A method for controlling energy storage charging using welding off-periods

Abstract

This invention proposes an energy storage charging control method utilizing welding intervals, relating to the field of energy storage charging technology. It involves data acquisition and dual filtering of the welding inverter unit via a sampling unit, multi-criteria linkage and dynamic delay determination of the welding operation status using interference-free sampling data, monitoring welding operation parameters via a controller, and dynamically controlling the charging process during intervals by combining welding status monitoring data with welding interval determination results. Based on the charging control effect data, it obtains charging termination trigger signals and system operation anomaly signals, and uses these signals to perform multi-condition termination control and collaborative optimization protection of the charging process, obtaining system operation effect data. This invention achieves coordinated adaptation between charging and welding, and possesses efficient, safe, and energy-saving characteristics in its energy storage charging control method.

Description

Technical Field

[0001] This invention proposes an energy storage and charging control method utilizing welding intervals, relating to the field of energy storage and charging control technology, specifically to the field of energy storage and charging control utilizing welding intervals. Background Technology

[0002] In welding operations such as flash welding of steel rails, there are natural intervals between welding processes. However, existing welding power supply systems fail to effectively utilize these intervals for energy storage and charging, resulting in low energy utilization of the storage batteries and poor coordination between charging and welding. Current intermittent charging control has many shortcomings. Intermittent determination often relies on a single current criterion, which has weak anti-interference capabilities, is prone to misjudgment, and cannot adapt to the different operating conditions at different welding process stages. The charging strategy is fixed, lacking dynamic adaptation and refined control, which can easily cause battery damage and grid disturbances. At the same time, there is no reliable interlocking mechanism between charging and welding, which can easily lead to power supply conflicts, inadequate system protection, untimely fault response, and high standby power consumption. In addition, welding power supply systems also suffer from low power factor and unstable power supply, affecting welding quality and system lifespan. Summary of the Invention

[0003] This invention provides a method for controlling energy storage and charging during welding intervals to solve the above-mentioned problems: This invention proposes an energy storage charging control method utilizing welding intervals, the method comprising: S1. Data acquisition and dual filtering of the welding inverter unit are performed by the sampling unit to obtain interference-free sampling data. The welding working status is then determined by multi-criteria linkage and dynamic delay using the interference-free sampling data to obtain the welding interval determination result. S2. The welding working parameters are monitored by the controller to obtain welding status monitoring data. The welding status monitoring data is combined with the welding interval determination results to dynamically control the charging process during the interval and obtain charging control effect data. S3. Obtain the charging termination trigger signal and system operation abnormality signal based on the charging control effect data. Perform multi-condition termination control and collaborative optimization protection on the charging process through the charging termination trigger signal and system operation abnormality signal to obtain system operation effect data.

[0004] Furthermore, the system includes: The intermittent determination module is used to collect data from the welding inverter unit and perform dual filtering processing through the sampling unit to obtain interference-free sampling data. The welding working status is then determined by multi-criteria linkage and dynamic delay based on the interference-free sampling data to obtain the welding intermittent period determination result. The charging control module is used to monitor welding working parameters through the controller, obtain welding status monitoring data, and dynamically control the charging process during the interval by combining the welding status monitoring data with the welding interval determination results, and obtain charging control effect data. The operation monitoring module is used to obtain charging termination trigger signals and system operation abnormality signals based on charging control effect data. Through the charging termination trigger signals and system operation abnormality signals, the module performs multi-condition termination control and collaborative optimization protection of the charging process to obtain system operation effect data.

[0005] The beneficial effects of this invention are as follows: This method solves the technical problems in existing welding interval charging control, such as inaccurate interval determination, poor coordination between charging and welding, imperfect system protection, and low charging efficiency; it achieves accurate identification and efficient charging of welding intervals, ensuring that the charging process does not affect the normal operation of welding work, while making full use of the interval to complete the charging of the energy storage battery, thereby improving the energy utilization rate of the energy storage battery; it improves the operational stability, reliability, and intelligence level of the entire rail flash welding power supply system, reduces the risks of battery damage, power grid disturbance, and welding power supply conflicts during the charging process, reduces the system failure rate and standby energy consumption, extends the overall service life of the system, and adapts to the actual needs of different rail welding conditions. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of an energy storage and charging control method that utilizes the welding interval. Detailed Implementation

[0007] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0008] In one embodiment of the present invention, an energy storage charging control method utilizing welding intervals is proposed, the method comprising: S1. Data acquisition and dual filtering of the welding inverter unit are performed by the sampling unit to obtain interference-free sampling data. The welding working status is then determined by multi-criteria linkage and dynamic delay using the interference-free sampling data to obtain the welding interval determination result. S2. The welding working parameters are monitored by the controller to obtain welding status monitoring data. The welding status monitoring data is combined with the welding interval determination results to dynamically control the charging process during the interval and obtain charging control effect data. S3. Obtain the charging termination trigger signal and system operation abnormality signal based on the charging control effect data. Perform multi-condition termination control and collaborative optimization protection on the charging process through the charging termination trigger signal and system operation abnormality signal to obtain system operation effect data, as shown in Figure 1.

