Battery pack swelling monitoring system, method, and apparatus

Abstract

The application relates to the technical field of battery detection, in particular to a battery pack expansion monitoring system, method and equipment. The battery pack expansion monitoring system comprises a battery pack and a detection piece. The battery pack comprises a battery group and a battery pack shell, the battery group is located in the battery pack shell, and the battery pack shell has a sealed end. The detection piece is used for monitoring the displacement of the sealed end deviating from an initial position in the battery pack in real time and outputting displacement data. The displacement data are used for determining the structural damage risk of the battery pack. By judging the expansion condition of the battery pack according to the displacement data, the detection result is more direct, the reliability of the detection result is improved, and the effect of improving the safety performance of the battery pack is achieved.

Description

Technical Field

[0001] This application relates to the field of battery testing technology, and in particular to a battery pack expansion monitoring system, method and device. Background Technology

[0002] With the rapid development of electronic devices, electric vehicles, and energy storage systems, battery packs have been widely used. However, during long-term use or under special operating conditions, the cells inside a battery pack are prone to expansion, causing the entire battery pack casing to expand. This expansion not only affects the performance and lifespan of the battery pack but may also lead to safety hazards such as leakage, short circuits, or even fire and explosion.

[0003] Currently, related technologies typically detect pressure and temperature signals between battery cells, convert the detected signals into voltage, and compare them with preset values. Alternatively, they detect the voltage and current of the battery cells and compare the real-time resistance changes of the cells with threshold values ​​to determine the expansion status of the cells. However, these technologies suffer from low reliability of detection results, which affects the safety performance of the battery pack. Summary of the Invention

[0004] This application provides a battery pack expansion monitoring system, method, and device, which can improve the reliability of battery pack expansion detection, thereby improving battery pack safety performance.

[0005] In a first aspect, embodiments of this application provide a battery pack expansion monitoring system, the system comprising:

[0006] A battery pack, comprising a battery pack and a battery pack housing, wherein the battery pack is located within the battery pack housing and the battery pack housing has a sealed end;

[0007] The detection device is used to monitor the displacement of the sealed end in the battery pack from its initial position in real time and output displacement data; the displacement data is used to determine the structural damage risk of the battery pack.

[0008] This application provides a battery pack expansion monitoring system. The battery pack is housed within a battery pack housing, which provides support and protection for the battery pack. When the battery pack expands, a force is applied to the sealed end of the battery pack housing, causing displacement of the sealed end. Therefore, the expansion status of the battery pack can be detected based on the displacement of the sealed end of the battery pack housing.

[0009] Therefore, the battery pack expansion monitoring system in this application includes a detection element. This element can monitor the displacement of the sealed end from its initial position in real time and output displacement data. The displacement data is used to determine the structural damage risk of the battery pack, allowing users to take timely countermeasures based on the damage risk, thereby reducing the probability of safety accidents. Compared to traditional detection methods that calculate and analyze the battery pack's expansion using information such as voltage, current, temperature, and pressure, the displacement data from the detection element does not require calculation and can be directly used as the basis for judging the internal expansion of the battery pack. This reduces the difficulty of monitoring, minimizes the introduction of errors, and makes the detection results more reliable.

[0010] The battery pack expansion monitoring system of this application determines the damage risk of the battery pack based on the displacement data detected by the detection device. Therefore, the battery pack expansion monitoring system of this application makes a more direct and reliable judgment on the damage risk of the battery pack, thereby improving the safety performance of the battery pack.

[0011] In one possible implementation, the battery pack expansion monitoring system further includes a battery management system, which includes a data analysis module and a risk determination module. The data analysis module receives the displacement data and compares the displacement data with a preset threshold. The risk determination module determines the structural damage risk of the battery pack based on the comparison result from the data analysis module.

[0012] In one possible implementation, the battery pack expansion monitoring system further includes a controller, and the risk determination module is also used to issue an early warning command when the battery pack has a risk of structural damage, and the controller or the battery management system is used to execute an early warning action according to the early warning command.

[0013] In one possible implementation, the preset threshold includes a safety threshold and a first risk threshold, wherein the first risk threshold is greater than the safety threshold;

[0014] The data analysis module is also used to compare the displacement data with the safety threshold and the first risk threshold;

[0015] The risk determination module is further configured to issue a first-level warning instruction when the displacement data is greater than the safety threshold and less than or equal to the first risk threshold, the warning instruction including the first-level warning instruction.

[0016] And / or, the preset threshold further includes the first risk threshold and the second risk threshold, wherein the second risk threshold is greater than the first risk threshold;

[0017] The data analysis module is also used to compare the displacement data with the second risk threshold;

[0018] The risk determination module is further configured to issue a secondary warning instruction when the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold, and the warning instruction further includes the secondary warning instruction;

[0019] And / or, the preset threshold further includes the second risk threshold and the third risk threshold, wherein the third risk threshold is greater than the second risk threshold;

[0020] The data analysis module is also used to compare the displacement data with the third risk threshold;

[0021] The risk determination module is further configured to issue a level-three warning instruction when the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, and the warning instruction further includes the level-three warning instruction.

[0022] In one possible implementation, the battery management system is configured to execute a first warning action according to the first-level warning instruction, the first warning action including reducing the current of the battery pack, the current of the battery pack including charging current and / or discharging current;

[0023] And / or, the battery management system is further configured to execute a second warning action according to the secondary warning instruction, the second warning action including reducing the current of the battery pack, and the reduction of the current in the second warning action is greater than the reduction of the current in the first warning action;

[0024] And / or, the controller is further configured to execute a third warning action according to the three-level warning instruction, the third warning action including controlling the display device to issue a risk warning that the battery pack needs to be inspected.

[0025] In one possible implementation, the risk determination module is further configured to issue a level four warning instruction when the displacement data is greater than the third risk threshold, the warning instruction further including the level four warning instruction.

[0026] The controller is also used to execute a fourth warning action according to the fourth warning instruction, the fourth warning action including controlling the display device to issue a risk warning that the battery pack needs to be replaced.

[0027] In one possible implementation, the controller is further configured to transmit the expansion data of the battery pack and the warning command to a warning platform, wherein the expansion data includes the displacement data and a preset threshold; the expansion data and the warning command are used to determine the remaining lifespan of the battery pack.

[0028] In one possible implementation, the battery pack housing includes a baffle located on one side of the battery pack, the baffle having the sealed end.

[0029] In one possible implementation, the battery pack housing has a seal, and the sealed end of the baffle has a connector. The seal and the baffle are sealed together via the connector. The detection element is used to monitor the displacement of the connector in a first direction in real time, in which the displacement of the connector is the same as the displacement of the sealed end.

