliminates dynamic operating condition interference and recalibrates SOC. S5. Collect the voltage of all individual cells in the battery pack and select the highest individual cell voltage as the equalization benchmark. S6. By using an independent regulated power supply, all low-voltage cells below the reference voltage are charged one by one to catch up, smoothing out the voltage difference between strings and restoring the consistency of cell operation. S7. The address code identification unit can be used to retrieve the identity and operation data of any single cell to achieve accurate fault tracing; when replacing a damaged cell, the address code and identity information of the new cell can be written online to complete the network adaptation and make it ready to use immediately. S8 and controller module B upload all battery parameters via 485 communication to achieve remote monitoring, unattended operation and maintenance, and remote equalization control.

[0022] Compared with the prior art, the present invention has the following beneficial effects: 1. Strong safety protection capabilities: The physical-level safety interlock design ensures that the battery has no voltage output when not connected to the controller, completely eliminating the risk of short circuit and accidental contact of the bare battery; the soft-start protection avoids relay arcing and burning, improving system reliability.

[0023] 2. High equalization and repair efficiency: It adopts a high-voltage active equalization method that uses the highest cell voltage as a reference to replenish the low-voltage cells. Compared with traditional passive equalization, the repair efficiency is greatly improved, which can quickly reduce the cell voltage difference and restore the usable capacity of the battery pack.

[0024] 3. Precise status monitoring: Through AFE data acquisition and MCU main control unit algorithm, it can accurately calculate the state of charge, state of energy and health status, monitor cell voltage, current and temperature in real time, and provide early warning of anomalies.

[0025] 4. Convenient operation and maintenance: With a built-in unique address code identifier and 485 remote communication, it realizes the precise positioning and remote operation and maintenance of individual batteries in large-scale energy storage systems.

[0026] 5. Wide range of applicable scenarios: Supports wide voltage AC input and multiple output specifications, and can be adapted to various scenarios such as residential energy storage, industrial and commercial energy storage, and off-grid wind and solar power generation. Attached Figure Description

[0027] Figure 1 Overall structural diagram of the invention; Figure 2 : Flowchart of the energy storage battery monitoring and repair method of the present invention. Detailed Implementation

[0028] The present invention will be further described below with reference to specific embodiments, but the scope of protection of the present invention is not limited to the following embodiments.

[0029] See Figure 1 This includes battery module A and controller module B, which communicate via a multi-core data cable. Battery module A has an internal startup module that establishes a physical-level safety interlock mechanism. If the multi-core data cable is not reliably connected or the controller is not started normally, the battery module will not output voltage. This eliminates the risk of short circuits caused by incorrect wiring, bare wiring, or loose wiring at the hardware level, greatly improving the overall safety of the device assembly, maintenance, and daily operation.

[0030] Battery module A integrates an AFE acquisition unit, a first MCU main control unit, an active height tracking equalization unit, a soft start protection unit, and an address code identification unit. It integrates real-time battery status monitoring, intelligent equalization repair, circuit arc protection, individual cell identification traceability and precise positioning functions, realizing intelligent management and non-disassembly operation and maintenance of energy storage battery packs.

[0031] The AFE (Active Battery Feedback) acquisition unit can collect key operating parameters such as battery pack charging and discharging current, individual cell temperature, real-time stored capacity, and total battery capacity in real time, and transmit the collected data to the first MCU (Microcontroller Unit). The first MCU, through its built-in precise algorithm, performs calculations and outputs three core indicators: remaining battery SOC (State of Charge), SOE (State of Energy), and SOH (State of Health). It also performs real-time data storage and dynamic updates, comprehensively recording the full-dimensional operating conditions and health trends of individual battery cells and the entire battery pack.

[0032] The active high-level balancing unit is equipped with a dedicated high-level intelligent operation and maintenance repair logic, specifically addressing issues such as individual cell voltage imbalance and inconsistent capacity decay caused by differences in cell manufacturing processes, electrolyte density, operating temperature deviations, and self-discharge rates during long-term use of energy storage batteries. It effectively overcomes the shortcomings of traditional passive balancing, such as slow balancing speed, incomplete balancing, and large residual voltage differences, avoiding a series of industry drawbacks such as reduced overall usable capacity of the battery pack, shortened cycle life, limited charging and discharging power, and decreased overall operational safety.