[0009] The working principle and technical effect of the above technical solution are as follows: This method completes the collection and purification of relevant data of the welding inverter unit through the sampling unit, and accurately determines the welding interval after eliminating interference; then the controller monitors the working parameters of the entire welding process in real time, and combines the interval determination results to implement dynamic control of the charging process to ensure that the charging process is adapted to the battery status, grid status and welding conditions; by analyzing the charging control effect, capturing the termination trigger signal and system abnormal signal, implementing multi-condition termination control and full-process collaborative protection, forming a complete control closed loop, and realizing intelligent and refined control of energy storage charging during the welding interval.

[0010] This method solves the technical problems in existing welding interval charging control, such as inaccurate interval determination, poor coordination between charging and welding, imperfect system protection, and low charging efficiency. It achieves accurate identification and efficient charging of welding intervals, ensuring that the charging process does not affect the normal operation of welding work. At the same time, it makes full use of the interval to complete the charging of the energy storage battery, improving the energy utilization rate of the energy storage battery. It improves the operational stability, reliability, and intelligence level of the entire rail flash welding power supply system, reduces the risks of battery damage, power grid disturbance, and welding power supply conflicts during the charging process, reduces the system failure rate and standby power consumption, extends the overall service life of the system, and adapts to the actual needs of different rail welding conditions.

[0011] In one embodiment of the present invention, S1 includes: The sampling unit collects the output current of the welding inverter unit, the welding start / stop enable signal, the closing signal, and the welding process stage instructions. By employing a dual filtering process that combines isolation filtering and digital filtering, interference signals are eliminated to obtain interference-free sampling data. Dual-criteria linkage analysis is performed based on welding current threshold and welding enable signal to obtain dual-criteria linkage analysis data. Based on the dual-criteria linkage analysis data, delay judgment and anti-shake verification mechanism, the interference-free sampling data is verified multiple times to obtain verification data; The welding working status is determined based on the verification data, and the welding interval determination result is obtained.

[0012] The working principle and technical effect of the above technical solution are as follows: The sampling unit comprehensively collects key operating parameters of the welding inverter unit, covering welding current, start / stop control signals, process stages, etc., ensuring the comprehensiveness of the collected data. Then, a dual filtering method combining isolation filtering and digital filtering is used to isolate electromagnetic interference on-site, eliminate sampling noise and signal drift, purifying the sampled data and obtaining interference-free sampling data. Next, through the dual-criteria linkage analysis of the welding current threshold and the welding enable signal, combined with dynamic delay judgment and anti-jitter verification mechanisms, the interference-free sampling data is repeatedly verified to eliminate the influence of instantaneous fluctuations and false triggers. Finally, the verification data accurately determines the welding working state, distinguishes between the welding working period and the intermittent period, and outputs a reliable welding intermittent period determination result.

[0013] This method solves the technical problems of existing intermittent period determination, such as relying solely on a single current criterion, weak anti-interference capability, susceptibility to misjudgment, and poor adaptability. It achieves accurate and stable determination of welding intermittent periods, effectively eliminating the risk of misjudgment caused by on-site electromagnetic interference, sampling noise, and instantaneous current fluctuations. It improves the reliability and accuracy of intermittent period determination, avoids conflicts between charging and welding power supply caused by misjudgment, and avoids low energy storage efficiency caused by missing the intermittent period charging window. It reduces the failure probability of the determination process, improves the pre-determination accuracy of the entire control method, and adapts to the welding conditions of different welding processes and different rail types.

[0014] In one embodiment of the present invention, the step of performing dual-criteria linkage analysis based on a welding current threshold and a welding enable signal to obtain dual-criteria linkage analysis data includes: Preset welding current judgment thresholds to adapt to different rail types and welding processes, and compare the output current of the welding inverter unit in the interference-free sampling data with the preset current thresholds in real time to obtain current status judgment data. The high and low level status of the welding start / stop enable signal is acquired in real time. A high level indicates the welding working state and a low level indicates the welding standby state, thereby obtaining enable status determination data. The current state determination data and the enable state determination data are linked and analyzed. Only when the welding output current is lower than the preset threshold and the welding enable signal is continuously at a low level, the effective interval pre-determination data is generated. All other states are determined to be welding working states. Finally, the dual-criteria linkage analysis data is obtained.