[0030] In one possible implementation, the seal includes a cold plate, and the connector is used to connect the baffle and the cold plate;

[0031] And / or, the detection element is disposed on the cold plate.

[0032] In one possible implementation, the battery pack further includes a test element, at least a portion of which is located on one side of the connector in the first direction;

[0033] The detection element is used to monitor the displacement of the component to be detected in the first direction in real time, and the displacement of the component to be detected in the first direction is the same as the displacement of the connecting element.

[0034] And / or, the number of baffles is two, the two baffles include a first baffle and a second baffle, the first baffle and the second baffle are respectively disposed at opposite ends of the battery pack in the first direction, and the sealing ends of the first baffle and the second baffle are connected to the cold plate through a plurality of the connectors;

[0035] The cold plate has the detection element in the region adjacent to the first baffle and / or the second baffle, and the detection element and one of the connecting members are disposed opposite each other in the first direction.

[0036] Secondly, this application provides a monitoring method for a battery pack expansion monitoring system, applicable to the battery pack expansion monitoring system described in any of the preceding claims. The monitoring method includes the following steps:

[0037] Step S100: Monitor the displacement of the battery pack housing at the sealed end in real time and output the displacement data. The sealed end is connected to the cold plate in the battery pack.

[0038] Step S200: Determine the structural damage risk of the battery pack based on the displacement data.

[0039] This application provides a monitoring method for a battery pack expansion monitoring system. In step S100, when the battery pack expands, the sealed end displaces, allowing real-time monitoring of this displacement to reflect the expansion status of the battery pack. Outputting displacement data provides a direct data basis for subsequent judgment of the battery pack expansion status, facilitating further analysis and ensuring the reliability of the detection results. In step S200, the structural damage risk of the battery pack is determined based on the displacement data, enabling users to take timely countermeasures based on the damage risk, thereby reducing the probability of safety accidents.

[0040] Therefore, the monitoring method provided in this application determines the damage risk of the battery pack based on the displacement data detected by the detection device. Since the displacement data of the detection device does not require calculation and can be directly used as the basis for judging the internal expansion of the battery pack, the monitoring difficulty is reduced while the introduction of errors is minimized, making the detection results more reliable. Compared with traditional detection methods, the monitoring method in this application provides a more direct and reliable assessment of the damage risk of the battery pack, thereby improving the safety performance of the battery pack.

[0041] In one possible implementation, step S200 includes:

[0042] Step S210: Compare the displacement data with a preset threshold;

[0043] Step S220: Based on the comparison result in step S210, determine whether the battery pack has a structural damage risk, and issue a warning command when the battery pack has a structural damage risk, and execute a warning action according to the warning command.

[0044] In one possible implementation, the preset threshold includes a safety threshold and a first risk threshold, wherein the first risk threshold is greater than the safety threshold;

[0045] Step S210 includes:

[0046] The displacement data is compared with the safety threshold and the first risk threshold;

[0047] Step S220 includes:

[0048] When the displacement data is greater than the safety threshold and less than or equal to the first risk threshold, a first-level warning command is issued to determine that the battery pack has a structural damage risk, and a first warning action is executed according to the first-level warning command, wherein the pre-tightening action includes the first warning action;

[0049] The first warning action includes reducing the current of the battery pack, the current of the battery pack including charging current and / or discharging current, and the warning instruction includes the first-level warning instruction.

[0050] And / or, the preset threshold further includes the first risk threshold and the second risk threshold, wherein the second risk threshold is greater than the first risk threshold;

[0051] Step S210 includes:

[0052] The displacement data is compared with the second risk threshold;

[0053] Step S220 includes:

[0054] When the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold, it is determined that the battery pack has a structural damage risk, and a secondary warning instruction is issued. The second warning action is executed according to the secondary warning instruction, and the warning action also includes the second warning action.

[0055] The second warning action includes reducing the current of the battery pack, and the reduction in current in the second warning action is greater than the reduction in current in the first warning action; the warning instruction also includes the secondary warning instruction;

[0056] And / or, the preset threshold further includes the second risk threshold and the third risk threshold, wherein the third risk threshold is greater than the second risk threshold;

[0057] Step S210 includes:

[0058] Compare the displacement data with the third risk threshold;

[0059] Step S220 includes:

[0060] When the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, it is determined that the battery pack has a risk of structural damage, and a level three warning instruction is issued. A third warning action is executed according to the level three warning instruction, and the warning action also includes the third warning action.

[0061] The third early warning action includes controlling the display device to issue a risk warning that the battery pack needs maintenance; the early warning instruction also includes the three-level early warning instruction.

[0062] And / or, the preset threshold further includes the third risk threshold, and step S220 further includes:

[0063] When the displacement data exceeds the third risk threshold, a level four warning command is issued, and the fourth warning action is executed according to the level four warning command. The warning action also includes the fourth warning action; the fourth warning action includes controlling the display device to issue a risk warning that the battery pack needs to be replaced; the warning command also includes the level four warning command.

[0064] Thirdly, this application provides an electrical device including a battery pack expansion monitoring system as described in any of the preceding claims.

[0065] The electrical device provided in this application includes the battery pack expansion monitoring system provided in any embodiment of the first aspect of this application, and therefore has the same effect, namely, the judgment of the damage risk of the battery pack is more direct and reliable, thereby improving the safety performance of the battery pack. Attached Figure Description

[0066] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0067] Figure 1 A schematic diagram of the battery pack provided for the first related technology;

[0068] Figure 2 A flowchart illustrating the cell expansion detection method provided for the second related technology;

[0069] Figure 3 A schematic diagram of the hardware structure of the cell expansion detection method provided for the second related technology;

[0070] Figure 4 This is a schematic diagram of the battery pack expansion monitoring system provided in an embodiment of this application;

[0071] Figure 5 This is a left view of the battery pack expansion monitoring system provided in an embodiment of this application;

[0072] Figure 6 This is a partial schematic diagram of the battery pack expansion monitoring system provided in an embodiment of this application;

[0073] Figure 7 This is a partial schematic diagram of the battery pack expansion monitoring system provided in an embodiment of this application;

[0074] Figure 8 This is a schematic diagram of the hardware structure of the battery pack expansion monitoring system provided in an embodiment of this application;

[0075] Figure 9 This is a flowchart illustrating the monitoring method of the battery pack expansion monitoring system provided in this application embodiment.