[0033] The device's operation and maintenance repair process does not require disassembly or disassembly, supporting whole-device maintenance and calibration without disassembly: After receiving the operation and maintenance start command, the system first pauses the charger's output voltage, allowing the entire battery pack to enter a voltage stabilization state, eliminating dynamic operating condition interference, and recalibrating the SOC parameters accurately to obtain the most accurate battery status data; then, the system uses the highest single cell voltage in the current battery pack as a reference, and uses an independent regulated power supply to quickly replenish and boost all low-voltage cells below the reference voltage, quickly smoothing out the voltage difference between each string of cells, making the voltage and capacity of the entire battery pack tend to be linearly consistent, restoring the battery pack to its factory-optimal operating state, effectively suppressing the accumulation of battery inconsistencies, significantly slowing down the battery degradation rate, and extending the overall service life of the energy storage battery pack.

[0034] The soft-start protection unit adopts a timing control strategy in which the relay closes first and the MOSFET turns on after a delay. This effectively eliminates the instantaneous current surge during switching, completely avoids arcing and sputtering during power switching, protects the relay, MOSFET and surrounding circuit devices, and significantly improves the stability of circuit operation and the service life of components.

[0035] The address code identification unit is a built-in electronic ID system for the battery. Each individual battery is equipped with a unique electronic identity and a dedicated device address code at the factory, making it suitable for large-scale energy storage cabinets with hundreds of batteries connected in series and parallel. The system can accurately locate any single cell in the energy storage cluster using the electronic ID and corresponding address code, independently retrieve real-time voltage, temperature, health status, and historical operating data of the individual cell, enabling precise fault tracing and accurate status monitoring, significantly simplifying the on-site operation and maintenance and remote monitoring of large-scale energy storage clusters.

[0036] Meanwhile, this device supports online address code modification and identity reconfiguration. When a single battery cell in the energy storage system ages or is damaged and needs to be replaced, the new battery cell only needs to be connected to the front-end controller to rewrite the battery's electronic identity information and update the address code in the battery pack online. This quickly completes the network adaptation of the new battery cell without disassembly or complex debugging, achieving immediate replacement and immediate use, which greatly reduces the later operation and maintenance costs and difficulty of the energy storage system.

[0037] Controller module B integrates a second MCU main control unit, a bidirectional inverter, a 485 communication unit, a human-machine interface unit, and a power output unit, supporting wide voltage input and stable power output of various specifications. Controller module B establishes high-speed real-time communication with battery module A via a multi-core data cable, continuously receiving all operating data such as battery SOC, SOE, SOH, individual cell voltage, inter-series voltage difference, and cell temperature, and visually displays the overall health status and various parameters of the battery pack on a screen. Simultaneously, relying on the 485 communication unit, a remote data transmission link is established, supporting remote battery status monitoring, remote parameter query, and remote equalization repair start / stop control, achieving intelligent unattended operation and maintenance.

[0038] The overall workflow of this device is as follows: After the controller module B and battery module A complete the wiring harness connection and communication handshake, the controller module B continuously monitors the battery's operating status in all dimensions in real time. Maintenance personnel can manually enable the equalization maintenance function through the human-machine interaction unit. After the controller issues the equalization repair command, battery module A immediately starts the active high-level equalization repair mode, automatically completing static calibration, differential voltage correction, low-voltage charging, and overall equalization optimization, dynamically correcting the consistency of the battery pack, and continuously optimizing the battery pack's working performance.

[0039] Example 1: Residential Off-Grid Energy Storage Scenario See Figure 1 In this embodiment, battery module A uses lithium iron phosphate cell packs, with a built-in AFE acquisition chip to collect the voltage of each cell in real time. The first MCU main control unit calculates the state of charge, state of energy, and health status. Controller module B is connected to battery module A via a multi-core data cable, and the LCD screen displays the voltage of each cell, the voltage difference between cells, and the state of charge of the battery pack in real time.