[0015] Specifically, current state determination data and enable state determination data are linked and analyzed. Only when the welding output current is below a preset threshold and the welding enable signal remains low is effective intermittent period pre-determination data generated; all other states are considered welding working states. The final integrated data includes dual-criteria linked analysis data: Establish a linkage verification model between current state and enable state, synchronously bind the real-time acquired current state judgment data with the enable state judgment data, and set a threshold for the duration of continuous low-level judgment of the enable signal. If the welding output current is lower than the preset threshold, and the welding start / stop enable signal remains at a low level and reaches the set duration threshold, it is determined that the preconditions for the interval period are met, valid preconditions for the interval period are generated, and it is marked as a state where charging can be started. If the welding output current is higher than the preset threshold, or the enable signal is high, or the duration of the low level enable signal does not reach the threshold, it is determined to be a welding working state, invalid pre-judgment data is generated, and it is marked as a prohibited charging state. All linkage analysis results, status markers, and judgment criteria are integrated to form dual-criteria linkage analysis data, which is then synchronously transmitted to the verification stage.

[0016] The working principle and technical effect of the above technical solution are as follows: Pre-set current judgment thresholds adapted to different rail types and welding processes to ensure the adaptability of current judgment; obtain current status judgment data by comparing the output current sampled in real time with the preset thresholds without interference; simultaneously collect the high and low levels of the welding start / stop enable signal to clarify the working and standby states of welding and obtain enable status judgment data; then establish a linkage verification model to synchronously bind the two types of data, setting a threshold for the duration of the low level of the enable signal to avoid misjudgments caused by instantaneous low levels; through logical judgment, filter out valid and invalid pre-judgment data that meet the current and enable signal and duration standards, mark the status respectively, and finally integrate all analysis results, status marks, and judgment criteria to form complete dual-criteria linkage analysis data, providing accurate data support for subsequent verification stages.

[0017] This method addresses the technical problems of existing intermittent pre-judgment methods, which rely on a single current criterion, are susceptible to current fluctuations, have poor adaptability, and suffer from high misjudgment rates. It achieves greater accuracy and adaptability in inter-welding intermittent pre-judgment, effectively eliminating the risk of misjudgment caused by instantaneous current fluctuations and false triggering signals through dual-criteria linkage and time threshold limitations. It improves the reliability and accuracy of pre-judgment data, ensuring that valid judgment data is only generated when the welding intermittent period actually begins. It reduces the risk of charging and welding conflicts caused by misjudgments in pre-judgment, enhancing the rigor of the entire judgment process. Furthermore, it adapts to the differentiated needs of different rail types and welding processes, increasing the method's versatility.

[0018] In one embodiment of the present invention, the step of performing multiple verifications on interference-free sampling data based on dual-criteria linkage analysis data, delay determination, and anti-shake verification mechanism to obtain verification data includes: Set an adaptive dynamic delay range to automatically match the corresponding delay parameters according to the current different process stages; The dual-criteria linkage analysis data is sampled and verified multiple times in a continuous cycle to eliminate misjudged data caused by single sampling fluctuations and instantaneous interference; If multiple consecutive verification results are all valid states before the interval and the duration meets the dynamic delay requirement, the verification is deemed qualified and valid verification data is output. If any verification result fails to meet the conditions, the timer is reset and the verification is repeated, and the verification data is output.

[0019] This includes setting an adaptive dynamic delay interval, which automatically matches the corresponding delay parameters according to different current process stages, including: The adaptive dynamic delay range is set to 5ms~50ms, and a model is established to correspond to the welding process stages and the delay parameters. When the current welding process is in the preheating stage, a delay parameter of 10ms~20ms is matched to adapt to the current fluctuation characteristics in the preheating stage and avoid misjudgment. When in the upsetting and holding stages, a delay parameter of 5ms~10ms is matched to shorten the judgment time and make full use of the short interval for charging; When in the tempering stage, a delay parameter of 20ms~50ms is matched to adapt to the characteristics of stable current and long interval time in the tempering stage. The controller collects welding process stage instructions in real time and automatically calls the corresponding delay parameters according to the instructions. If a process stage switch is detected, the delay parameters are immediately updated synchronously to ensure that the delay judgment is accurately adapted to the current welding conditions.

[0020] The working principle and technical effect of the above technical solution are as follows: An adaptive dynamic delay interval is set, and a correspondence model between welding process stages and delay parameters is established. Based on the current fluctuation characteristics and intermittent duration differences of different process stages such as preheating, upsetting, holding, and tempering, the corresponding delay parameters are automatically matched to ensure that the delay judgment is adapted to the current working condition. Subsequently, the dual-criteria linkage analysis data is continuously sampled and verified multiple times to eliminate misjudged data caused by single sampling fluctuations and instantaneous interference. Through logical judgment, only when the results of multiple consecutive verifications are all valid and the duration meets the dynamic delay requirements of the current process stage is the verification deemed qualified, and valid verification data is output. If any verification fails to meet the conditions, the timing is reset and re-verification is performed to ensure the stability and reliability of the verification data, providing solid support for the final intermittent period determination.