[0076] Figure label:

[0077] 100 - Battery pack; 110 - Battery array; 120 - Cold plate; 130 - Baffle; 131 - First baffle; 132 - Second baffle;

[0078] 200 - Inspection Items;

[0079] 300 - Battery Management System; 310 - Data Analysis Module; 320 - Risk Assessment Module;

[0080] 400-Controller;

[0081] 500-Early Warning Platform;

[0082] 600 - Connector;

[0083] 700 - Item to be inspected;

[0084] X - First direction. Detailed Implementation

[0085] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0086] With the rapid development of electronic devices, electric vehicles, and energy storage systems, battery packs have been widely used. However, under long-term use or special operating conditions (such as overcharging, over-discharging, high temperature, and high-rate charging and discharging), complex chemical and physical changes can easily occur inside the battery pack. These changes are usually accompanied by gas generation and changes in the battery pack material structure, leading to battery pack expansion. This expansion not only affects the performance and lifespan of the battery pack but may also cause safety hazards such as leakage, short circuits, or even fire and explosion.

[0087] Therefore, monitoring the expansion within the battery pack is crucial to ensuring its safety performance.

[0088] See Figure 1Currently, in the first related technology, the expansion within the battery pack 100a is monitored by arranging pressure sensors and temperature sensors, or a combined pressure and temperature sensor, between the battery cells. When a cell expands, the sensors detect changes in force and temperature and convert these changes into voltage signals. These voltage signals are then transmitted to the battery management system 300a. The battery management system 300a compares the received voltage signal with a preset threshold; if the voltage signal exceeds the preset threshold, the battery management system 300a outputs a warning signal.

[0089] However, errors may be introduced in the process of converting changes in force and temperature into voltage signals, affecting the reliability of the detection. Furthermore, the pressure sensor can only monitor localized forces within the battery pack 100a and cannot comprehensively reflect whether structural changes occur throughout the entire battery pack 100a under the influence of forces, thus having certain limitations and further reducing the reliability of the detection results. Moreover, this method requires multiple sensors to be placed between the cells, increasing the system's complexity and cost.

[0090] In addition, see Figure 2 and Figure 3 In the second related technology, pressure detection patches are also placed on the battery cells to monitor the expansion within the battery pack. Within a preset period, the current and voltage of the pressure detection patches are detected by a fuel gauge, and the resistance of the patches is calculated. Furthermore, by calculating the resistance change between adjacent sampling periods, a resistance change rate sequence is obtained to analyze the cell's trend. When the cell expands significantly, the pressure detection patches deform significantly, resulting in a significant decrease in resistance. A clear inflection point appears on the resistance change curve; the moment corresponding to the inflection point is the cell expansion moment. At this time, the system generates an early warning message, thus achieving real-time detection of battery pack expansion.

[0091] Similarly, errors may be introduced in the process of calculating resistance using current and voltage, affecting the reliability of the detection. Pressure detection patches can only monitor localized structural changes in the battery pack and cannot comprehensively reflect whether the entire battery pack undergoes structural changes under stress, thus having certain limitations and further reducing the reliability of the detection results. Furthermore, this method also requires pressure detection patches to be placed between the battery cells, increasing the system's complexity and cost.

[0092] In summary, existing detection methods all have certain limitations. There is an urgent need for a battery pack expansion monitoring system that can provide more direct data for judging the internal expansion of the battery pack, with higher reliability of the detection results, thereby improving the safety performance of the battery pack.

[0093] In view of this, this application provides a battery pack expansion monitoring system. The system uses a battery pack 110 housed within a battery pack casing, providing support and protection for the battery pack 110. When the battery pack 110 expands, it exerts a force on the sealing end of the battery pack casing, causing displacement of the sealing end. Therefore, the expansion of the battery pack 110 can be reflected by the displacement of the sealing end. The detection element 200 can monitor the displacement of the sealing end from its initial position in real time and output displacement data. This displacement data is used to determine the structural damage risk of the battery pack 100b, allowing users to take timely countermeasures based on the damage risk, thereby reducing the probability of safety accidents. Compared to traditional detection methods that calculate and analyze the expansion of the battery pack 100b using information such as voltage, current, temperature, and pressure, the displacement data from the detection element 200 does not require calculation and can be directly used as the basis for judging the internal expansion of the battery pack 100b. This reduces the difficulty of monitoring, minimizes the introduction of errors, and makes the detection results more reliable. The battery pack expansion monitoring system of this application determines the damage risk of the battery pack 100b based on the displacement data detected by the detection element 200. Therefore, the battery pack expansion monitoring system of this application makes a more direct and reliable judgment on the damage risk of the battery pack 100b, thereby improving the safety performance of the battery pack 100b.

[0094] The following description, in conjunction with the accompanying drawings and embodiments, further elaborates on a battery pack expansion monitoring system provided in this application.

[0095] See Figure 4 and Figure 5 This application provides a battery pack expansion monitoring system, which includes a battery pack 100b and a detection element 200.

[0096] The battery pack 100b includes a battery assembly 110 and a battery pack housing. The battery assembly 110 is located within the battery pack housing, and the battery pack housing has a sealed end. The battery pack housing has a receiving cavity for accommodating the battery assembly 110, thus providing support and protection for the battery assembly 110. When the battery assembly 110 expands, a force is applied to the sealed end of the battery pack housing, causing displacement of the sealed end. Therefore, the expansion of the battery assembly 110 can be reflected by the displacement of the sealed end of the battery pack housing.

[0097] It should be noted that the battery pack housing may include a seal and a frame. The frame has an opening. The seal is connected to the open end of the frame, thereby sealing the frame and forming a receiving cavity for accommodating the battery pack 110. The frame may include a baffle 130 disposed on one side of the battery pack 110 to provide support and protection for the battery pack 110.

[0098] For example, the seal can be a sealing plate. For instance, the seal can be a metal plate or a non-metal plate. The seal can be a cold plate 120, which is located on different sides of the battery pack 110 along with the baffle 130. The cold plate 120 can be connected to the baffle 130 to seal the receiving cavity. Alternatively, the cold plate 120 can be a heat dissipation plate with internal liquid cooling channels, typically used for thermal management to dissipate heat from the battery pack 110 via liquid cooling. In this application, the material of the seal is not further limited, only needing to meet the sealing requirements of the battery pack 100b.

[0099] The sealed end of the battery pack housing can be understood as the end where the frame connects to the seal. Specifically, the end where the baffle 130 connects to the seal (such as the cold plate 120) is the sealed end of the battery pack housing.