[0040] When the system detects that the cell voltage difference exceeds the preset threshold, the user presses the maintenance button, and the system immediately triggers the equalization repair process: stop charging and discharging, let the cell stand still and stabilize, and then use the current highest cell voltage as a reference value to replenish the low voltage cell through an independent equalization power supply until the voltage difference between the cells drops below the target value.

[0041] During system startup, the soft-start protection unit controls the relay to close completely first. After a preset delay, the MOSFET turns on, outputting AC power to supply household appliances. There is no arcing during the entire startup process.

[0042] This device supports solar and wind power input, enabling wind-solar hybrid charging to meet daily electricity needs in off-grid scenarios.

[0043] Example 2: Large-scale energy storage scenarios in industrial and commercial settings See Figure 1 In this embodiment, multiple battery modules A are connected in parallel to form an energy storage cabinet. Each battery module A has a unique address code built into it at the factory. The controller module B transmits the status data of each battery module A to a remote operation and maintenance platform through a 485 communication module. Operation and maintenance personnel can quickly locate any single battery cell using the address code.

[0044] When the remote platform detects that the cell voltage difference of a certain battery module A exceeds the preset threshold, the maintenance personnel can remotely trigger the equalization repair process without going to the site.

[0045] This device supports peak-valley arbitrage mode of mains power, and its wide voltage input can be adapted to industrial and commercial power grid environments. The bidirectional inverter realizes efficient conversion and utilization of electrical energy.

[0046] Example 3: See Figure 2 The method for monitoring and repairing energy storage batteries includes the following steps: S1. Battery module A and controller module B communicate and handshake through a multi-core data cable. The startup module performs hardware safety interlock verification. If the connection is abnormal or the controller is not started, the battery module will not output external voltage. The S2 and AFE acquisition units collect battery current, individual cell voltage, temperature, and power parameters around the clock and upload them to the first MCU main control unit. S3. The first MCU main control unit calculates, generates, and updates the core status parameters of SOC, SOE, and SOH in real time, and stores the health change data of individual units and the entire group. S4. After receiving the local or remote equalization operation and maintenance start command, pause the charger output, so that the battery pack enters the static voltage regulation state, eliminates dynamic operating condition interference and recalibrates SOC. S5. Collect the voltage of all individual cells in the battery pack and select the highest individual cell voltage as the equalization benchmark. S6. By using an independent regulated power supply, all low-voltage cells below the reference voltage are charged one by one to catch up, smoothing out the voltage difference between strings and restoring the consistency of cell operation. S7. The address code identification unit can be used to retrieve the identity and operation data of any single cell to achieve accurate fault tracing; when replacing a damaged cell, the address code and identity information of the new cell can be written online to complete the network adaptation and make it ready to use immediately. S8 and controller module B upload all battery parameters via 485 communication to achieve remote monitoring, unattended operation and maintenance, and remote equalization control.

Claims

1. A multifunctional energy storage battery monitoring and repair device, characterized in that, The system includes a battery module A and a controller module B. Battery module A includes a cell pack, an AFE acquisition unit, a first MCU main control unit, an active height tracking and equalization unit, a soft start protection unit, and an address code identification unit. The first MCU main control unit is electrically connected to the AFE acquisition unit, the active height tracking and equalization unit, the soft start protection unit, and the address code identification unit. The AFE acquisition unit is electrically connected to the cell pack to acquire cell status data. The active height tracking and equalization unit is electrically connected to the cell pack to perform supplementary power equalization on the cells. The soft start protection unit is connected in series in the power supply circuit of the cell pack. Controller module B includes a second MCU main control unit, a bidirectional inverter, a 485 communication unit, an interaction unit, and a power supply output unit; the second MCU main control unit is electrically connected to the bidirectional inverter, the 485 communication unit, and the interaction unit, respectively, and the power supply output unit is electrically connected to the bidirectional inverter. Battery module A and controller module B are connected via a multi-core data cable to enable power supply, communication and control between battery module A and controller module B; Battery module A has a start-up module that controls the on / off state of the positive and negative terminals. The start-up module is connected in series with the soft-start protection unit and then connected to the power supply circuit of the battery cell group. Controller module B sends control signals to the start-up module through a multi-core data line, thereby realizing physical-level safety interlock between battery module A and controller module B. When the multi-core data cable is not connected, and the controller module B is not powered on or not started, the start-up module is disconnected, and the positive and negative terminals of the battery module A have no voltage output to the outside. Only when the battery module A and the controller module B are normally connected through the multi-core data cable and the controller module B has completed the start-up, the start-up module closes, and the positive and negative terminals of the battery module A supply power to the outside.

2. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The active height-tracking equalization unit includes an independent equalization power supply and a relay array. The relay array is connected to each cell in the cell group. The control logic of the active height-tracking equalization unit is as follows: the first MCU main control unit first controls the relay array to disconnect the charging and discharging circuit of the cell group. After the cell voltage is stabilized, the highest cell voltage in the current cell group is used as a reference value. The relay array is used to charge the cells with voltage values ​​lower than the reference voltage value until the voltage difference between the cells drops below the preset threshold.

3. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The soft start protection unit includes a relay and a MOSFET that work together. The relay and MOSFET are connected in series in the power supply circuit of the battery pack. During startup, the relay is fully closed first. After a preset delay time, once the relay contacts have stabilized, the MOSFET is driven to conduct the load current to avoid the relay from arcing and burning under load. The soft start protection unit includes multiple soft start protection circuits, which are used for relay protection during the battery pack startup phase and relay protection during the load output phase.

4. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The address code identification unit is built into battery module A and is used to store a unique address code. The unique address code serves as an electronic ID card and is used for the location and operation and maintenance management of individual batteries in a large-scale energy storage system.

5. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The interactive unit includes an LCD screen and maintenance buttons. The LCD screen is used to display the overall status of the battery pack, the voltage of each cell, and the voltage difference between cells in real time. When the maintenance button is pressed, the active high-level equalization repair process is triggered.

6. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The power supply output unit supports wide voltage AC input and can output AC and DC power.

7. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The controller module B also includes a DC-DC module, a backup battery module, and a fan control module. The DC-DC module and the backup battery module are used to provide continuous power to the second MCU main control unit, and the fan control module is used to dissipate heat from the battery module A and the controller module B to ensure stable operation under different working conditions.

8. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The AFE acquisition unit collects the voltage, total charging and discharging current, and temperature data of each cell in the battery pack in real time, and transmits them to the first MCU main control unit, which calculates the state of charge, state of energy, and state of health values.

9. A multifunctional energy storage battery monitoring and repair device according to claim 1, characterized in that, The second MCU main control unit communicates with the remote monitoring platform through the 485 communication unit to transmit the battery pack status data to the remote platform, thereby realizing remote monitoring and remote operation and maintenance management.

10. A method for monitoring and repairing multi-energy storage batteries, comprising the following steps: S1. Battery module A and controller module B communicate and handshake through a multi-core data cable. The startup module performs hardware safety interlock verification. If the connection is abnormal or the controller is not started, the battery module will not output external voltage. The S2 and AFE acquisition units collect battery current, individual cell voltage, temperature, and power parameters around the clock and upload them to the first MCU main control unit. S3. The first MCU main control unit calculates, generates, and updates the core status parameters of SOC, SOE, and SOH in real time, and stores the health change data of individual units and the entire group. S4. After receiving the local or remote equalization operation and maintenance start command, pause the charger output, so that the battery pack enters the static voltage regulation state, eliminates dynamic operating condition interference and recalibrates SOC. S5. Collect the voltage of all individual cells in the battery pack and select the highest individual cell voltage as the equalization benchmark. S6. By using an independent regulated power supply, all low-voltage cells below the reference voltage are charged one by one to catch up, smoothing out the voltage difference between strings and restoring the consistency of cell operation. S7. The address code identification unit can be used to retrieve the identity and operation data of any single cell to achieve accurate fault tracing; when replacing a damaged cell, the address code and identity information of the new cell can be written online to complete the network adaptation and make it ready to use immediately. S8 and controller module B upload all battery parameters via 485 communication to achieve remote monitoring, unattended operation and maintenance, and remote equalization control.

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