[0021] This method addresses the technical problems of existing delay determination methods, which rely on fixed parameters, have poor adaptability, lack anti-jitter verification, and are susceptible to misjudgments due to transient interference. It achieves adaptive dynamic adjustment of delay parameters to suit the characteristics of different welding process stages, avoiding misjudgments during the preheating stage and fully utilizing the brief intervals during the upsetting and holding stages, thus improving the utilization rate of the charging window. Through multiple anti-jitter verifications, it further eliminates the risk of misjudgments caused by transient interference and sampling fluctuations, improving the reliability and accuracy of the verification data. It reduces the misjudgment rate of interval determination, ensuring that charging only starts during the actual interval, avoiding conflicts with welding operations. Simultaneously, it improves the adaptability of the method to different welding processes, enhancing the versatility and practicality of the entire control method.

[0022] In one embodiment of the present invention, S2 includes: Welding parameters are monitored by a controller to obtain welding status monitoring data; Based on the welding interval determination result, charging control is initiated when the welding interval is determined to be entered, and charging control data is obtained. Based on the charging control data and welding status monitoring data, dynamic current limiting control, charging optimization and dual interlocking control are performed respectively to obtain monitoring and control data; Analyze the charging control effect of the monitoring and control data to obtain charging control effect data.

[0023] The working principle and technical effects of the above technical solution are as follows: The controller monitors the working parameters of the entire welding process in real time, covering AC power supply status, energy storage battery status, and welding inverter unit operating status, obtaining comprehensive welding status monitoring data. Based on the welding interval determination result, charging control is initiated only when the interval is determined, generating basic charging control data. Combined with the welding status monitoring data, dynamic current limiting control, charging optimization control, and dual interlocking control are implemented to ensure that the charging current is adapted to the battery and grid status, the charging method is adapted to the battery operating status, and charging and welding do not conflict. Finally, the monitoring and control data of the above control process are analyzed to quantify the stability, safety, and adaptability of the charging process, generating charging control effect data.

[0024] This method addresses the technical problems in existing intermittent charging control, such as fixed charging current, poor adaptability, unreasonable charging methods, high risk of battery damage, lack of reliable interlocking between charging and welding, easy power supply conflicts, and lack of charging effect monitoring. It achieves precise charging control during welding intervals, ensuring accurate adaptation of the charging process to welding conditions, battery status, and grid status. This improves charging safety and efficiency, avoids risks such as grid overload, battery overcharging, and damage, and extends the lifespan of the energy storage battery. Dual interlocking ensures priority power supply for welding, preventing conflicts between charging and welding and improving system stability. Charging effect analysis reduces the failure rate during charging, improving the overall charging efficiency and reliability of the system.

[0025] In one embodiment of the present invention, the step of performing dynamic current limiting control, charging optimization, and dual interlocking control based on charging control data and welding status monitoring data to obtain monitoring and control data includes: The basic charging current limit value is set based on the battery's maximum charging current data. The charging current is dynamically adjusted by combining the battery's aging degree, individual cell voltage difference, ambient temperature, and available AC power margin to achieve dynamic current limiting control. Based on the battery SOC segment range and temperature range, a constant current, constant voltage, and float full-segment charging strategy is adopted, combined with the equalization adjustment of individual battery cells, to obtain equalization adjustment data; With a dual protection mode of software logic interlocking and hardware relay hard interlocking, the welding start signal is monitored, and the charging circuit is cut off within a preset time. After the welding recovery interval, the charging is resumed by soft start after anti-shake delay and voltage verification. It integrates all execution parameters and operating status of current limiting control, charging optimization, and interlock control to generate monitoring and control data.

[0026] Specifically, based on the battery SOC segmentation range and temperature range, a constant current, constant voltage, and float full-charge strategy is adopted, combined with battery cell balancing adjustment, to obtain balancing adjustment data, including: Preset battery SOC three-stage range and corresponding charging strategies: When the SOC is less than 30%, it is considered undercharged and a constant current charging mode is used, with the charging current being 70% to 80% of the battery's maximum charging current. The standard charging range is 30% ≤ SOC ≤ 80%, using a constant current and constant voltage charging mode, with the current maintained at 50% to 70% of the battery's maximum charging current. The full charge phase is defined as 80% < SOC ≤ 95%, employing a constant voltage float charge mode where the current gradually decreases to 10%~20% of the battery's maximum charging current. Simultaneously, four preset temperature ranges are used to adapt to charging adjustments under different temperatures. When the battery temperature is below 0℃, charging is stopped and heating is activated to maintain the temperature. When the temperature is between 0℃ and 10℃, the charging current drops to 30%~50%. When the temperature is between 10℃ and 45℃, charge normally according to the corresponding SOC range; When the temperature is >45℃, the charging current is reduced to 20%~30% and the temperature rise rate is monitored; During each segment of charging, the battery balancing unit collects the voltage of each individual battery cell in real time. When the voltage difference between individual cells is detected to be ≥30mV, the balancing adjustment is initiated. The balancing circuit discharges cells with high voltage and replenishes cells with low voltage. The unit records data such as individual cell voltage changes, balancing current, and balancing time in real time during the balancing adjustment process. These data are then integrated to form balancing adjustment data and synchronously fed back to the charging optimization stage to dynamically adjust the charging parameters.