[0100] When the battery pack 110 expands, it expands along the first direction X, and comes into contact with the baffle 130, applying a force to the baffle 130. This force acts on the baffle 130 along the first direction X, causing the baffle 130 to displace along the first direction X. The expansion status of the battery pack 110 can be determined based on the displacement of the baffle 130 in the first direction X.

[0101] Additionally, the baffle 130 and the seal can be connected via a connector 600. When the sealed end shifts, it will cause the connector 600 to move as well. Similarly, the expansion of the battery pack 110 can be determined based on the displacement of the connector in the first direction X.

[0102] The detection element 200 monitors the displacement of the sealed end of the battery pack 100b from its initial position in real time and outputs the displacement data. By monitoring the displacement of the sealed end in real time, the expansion of the battery pack 110 and other structural changes can be identified in a timely manner, thereby promptly detecting potential safety hazards and improving the safety performance of the safety pack.

[0103] The detection component 200 provides direct data for determining whether expansion has occurred within the battery pack 100b by detecting displacement data. Furthermore, the detected displacement data allows for the assessment of the overall expansion status of the battery pack 100b, resulting in higher reliability and improved safety performance. In addition, using displacement data to determine expansion reduces the scope of detection and the number of detection components 200, thereby lowering the complexity and cost of the battery pack expansion monitoring system.

[0104] This application provides a battery pack expansion monitoring system. By placing the battery pack 110 inside the battery pack housing, the battery pack housing provides support and protection for the battery pack 110. When the battery pack 110 expands, it exerts a force on the sealing end of the battery pack housing, causing the sealing end of the battery pack housing to displace. Therefore, the expansion of the battery pack 110 can be detected based on the displacement of the sealing end of the battery pack housing.

[0105] Therefore, the battery pack expansion monitoring system of this application includes a detection element 200. The detection element 200 can monitor the displacement of the sealed end from its initial position in real time and output displacement data. This displacement data is used to determine the structural damage risk of the battery pack 100b, allowing users to take timely countermeasures based on the damage risk, thereby reducing the probability of safety accidents. Compared to traditional detection methods, which calculate and analyze the expansion of the battery pack 100a using information such as voltage, current, temperature, and pressure, the displacement data detected by the detection element 200 does not require calculation and can be directly used as the basis for judging the internal expansion of the battery pack 100b. This reduces the difficulty of monitoring and minimizes the introduction of errors, making the detection results more reliable.

[0106] The battery pack expansion monitoring system of this application determines the damage risk of the battery pack 100b based on the displacement data detected by the detection element 200. Therefore, the battery pack expansion monitoring system of this application makes a more direct and reliable judgment on the damage risk of the battery pack 100b, thereby improving the safety performance of the battery pack 100b.

[0107] In some embodiments, the battery pack expansion monitoring system includes a battery management system (BMS) 300b, which includes a data analysis module 310 and a risk determination module 320. The data analysis module 310 compares displacement data with preset thresholds to determine the degree of expansion of the battery pack 110. The risk determination module 320 determines the structural damage risk of the battery pack 100b based on the comparison results from the data analysis module 310. The detection element 200 transmits detected displacement data to the data analysis module 310; this displacement data reflects the displacement of the sealed end.

[0108] See Figure 8In some embodiments, the battery pack expansion monitoring system also includes a controller 400. For example, when the electrical equipment is a vehicle, the controller 400 can be the vehicle controller 400 of the electrical equipment. The risk determination module 320 is also used to issue a warning command when the battery pack 100b has a risk of structural damage, and the controller 400 or the battery management system 300b is used to execute a warning action according to the warning command. When the risk determination module 320 determines that the battery pack 100b has a risk of structural damage based on the comparison result, the risk determination module 320 issues a warning command, and the controller 400 or the battery management system 300b executes a warning action according to the warning command. Through the warning action, users can promptly detect the risks existing in the battery pack 100b and then take necessary countermeasures to reduce the probability of safety accidents.

[0109] The risk assessment module 320 can issue different warning commands based on the severity of the structural damage risk to the battery pack 100b. According to the corresponding warning command, the controller 400 or the battery management system 300b executes the warning action. By classifying the severity of the structural damage risk to the battery pack 100b, different warning commands can be triggered by the risk assessment module 320, thus enabling different countermeasures to be taken for different levels of structural damage risk to the battery pack 100b. This ensures that the basic functionality of the battery pack 100b is maintained while improving its safety performance, thereby achieving a balance between safety and functionality.

[0110] In some embodiments, the preset threshold includes a safety threshold and a first risk threshold, wherein the first risk threshold is greater than the safety threshold. The data analysis module 310 is further configured to compare the displacement data with the safety threshold and the first risk threshold. The risk determination module 320 is further configured to issue a first-level warning instruction when the displacement data is greater than the safety threshold and less than or equal to the first risk threshold. The warning instruction includes a first-level warning instruction.

[0111] And / or, the preset thresholds also include a first risk threshold and a second risk threshold. The second risk threshold is greater than the first risk threshold. The data analysis module 310 is also used to compare the displacement data with the second risk threshold. The risk determination module 320 is also used to issue a secondary warning instruction when the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold. The warning instruction also includes a secondary warning instruction.

[0112] And / or, the preset threshold also includes a second risk threshold and a third risk threshold, wherein the third risk threshold is greater than the second risk threshold. The data analysis module 310 is also used to compare the displacement data with the third risk threshold. The risk determination module 320 is also used to issue a three-level early warning instruction when the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, wherein the early warning instruction also includes a three-level early warning instruction.

[0113] In some embodiments, the battery management system 300b is used to execute a first warning action according to a first warning instruction. The first warning action includes reducing the current of the battery pack 100b, the current of the battery pack 100b including charging current and / or discharging current.

[0114] For example, the safety threshold can be 0.8 mm, and the first risk threshold can be 1.5 mm. When the displacement data is less than or equal to 0.8 mm, the data analysis module 310 compares the displacement data with the safety threshold and the first risk threshold, and the result is that the displacement data is less than or equal to the safety threshold; therefore, the risk determination module 320 does not generate a warning message. For example, when the displacement of the sealing end from the initial position is 0.5 mm, the data analysis module 310 compares the result and the result is that the displacement data is less than the safety threshold; therefore, the risk determination module 320 does not generate a warning message.

[0115] When the displacement data is greater than 0.8 mm and less than or equal to 1.5 mm, the data analysis module 310 compares the displacement data with the safety threshold and the first risk threshold. If the displacement data is greater than the safety threshold and less than or equal to the first risk threshold, the risk determination module 320 determines that the structural damage risk of the battery pack 100b is a minor risk and issues a first-level warning command.