[0027] The working principle and technical effect of the above technical solution are as follows: through dynamic current limiting, refined charging optimization and dual interlocking, safe, efficient and stable charging during intermittent periods can be achieved, while adapting to the dynamic changes of battery and welding conditions. Based on the battery's maximum charging current, a basic current limit value is set. This is combined with factors such as battery aging, individual cell voltage difference, ambient temperature, and available AC power margin to dynamically adjust the charging current, preventing grid overload and battery damage, thus achieving dynamic current limiting control. Subsequently, differentiated segmented charging strategies are adopted for different battery SOC and temperature ranges. In the undercharged SOC range, constant current fast charging is used to improve efficiency; in the normal range, constant current and constant voltage are used to balance efficiency and safety; and in the full charge range, float charging is used to avoid overcharging. Simultaneously, the charging current is adjusted according to the temperature range, and heat preservation or current reduction measures are implemented under extreme temperatures. In conjunction with the battery balancing unit, individual cell voltage is monitored in real time. When an individual cell voltage difference exceeds the limit, balancing adjustment is initiated, recording the balancing data and feeding it back to the charging optimization stage to dynamically adjust charging parameters, achieving refined charging optimization. Finally, a combination of software logic interlocking and hardware relay hard interlocking is used to monitor the welding start signal in real time, ensuring rapid disconnection of the charging circuit upon welding start. After welding recovery, charging is soft-started after anti-jitter and voltage verification to avoid power supply conflicts. Finally, all execution parameters and operating statuses of current limiting, charging optimization, and interlocking control are integrated to generate complete monitoring and control data.

[0028] This method addresses the technical problems in existing charging control systems, such as fixed current limiting strategies, poor adaptability, single charging methods, high risk of battery damage, poor individual cell balance affecting battery life, and unreliable charging and welding interlocking leading to power supply conflicts. It achieves dynamic adaptation of charging current, avoiding damage such as AC power overload, overcharging of energy storage batteries, and lithium plating, thus improving charging safety. Through a segmented charging strategy based on SOC and temperature, it balances charging efficiency and battery protection, adapting to the charging needs of batteries under different operating conditions. Individual cell balancing adjustment improves battery pack consistency, preventing overcharging and undercharging of individual cells and extending battery pack lifespan. A dual interlocking mechanism ensures priority power supply for welding, completely eliminating power supply conflicts between charging and welding, and improving system stability. Simultaneously, it enhances the precision and intelligence of charging control, reducing the risk of battery damage and system failure, and adapting to charging needs under different operating conditions.

[0029] In one embodiment of the present invention, the step of analyzing the charging control effect of the monitoring and control data to obtain charging control effect data includes: Real-time acquisition and monitoring of charging current fluctuations, bus voltage stability, battery temperature rise changes, individual cell voltage consistency, grid harmonic content, and welding power supply response status in the monitoring and control data; Quantitative analysis of various parameters is conducted to determine whether the charging process meets battery safety charging standards, power grid stability standards, and welding priority power supply standards. By statistically analyzing key indicators of the charging process and integrating all quantitative analysis results with operational indicator data, charging control effectiveness data is generated.

[0030] The working principle and technical effects of the above-mentioned technical solution are as follows: The charging control effect is quantified through comprehensive monitoring and analysis of the charging control process. Key parameters in the monitoring and control data are collected in real time, covering charging current fluctuations, bus voltage stability, battery temperature rise, individual cell voltage consistency, grid harmonic content, and welding power supply response, comprehensively covering the three core dimensions of charging safety, grid stability, and welding assurance. Subsequently, the collected parameters are quantitatively analyzed, and compared with battery safety charging standards, grid stability standards, and welding priority power supply standards to determine whether the charging process meets the requirements of each standard and identify abnormal situations during the charging process. Finally, key operating indicators during the charging process are statistically analyzed, and all quantitative analysis results and operating indicator data are integrated to form complete charging control effect data, clearly reflecting the stability, safety, and adaptability of the charging control.

[0031] This method addresses the technical problems in existing charging control systems, such as the lack of effective performance monitoring, inability to promptly identify charging anomalies, and difficulty in supporting subsequent optimization and adjustments. It achieves comprehensive and accurate monitoring and quantitative analysis of charging control performance, enabling timely detection of anomalies during the charging process and providing a basis for subsequent fault handling and optimization adjustments. It improves the traceability and controllability of charging control, ensuring that the charging process always meets the requirements of safety, stability, and efficiency. It reduces the risks of battery damage, grid disturbances, and decreased welding quality caused by charging anomalies, further enhancing the reliability and intelligence level of the entire control method.

[0032] In one embodiment of the present invention, S3 includes: Analyze and filter the charging control effect data to obtain normal charging termination trigger signals, fault termination trigger signals and standby termination trigger signals; The system captures abnormal signals during operation based on normal charging termination trigger signals, fault termination trigger signals, and standby termination trigger signals, thereby obtaining charging termination trigger signals and abnormal system operation signals. Based on different types of charging termination trigger signals, normal termination, fault termination and standby termination control are implemented respectively. After normal termination, the system switches to float charging mode. After fault termination, the system stops immediately and triggers an alarm. After standby termination, the system enters hibernation mode. By combining abnormal system operation signals, collaborative optimization and full-process protection are carried out. Through multi-condition termination control and collaborative optimization protection, system operation effect data can be obtained.

[0033] The working principle and technical effects of the above technical solution are as follows: A comprehensive analysis and screening of charging control effect data is performed. Based on the charging effect, battery status, and system operating status, three trigger signals are obtained: normal charging termination, fault termination, and standby termination. Subsequently, based on these three termination trigger signals, various abnormal signals during system operation are captured and integrated to form complete charging termination trigger signals and system operation abnormal signals. Differentiated termination control strategies are implemented for different types of termination trigger signals. After normal termination, the system switches to float charging mode to ensure the battery is fully charged and ready for operation. After fault termination, the system immediately stops and issues an alarm to prevent the fault from escalating. After standby termination, the system enters hibernation mode to reduce energy consumption. Finally, combined with system operation abnormal signals, the entire system is collaboratively optimized and protected throughout the entire process to resolve abnormal issues during system operation, improve system performance, integrate all termination control and collaborative protection operation data, generate system operation effect data, and complete the entire control closed loop.

[0034] This method addresses the technical problems of existing charging termination conditions being singular, fault handling being untimely, standby power consumption being high, and system protection being inadequate. It achieves multi-condition differentiated termination control during the charging process, ensuring that the battery is fully charged while avoiding fault escalation and wasted standby power. It enhances the system's safety protection capabilities, enabling timely detection of system anomalies and implementation of protective measures, reducing the system failure rate and equipment damage risk. Through collaborative optimization, it further improves the stability and efficiency of system operation, reduces standby power consumption and operating losses, and extends the overall service life of the system. At the same time, it generates complete system operation performance data, enhancing the practicality and reliability of the entire control method.

[0035] In one embodiment of the present invention, the control of normal termination, fault termination, and standby termination is implemented according to different types of charging termination trigger signals. After normal termination, the system switches to float charging mode. After fault termination, the system immediately stops and triggers an alarm. After standby termination, the system enters hibernation mode. When the preset normal state is detected, it is determined that charging is complete, the high-current charging is immediately terminated, and the low-current float charging mode is switched to replenishment mode. When a preset abnormal signal is detected, the charging circuit is immediately cut off to stop the machine, fault codes are uploaded simultaneously, audible and visual alarms are triggered, the current operating status is locked, and logs are recorded. When the system detects that there is no welding task trigger command and the battery status is normal, the charging process is automatically terminated and the control system enters a low-power sleep mode to reduce the standby power consumption of the equipment. The system monitors welding preparation signals in real time and automatically wakes up upon receiving a power-on preparation command, resuming intermittent charging standby mode.

[0036] The working principle and technical effects of the above technical solution are as follows: Different termination control strategies are implemented for different termination trigger scenarios to ensure the rationality, safety, and energy efficiency of charging termination. When a preset normal charging state (battery fully charged and stable) is detected, charging is determined to be complete, high-current charging is immediately terminated, and a low-current float charging mode is switched to compensate for battery self-discharge losses, ensuring the battery is fully charged and ready for use. When a preset system abnormal signal (battery abnormality, charging circuit fault, power grid abnormality, etc.) is detected, the charging circuit is immediately cut off, shutdown protection is implemented, fault codes are uploaded, audible and visual alarms are triggered, the operating status is locked, and logs are recorded to facilitate fault diagnosis and handling, preventing the fault from escalating. When the system has no welding tasks for a long time and the battery status is normal, charging is automatically terminated, and the control system enters a low-power sleep mode to reduce standby power consumption. Simultaneously, welding preparation signals are monitored in real time to ensure that the system can be woken up in time when a welding task starts, restoring the intermittent charging standby state without affecting the normal operation of welding work.

[0037] This method addresses the technical problems of existing charging termination control strategies, such as simplistic approaches, untimely fault response, high standby power consumption, and inability to quickly respond to welding tasks. It achieves differentiated and precise control of charging termination, ensuring a fully charged battery during normal termination, rapid damage mitigation and easier troubleshooting during fault termination, and reduced power consumption during standby termination. This improves the system's fault response capability and safety protection level, preventing equipment damage caused by fault escalation and reducing the difficulty of fault diagnosis. It also reduces system standby power consumption, achieving energy-saving operation. Simultaneously, it ensures the system can quickly wake up when a welding task is initiated, guaranteeing coordinated adaptation between welding and charging, improving the system's response speed and practicality, and further enhancing the reliability and adaptability of the entire control method.