[0116] When the risk assessment module 320 issues a level one warning command, the battery management system 300b executes the first warning action. Specifically, the first warning action includes reducing the current of the battery pack 100b.

[0117] The current may include charging current or discharging current, or it may include both charging current and discharging current simultaneously. For example, when the risk determination module 320 issues a level one warning command, the battery management system 300b controls the reduction of the peak charging current of the battery pack 100b to 80% of the original specified peak current, or the peak discharging current to 90% of the original specified peak current, or the battery management system 300b simultaneously controls the reduction of the peak charging current of the battery pack 100b to 80% of the original specified peak current and the peak discharging current to 90% of the original specified peak current.

[0118] In this application, the proportion of current reduction in the first warning action is not further limited, as long as it can meet the usage requirements of battery pack 100b and reduce the risk of structural damage to battery pack 100b.

[0119] And / or, the battery management system 300b is also used to execute a second warning action according to a secondary warning instruction, the second warning action including reducing the current of the battery pack 100b, and the reduction in current in the second warning action is greater than the reduction in current in the first warning action.

[0120] For example, the second risk threshold can be 3mm. When the displacement data is greater than 1.5mm and less than or equal to 3mm, the displacement data comparison result obtained by the data analysis module 310 is that the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold. The risk determination module 320 determines that the structural damage risk of the battery pack 100b is a moderate risk and issues a level two warning instruction.

[0121] When the risk assessment module 320 issues a secondary warning command, the battery management system 300b executes a second warning action. Specifically, the second warning action at this time includes reducing the current of the battery pack 100b, and the reduction in current in the second warning action is greater than the reduction in current in the first warning action.

[0122] Similarly, the current can include charging current or discharging current, or both. For example, when the risk determination module 320 issues a level 2 warning command, the battery management system 300b controls the reduction of the peak charging current of the battery pack 100b to 70% of the original specified peak current, or the peak discharging current to 80% of the original specified peak current, or the battery management system 300b simultaneously controls the reduction of the peak charging current of the battery pack 100b to 70% of the original specified peak current and the peak discharging current to 80% of the original specified peak current.

[0123] In this application, the proportion of current reduction in the second warning action is not further limited, as long as it can meet the usage requirements of battery pack 100b and reduce the risk of structural damage to battery pack 100b.

[0124] And / or, the controller 400 is also used to execute a third warning action according to the three-level warning instruction, the third warning action including controlling the display device to issue a risk warning that the battery pack 100b needs to be inspected.

[0125] For example, the third risk threshold can be 6 mm. When the displacement data is greater than 3 mm and less than or equal to 6 mm, if the displacement data comparison result obtained by the data analysis module 310 is that the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, the risk determination module 320 determines that the structural damage risk of the battery pack 100b is high risk and issues a level three warning command.

[0126] When the risk assessment module 320 issues a Level 3 warning command, the controller 400 executes the third warning action. Specifically, when the risk assessment module 320 issues a Level 3 warning command, the controller 400 controls the display device to issue a risk warning that the battery pack 100b needs maintenance. For example, when the electrical equipment is a vehicle, the risk warning that the battery pack 100b needs maintenance can be issued through the vehicle's screen, thereby reminding the user to go to a car dealership or service center to have the battery pack 100b inspected and repaired, thus preventing safety accidents.

[0127] The display device can be an in-vehicle screen, a mobile phone, a home energy storage device, a commercial energy storage device, etc. This application does not further limit the type of display device; it only needs to be able to issue a risk warning that the battery pack 100b requires maintenance.

[0128] In some embodiments, the risk determination module 320 is further configured to issue a level 4 warning instruction when the displacement data is greater than a third risk threshold, and the warning instruction may also include a level 4 warning instruction.

[0129] The controller 400 is used to execute the fourth warning action according to the fourth warning instruction. The fourth warning action includes controlling the display device to issue a risk warning that the battery pack 100b needs to be replaced.

[0130] For example, the third risk threshold can be 6 mm. When the displacement data is greater than 6 mm, the risk determination module 320 determines that the battery pack 100b is structurally dangerous and issues a level four warning command.

[0131] When the risk assessment module 320 issues a Level 4 warning command, the controller 400 executes the fourth warning action. Specifically, when the risk assessment module 320 issues a Level 4 warning command, the controller 400 controls the display device to issue a risk warning that the battery pack 100b needs to be replaced. For example, when the electrical device is a vehicle, the risk warning that the battery pack 100b needs to be replaced can be displayed on the vehicle's in-vehicle screen, thus reminding the user to go to the vehicle's after-sales service center to replace the battery pack 100b and avoid safety accidents.

[0132] In summary, the battery pack expansion monitoring system provided in this application embodiment can issue early warning information of different risk levels through the risk determination module 320, which can provide a clear risk assessment and help the battery management system 300b or controller 400 to take different countermeasures for different degrees of structural damage risk to the battery pack 100b. While ensuring the improvement of the safety performance of the battery pack 100b, its basic functions are maintained, thereby achieving a balance between safety and functionality.

[0133] In some embodiments, the controller 400 is further configured to transmit expansion data and warning commands of the battery pack 100b to the warning platform 500. The expansion data includes displacement data and a preset threshold. The expansion data and warning commands are used to determine the remaining lifespan of the battery pack 100b.

[0134] For example, the early warning platform 500 can be a cloud-based early warning platform 500. The controller 400 can send expansion data and early warning commands to the cloud-based early warning platform 500 via wireless data transmission. The expansion data includes displacement data and preset thresholds. After receiving the expansion data and early warning commands, the cloud-based early warning platform 500 performs further data analysis. For example, based on the historical trend and current status of the expansion data, the early warning platform 500 can use algorithms or models to assess the status and remaining lifespan of the battery pack 100b, so that the after-sales team can prepare spare parts. Simultaneously, the after-sales team can also assess the status and remaining lifespan of the battery pack 100b based on the historical trend and current status of the expansion data, so as to prepare spare parts.

[0135] In some embodiments, the battery pack housing includes a baffle 130 located on one side of the battery pack 110, and the baffle 130 has a sealed end.

[0136] The baffle 130 is located on one side of the battery pack 110 and mainly serves to provide mechanical support. It has a certain degree of flexibility and can absorb and mitigate the forces caused by the expansion of the battery pack 110. The sealed end of the baffle 130 is the most sensitive position when the battery pack 110 expands. When the battery pack 110 expands, the sealed end of the baffle 130 is compressed by the battery pack 110, causing it to shift. For example, when the battery pack 110 expands, the sealed end of the baffle 130 will move relative to its bottom towards the side away from the battery pack 110, causing the sealed end of the baffle 130 to deviate from its original position.