[0038] In one embodiment of the present invention, the system includes: The intermittent determination module is used to collect data from the welding inverter unit and perform dual filtering processing through the sampling unit to obtain interference-free sampling data. The welding working status is then determined by multi-criteria linkage and dynamic delay based on the interference-free sampling data to obtain the welding intermittent period determination result. The charging control module is used to monitor welding working parameters through the controller, obtain welding status monitoring data, and dynamically control the charging process during the interval by combining the welding status monitoring data with the welding interval determination results, and obtain charging control effect data. The operation monitoring module is used to obtain charging termination trigger signals and system operation abnormality signals based on charging control effect data. Through the charging termination trigger signals and system operation abnormality signals, the module performs multi-condition termination control and collaborative optimization protection of the charging process to obtain system operation effect data.

[0039] The working principle and technical effect of the above technical solution are as follows: This system completes the collection and purification of relevant data of the welding inverter unit through the sampling unit, and accurately determines the welding interval after eliminating interference; then the controller monitors the working parameters of the entire welding process in real time, and combines the interval determination results to implement dynamic control of the charging process to ensure that the charging process is adapted to the battery status, grid status and welding conditions; by analyzing the charging control effect, capturing the termination trigger signal and system abnormal signal, implementing multi-condition termination control and full-process collaborative protection, forming a complete control closed loop, and realizing intelligent and refined control of energy storage charging during the welding interval.

[0040] This system solves the technical problems in existing welding interval charging control, such as inaccurate interval determination, poor coordination between charging and welding, imperfect system protection, and low charging efficiency. It achieves accurate identification and efficient charging of welding intervals, ensuring that the charging process does not affect the normal operation of welding work. At the same time, it makes full use of the interval to charge the energy storage battery, improving the energy utilization rate of the energy storage battery. It improves the operational stability, reliability, and intelligence level of the entire rail flash welding power supply system, reduces the risks of battery damage, power grid disturbance, and welding power supply conflicts during charging, reduces the system failure rate and standby power consumption, extends the overall service life of the system, and adapts to the actual needs of different rail welding conditions.

[0041] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for controlling the charging of an energy storage using welding off-periods, characterized in that, The method includes: S1. Data acquisition and dual filtering of the welding inverter unit are performed by the sampling unit to obtain interference-free sampling data. The welding working status is then determined by multi-criteria linkage and dynamic delay using the interference-free sampling data to obtain the welding interval determination result. S2. The welding working parameters are monitored by the controller to obtain welding status monitoring data. The welding status monitoring data is combined with the welding interval determination results to dynamically control the charging process during the interval and obtain charging control effect data. S3. Obtain the charging termination trigger signal and system operation abnormality signal based on the charging control effect data. Perform multi-condition termination control and collaborative optimization protection on the charging process through the charging termination trigger signal and system operation abnormality signal to obtain system operation effect data.

2. The method of claim 1, wherein the welding interval is 1 to 10 seconds. S1 includes: The sampling unit collects the output current of the welding inverter unit, the welding start / stop enable signal, the closing signal, and the welding process stage instructions. By employing a dual filtering process that combines isolation filtering and digital filtering, interference signals are eliminated, resulting in interference-free sampling data. Dual-criteria linkage analysis is performed based on welding current threshold and welding enable signal to obtain dual-criteria linkage analysis data. Based on the dual-criteria linkage analysis data, delay judgment and anti-shake verification mechanism, the interference-free sampling data is verified multiple times to obtain verification data; The welding working status is determined based on the verification data, and the welding interval determination result is obtained.

3. The method of claim 2, wherein the welding interval is 1 to 10 seconds. The method of performing dual-criteria linkage analysis based on welding current threshold and welding enable signal to obtain dual-criteria linkage analysis data includes: Preset welding current judgment thresholds to adapt to different rail types and welding processes, and compare the output current of the welding inverter unit in the interference-free sampling data with the preset current thresholds in real time to obtain current status judgment data. The high and low level status of the welding start / stop enable signal is acquired in real time. A high level indicates the welding working state and a low level indicates the welding standby state, thereby obtaining enable status determination data. The current state determination data and the enable state determination data are linked and analyzed. Only when the welding output current is lower than the preset threshold and the welding enable signal is continuously at a low level, the effective interval pre-determination data is generated. All other states are determined to be welding working states. Finally, the dual-criteria linkage analysis data is obtained.

4. The method of claim 2, wherein the welding interval is 1 to 10 seconds. The process involves multiple verifications of the interference-free sampled data based on dual-criteria linkage analysis data, delay determination, and anti-shake verification mechanisms to obtain verification data, including: Set an adaptive dynamic delay range to automatically match the corresponding delay parameters according to the current different process stages; The dual-criteria linkage analysis data is continuously sampled and verified multiple times to eliminate misjudged data caused by single sampling fluctuations and instantaneous interference; If multiple consecutive verification results are all valid states before the interval and the duration meets the dynamic delay requirement, the verification is deemed qualified and valid verification data is output. If any verification result fails to meet the conditions, the timer is reset and the verification is repeated, and the verification data is output.

5. The method of claim 1, wherein the welding interval is 1 to 10 seconds. S2 includes: Welding working parameters are monitored by a controller to obtain welding status monitoring data; Based on the welding interval determination result, charging control is initiated when the welding interval is determined to be entered, and charging control data is obtained. Based on the charging control data and welding status monitoring data, dynamic current limiting control, charging optimization and dual interlocking control are performed respectively to obtain monitoring and control data; Analyze the charging control effect of the monitoring and control data to obtain charging control effect data.

6. The method of claim 5, wherein the welding interval is 1 to 10 seconds. The process involves performing dynamic current limiting control, charging optimization, and dual interlocking control based on charging control data and welding status monitoring data to obtain monitoring and control data, including: The basic charging current limit value is set based on the battery's maximum charging current data. The charging current is dynamically adjusted by combining the battery's aging degree, individual cell voltage difference, ambient temperature, and available AC power margin to achieve dynamic current limiting control. Based on the battery SOC segment range and temperature range, a constant current, constant voltage, and float full-segment charging strategy is adopted, combined with the equalization adjustment of individual battery cells, to obtain equalization adjustment data; With a dual protection mode of software logic interlocking and hardware relay hard interlocking, the welding start signal is monitored, and the charging circuit is cut off within a preset time. After the welding recovery interval, the charging is resumed by soft start after anti-shake delay and voltage verification. It integrates all execution parameters and operating status of current limiting control, charging optimization, and interlock control to generate monitoring and control data.

7. The energy storage and charging control method utilizing the welding interval as described in claim 5, characterized in that, The process of analyzing the charging control effect of the monitoring and control data to obtain charging control effect data includes: Real-time acquisition and monitoring of charging current fluctuations, bus voltage stability, battery temperature rise changes, individual cell voltage consistency, grid harmonic content, and welding power supply response status in the monitoring and control data; Quantitative analysis of various parameters is conducted to determine whether the charging process meets battery safety charging standards, power grid stability standards, and welding priority power supply standards. By statistically analyzing key indicators of the charging process and integrating all quantitative analysis results with operational indicator data, charging control effectiveness data is generated.

8. The energy storage and charging control method utilizing the welding interval according to claim 1, characterized in that, S3 includes: Analyze and filter the charging control effect data to obtain normal charging termination trigger signals, fault termination trigger signals and standby termination trigger signals; The system captures abnormal signals during operation based on normal charging termination trigger signals, fault termination trigger signals, and standby termination trigger signals, thereby obtaining charging termination trigger signals and abnormal system operation signals. Based on different types of charging termination trigger signals, normal termination, fault termination and standby termination control are implemented respectively. After normal termination, the system switches to float charging mode. After fault termination, the system stops immediately and triggers an alarm. After standby termination, the system enters hibernation mode. By combining abnormal system operation signals, collaborative optimization and full-process protection are carried out. Through multi-condition termination control and collaborative optimization protection, system operation effect data can be obtained.

9. The method of claim 8, wherein the welding interval is 1 to 10 seconds. The system implements normal termination, fault termination, and standby termination control based on different types of charging termination trigger signals. After normal termination, it switches to float charging mode; after fault termination, it immediately shuts down and triggers an alarm; and after standby termination, it puts the system into hibernation mode. When the preset normal state is detected, it is determined that charging is complete, the high-current charging is immediately terminated, and the low-current float charging mode is switched to replenishment mode. When a preset abnormal signal is detected, the charging circuit is immediately cut off to stop the machine, fault codes are uploaded simultaneously, audible and visual alarms are triggered, the current operating status is locked, and logs are recorded. When the system detects that there is no welding task trigger command and the battery status is normal, the charging process is automatically terminated and the control system enters a low-power sleep mode to reduce the standby power consumption of the equipment. The system monitors welding preparation signals in real time and automatically wakes up upon receiving a power-on preparation command, resuming intermittent charging standby mode.

10. A system for implementing the method for controlling the charging of an energy storage with welding pauses as claimed in claim 1, characterized in that, The system includes: The intermittent determination module is used to collect data from the welding inverter unit and perform dual filtering processing through the sampling unit to obtain interference-free sampling data. The welding working status is then determined by multi-criteria linkage and dynamic delay based on the interference-free sampling data to obtain the welding intermittent period determination result. The charging control module is used to monitor welding working parameters through the controller, obtain welding status monitoring data, and dynamically control the charging process during the interval by combining the welding status monitoring data with the welding interval determination results, and obtain charging control effect data. The operation monitoring module is used to acquire charging termination trigger signals and system operation abnormality signals based on charging control effect data; and to perform multi-condition termination control and collaborative optimization protection of the charging process through charging termination trigger signals and system operation abnormality signals, thereby obtaining system operation effect data.

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