[0137] In some embodiments, the battery pack housing has a seal, and the sealed end of the baffle 130 has a connector 600, the seal and the baffle 130 being sealed together by the connector 600. The detection element 200 is used to monitor the displacement of the connector 600 in a first direction X in real time, where the displacement of the connector 600 in the first direction X is the same as the displacement of the sealed end.

[0138] For example, the end of the baffle 130 connected to the seal is the sealing end. When the battery pack 110 expands, the sealing end of the baffle 130 will move toward the side away from the battery pack 110, causing the sealing end of the baffle 130 to deviate from its original position. When the sealing end moves, it will drive the connector 600 provided on the baffle 130 to move together.

[0139] In some embodiments, the seal includes a cold plate 120, and a connector 600 is used to connect the baffle 130 and the cold plate 120. And / or a detection element 200 is disposed on the cold plate 120.

[0140] For example, the seal may be a cold plate 120. The cold plate 120 and the baffle 130 are located on different sides of the battery pack 110 in the battery pack 100b, and the sealing end of the baffle 130 is connected to the cold plate 120. The connection between the sealing end of the baffle 130 and the cold plate 120 forms the structural frame of the battery pack 100b. This structural frame accommodates the battery pack 110, and the connection between the sealing end of the baffle 130 and the cold plate 120 serves a sealing function while also enhancing the overall rigidity and durability of the battery pack 100b.

[0141] The cold plate 120 is a heat dissipation plate with internal liquid cooling channels, which is usually used for thermal management to dissipate heat from the battery pack 110 through liquid cooling. In order to ensure that the cold plate 120 can effectively manage the thermal of the battery pack 110, the cold plate 120 usually needs to be tightly connected to the battery pack 110, and its displacement is restricted.

[0142] The detection element 200 is mounted on the cold plate 120. Since the displacement of the cold plate 120 is restricted, the displacement of the detection element 200 is also restricted when the battery pack 110 expands, thus maintaining stability. By monitoring the displacement of the connector 600 in the first direction X in real time, the detection element 200 is equivalent to monitoring the displacement of the sealing end of the baffle 130, thereby determining the expansion status of the battery pack 100b.

[0143] The connector 600 can be a rivet. The sealing end of the baffle 130 is connected to the cold plate 120 via the rivet. When the battery pack 110 expands, it expands along the first direction X, and the force acts on the baffle 130 along the first direction X, causing the baffle 130 to displace along the first direction X. Since the rivet rigidly connects the sealing end of the baffle 130 and the cold plate 120, the displacement of the sealing end of the baffle 130 is directly transmitted to the rivet. The rivet moves with the sealing end of the baffle 130, and the displacement of the rivet is the same as the displacement of the sealing end of the baffle 130.

[0144] Since the connector 600 can protrude from the surface of the cold plate 120, the detection component 200 is easier to align with the connector 600 for installation, which facilitates direct monitoring by the detection component 200, improves the reliability of the detection results, and thus improves the safety performance of the battery pack 100b.

[0145] See Figure 6 and Figure 7In some embodiments, the battery pack 100b further includes a test element 700, at least a portion of which is disposed on one side of the connector 600 in the first direction X. The detection element 200 is used to monitor the displacement of the test element 700 in the first direction X in real time, wherein the displacement of the test element 700 in the first direction X is the same as the displacement of the connector 600.

[0146] When the battery pack 110 expands, the baffle 130 is subjected to a force, and the sealing end of the baffle 130 is displaced in the first direction X. The displacement of the sealing end of the baffle 130 is directly transmitted to the connector 600, and the connector 600 moves with the sealing end of the baffle 130 in the first direction X. At least a portion of the component to be detected 700 is disposed on one side of the connector 600 in the first direction X, so that the component to be detected 700 can move with the connector 600, thereby reflecting the displacement of the connector 600 through the displacement of the component to be detected 700.

[0147] And / or, the number of baffles 130 is two. The two baffles 130 include a first baffle 131 and a second baffle 132. The first baffle 131 and the second baffle 132 are respectively disposed at opposite ends of the battery pack 110 in the first direction X. The sealed ends of the first baffle 131 and the second baffle 132 are connected to the cold plate 120 through multiple connectors 600.

[0148] The cold plate 120 is provided with a detection element 200 in the area adjacent to the first baffle 131 and / or the second baffle 132, and the detection element 200 is disposed opposite to one of the connecting members 600 in the first direction X.

[0149] For example, two baffles 130 are located at opposite ends of the battery pack 110 in the first direction X. Multiple connectors 600 connect the sealed ends of the first baffle 131 and the second baffle 132 to the cold plate 120. Together, the two baffles 130 provide mechanical support for the battery pack 110. When the battery pack 110 expands, the two baffles 130 displace in opposite directions in the first direction X, uniformly dispersing and absorbing the force. A detection element 200 is mounted on the cold plate 120, adjacent to the first baffle 131 or the second baffle 132, and is positioned opposite one of the connectors 600 in the first direction X to facilitate the detection of displacement data.

[0150] For example, a portion of the component 700 to be tested is disposed between the connector 600 and the cold plate 120, and the remaining portion of the component 700 to be tested is bent to the side of the connector 600 facing the component 200.

[0151] For example, the test piece 700 can be an "L"-shaped metal sheet. A portion of the test piece 700 extends along the first direction X and has a mounting hole through which a connector 600 passes, positioning the test piece 600 between the connector 600 and the cold plate 120. Another portion of the test piece 700 can be bent to be perpendicular to the first direction X, facing the test piece 200.

[0152] Or see Figure 7 The test piece 700 is located on the side of the connector 600 away from the test piece 200 in the first direction X, and is connected to the baffle 130. A portion of the test piece 700 extends to the side of the cold plate 120 away from the battery pack 110 and is opposite to the test piece 200.

[0153] For example, the test piece 700 may be a rectangular metal sheet. The test piece 700 is located on the side of the connector 600 facing away from the test piece 200 in the first direction X, and a portion of the test piece 700 is connected to the baffle 130, while another portion extends to the side of the cold plate 120 facing away from the battery pack 110 and is opposite to the test piece 200.

[0154] In this application, the shape, bending angle and material of the test piece 700 are not further limited, as long as it can reflect the displacement of the connector 600 and be detected by the test piece 200.

[0155] For example, the detection element 200 can be a wire displacement sensor or a non-wire displacement sensor. When the detection element 200 is a wire displacement sensor, the wire displacement sensor is connected to the object to be detected 700.

[0156] For example, the non-wire displacement sensor can measure displacement without physical contact with the object under test 700.

[0157] A wire displacement sensor is installed on the cold plate 120 near the baffle 130 and is connected to the device under test 700 via a wire. When the battery pack 100b expands, the movement of the device under test 700 pulls the wire of the wire displacement sensor. As the device under test 700 moves, the wire in the wire displacement sensor is pulled out or retracted, allowing the wire displacement sensor to obtain displacement data, thus providing accurate data for analysis by the data analysis module 310.

[0158] The cold plate 120 may have multiple detection elements 200 in the area adjacent to the first baffle 131 and / or the second baffle 132. The multiple detection elements 200 are arranged sequentially along the second direction and each corresponds to a connector 600. The data analysis module 310 is used to compare the maximum displacement data output by the multiple detection elements 200 with a preset threshold.

[0159] For example, in the area of ​​the cold plate 120 adjacent to the first baffle 131 or the second baffle 132, multiple detection elements 200 are provided. The detection elements 200 are arranged sequentially along the second direction and each corresponds to a connector 600, facilitating the detection of the expansion of the battery pack 110 at different positions. When the battery pack 110 is displaced, the sealing end of the first baffle 131 or the second baffle 132 is displaced, and the connector 600 moves along with the sealing end of the first baffle 131 or the second baffle 132. Each detection element 200 detects the displacement of a connector 600 and transmits these displacement data to the data analysis module 310. The data analysis module 310 receives these displacement data, identifies the maximum displacement data output by the multiple detection elements 200, and compares the maximum displacement data with a preset threshold.

[0160] Additionally, multiple detection elements 200 can be provided in the area adjacent to the first baffle 131 and the second baffle 132 of the cold plate 120. These detection elements 200 are arranged sequentially along the second direction and each corresponds to a connector 600, facilitating the detection of the expansion of the battery pack 110 at different locations. When the battery pack 110 shifts, the sealing ends of both the first baffle 131 and the second baffle 132 shift. The connector 600 connecting to the first baffle 131 moves with the sealing end of the first baffle 131, and the connector 600 connecting to the second baffle 132 moves with the sealing end of the second baffle 132. Each detection element 200 detects the displacement of one connector 600 and transmits this displacement data to the data analysis module 310. The data analysis module 310 receives this displacement data, identifies the maximum displacement data output by the multiple detection elements 200, and compares the maximum displacement data with a preset threshold.

[0161] By setting multiple detection elements 200, the comprehensiveness of monitoring and the reliability of displacement data are improved. Furthermore, the maximum displacement data represents the most severe expansion or displacement condition in the battery pack 100b. Identifying the maximum displacement data and comparing it with a preset threshold can effectively determine whether the battery pack 100b is in a safe state and can more accurately determine the expansion status of the battery pack 100b.

[0162] This application also provides a monitoring method for a battery pack expansion monitoring system (hereinafter referred to as the monitoring method), which is applied to the battery pack expansion monitoring system in any of the above embodiments.

[0163] The steps of the monitoring method will be further explained below with reference to the accompanying drawings. (Reference) Figure 9 The monitoring method includes the following steps:

[0164] Step S100: Monitor the displacement of the battery pack housing at the sealed end in real time in the battery pack 100b and output the displacement data. The sealed end is connected to the cold plate 120 in the battery pack 100b.

[0165] Step S200: Determine the structural damage risk of battery pack 100b based on displacement data.

[0166] Through the aforementioned step S100, when the battery pack 100b expands, the sealed end shifts, allowing the expansion status of the battery pack 100b to be reflected by real-time monitoring of the sealed end's displacement. Outputting displacement data provides a direct data basis for subsequent judgment of the battery pack 100b's expansion status, facilitating further analysis and ensuring the reliability of the detection results.

[0167] Through the above step S200, the structural damage risk of the battery pack 100b is determined based on the displacement data, so that the user can take timely countermeasures based on the damage risk, thereby reducing the probability of safety accidents.

[0168] Therefore, the monitoring method provided in this application embodiment uses the displacement data of the detection element 200 as a direct data basis for judging the internal expansion of the battery pack 100b, and determines the damage risk of the battery pack 100b based on the displacement data detected by the detection element 200. Therefore, compared with the traditional detection method, the monitoring method of this application embodiment is more direct and reliable in judging the damage risk of the battery pack 100b, thereby improving the safety performance of the battery pack 100b.

[0169] In some embodiments, step S200 includes:

[0170] Step S210: Compare the displacement data with a preset threshold;

[0171] Step S220: Based on the comparison results in step S210, determine whether the battery pack 100b has a structural damage risk, and issue a warning command when the battery pack 100b has a structural damage risk, and execute the warning action according to the warning command.

[0172] For example, when the displacement data exceeds a preset threshold, the risk determination module 320 determines that the battery pack 100b has a risk of structural damage and issues a warning command. The controller 400 or the battery management system 300b executes the warning action according to the warning command. Through the execution of the warning command and the warning action, users can promptly detect faults in the battery pack 100b and reduce the probability of safety accidents.

[0173] In some embodiments, the preset threshold mentioned in step S210 above includes a safety threshold and a first risk threshold, wherein the first risk threshold is greater than the safety threshold.

[0174] The step S210 mentioned above, which compares the displacement data with a preset threshold, includes:

[0175] The displacement data is compared with the safety threshold and the first risk threshold.

[0176] The step S220 mentioned above, which involves determining whether the battery pack 100b has a structural damage risk based on the comparison results in step S210, includes:

[0177] When the displacement data is greater than the safety threshold but less than or equal to the first risk threshold, a Level 1 warning command is issued to determine that battery pack 100b has a risk of structural damage, and the first warning action is executed according to the Level 1 warning command. The warning action includes the first warning action.

[0178] The first warning action includes reducing the current of battery pack 100b, which includes charging current and / or discharging current, and the warning instruction includes a first-level warning instruction.

[0179] For example, the preset thresholds include a safety threshold and a first risk threshold. The safety threshold can be 0.8 mm, and the first risk threshold can be 1.5 mm. When the displacement data is greater than 0.8 mm and less than or equal to 1.5 mm, the data analysis module 310 compares the displacement data with the safety threshold and the first risk threshold. If the result is that the displacement data is greater than the safety threshold and less than or equal to the first risk threshold, the risk determination module 320 determines that the structural damage risk of the battery pack 100b is a minor risk and issues a first-level warning command.

[0180] When the risk assessment module 320 issues a level one warning command, the battery management system 300b controls the reduction of the peak charging current of the battery pack 100b to 80% of the original peak current, or the peak discharging current to 90% of the original peak current, or the battery management system 300b simultaneously controls the reduction of the peak charging current of the battery pack 100b to 80% of the original peak current and the peak discharging current to 90% of the original peak current.

[0181] And / or, the preset threshold also includes a first risk threshold and a second risk threshold, wherein the second risk threshold is greater than the first risk threshold;

[0182] The step S210 mentioned above, which compares the displacement data with a preset threshold, includes:

[0183] The displacement data is compared with the second risk threshold.

[0184] The step S220 mentioned above, which involves determining the structural damage risk of the battery pack 100b based on the comparison results in step S210, includes:

[0185] When the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold, it is determined that the battery pack 100b has a risk of structural damage, and a second-level warning instruction is issued. The second warning action is executed according to the second-level warning instruction. The warning action also includes the second warning action.

[0186] The second warning action includes reducing the current of battery pack 100b, and the reduction in current in the second warning action is greater than the reduction in current in the first warning action. The warning instructions also include a secondary warning instruction.

[0187] For example, the second risk threshold can be 3mm. When the displacement data is greater than 1.5mm and less than or equal to 3mm, the displacement data comparison result obtained by the data analysis module 310 is that the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold. The risk determination module 320 determines that the structural damage risk of the battery pack 100b is a moderate risk and issues a level two warning instruction.

[0188] When the risk assessment module 320 issues a level-two warning command, the battery management system 300b executes the warning action. The battery management system 300b controls the reduction of the peak charging current of the battery pack 100b to 70% of the original specified peak current, or the peak discharging current to 80% of the original specified peak current, or the battery management system 300b simultaneously controls the reduction of the peak charging current of the battery pack 100b to 70% of the original specified peak current and the peak discharging current to 80% of the original specified peak current.

[0189] And / or, the preset threshold also includes a second risk threshold and a third risk threshold, wherein the third risk threshold is greater than the second risk threshold.

[0190] The step S210 mentioned above, which compares the displacement data with a preset threshold, includes:

[0191] The displacement data is compared with the third risk threshold.

[0192] The step S220 mentioned above, which involves determining the structural damage risk of the battery pack 100b based on the comparison results in step S210, includes:

[0193] When the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, it is determined that battery pack 100b has a structural damage risk, and a level three warning instruction is issued. The third warning action is then executed according to the level three warning instruction. The warning action includes the third warning action.

[0194] The third early warning action includes controlling the display device to issue a risk warning that battery pack 100b needs maintenance. The early warning instructions also include a three-level early warning instruction.

[0195] For example, the electrical equipment can be a vehicle. The third risk threshold can be 6mm. When the displacement data is greater than 3mm and less than or equal to 6mm, the displacement data comparison result obtained by the data analysis module 310 is that the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, and a level three warning command is issued.

[0196] When the risk assessment module 320 issues a Level 3 warning command, the controller 400 executes the warning action. The controller 400 controls the vehicle screen to display a risk warning that the battery pack 100b needs maintenance, thereby reminding the user to go to a car dealership or service center to have the battery pack 100b inspected and repaired, thus preventing safety accidents.

[0197] And / or, the preset threshold also includes a third risk threshold, and the aforementioned step S220 further includes:

[0198] When the displacement data exceeds the third risk threshold, a level four warning command is issued, and a fourth warning action is executed based on the level four warning command. The warning action includes controlling the display device to issue a risk warning that battery pack 100b needs to be replaced. The warning command also includes the level four warning command.

[0199] For example, the electrical equipment can be a vehicle. When the displacement data is greater than 6mm, the risk determination module 320 issues a level four warning command.

[0200] When the risk assessment module 320 issues a Level 4 warning command, the controller 400 executes the warning action. The controller 400 controls the vehicle screen to display a risk warning that the battery pack 100b needs to be replaced, thereby reminding the user to go to the vehicle's after-sales service center to replace the battery pack 100b and avoid safety accidents.

[0201] In summary, the monitoring method provided in this application, through real-time monitoring and early warning, can promptly identify and respond to the expansion risk of battery pack 100b in the early stages of a fault, preventing safety accidents. Furthermore, by providing early warning information at different risk levels, it can offer a clear risk assessment, helping the battery management system 300b or controller 400 to take appropriate measures to further ensure the safety of battery pack 100b.

[0202] For example, after step S200, the monitoring method further includes the following steps:

[0203] Step S300: Transmit the expansion data and warning command of battery pack 100b to the warning platform 500. The expansion data includes displacement data and a preset threshold. The expansion data and warning command are used to determine the remaining lifespan of battery pack 100b.

[0204] By transmitting the expansion data and warning commands of the battery pack 100b to the warning platform 500, the warning platform 500 can apply algorithms or models to analyze the above information, thereby assessing the health status of the battery pack 100b and predicting the remaining lifespan of the battery pack 100b, so that the after-sales team can prepare parts and provide preventive maintenance.

[0205] For example, when step S100 outputs multiple displacement data, step S210 includes:

[0206] The maximum displacement data is compared with a preset threshold.

[0207] By outputting multiple displacement data points in step S100, the comprehensiveness of monitoring and the reliability of the displacement data are improved. The maximum displacement data represents the most severe expansion or displacement condition in the battery pack 100b. Identifying the maximum displacement data and comparing it with a preset threshold can effectively determine whether the battery pack 100b is in a safe state.

[0208] In addition, embodiments of this application also provide an electrical device, which includes a battery pack expansion monitoring system as described above.

[0209] Therefore, this electrical device has the same effect as a battery pack expansion monitoring system, that is, the assessment of the damage risk of battery pack 100b is more direct and reliable, thereby improving the safety performance of battery pack 100b.

[0210] This application also provides a battery pack expansion monitoring system, including:

[0211] Memory stores the instructions that the computer executes;

[0212] The processor executes computer execution instructions stored in memory, causing the processor to perform the monitoring method provided in any of the embodiments above.

[0213] It should be understood that the processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), etc. A general-purpose processor can be a microprocessor or any conventional processor. The steps of the method disclosed in this invention can be directly manifested as being executed by a hardware processor, or executed by a combination of hardware and software modules within the processor.

[0214] The memory may include random access memory (RAM) and may also include non-volatile memory (NVM), such as at least one disk storage device.

[0215] This application provides a battery pack expansion monitoring system. Since the monitoring system performs the monitoring method provided in any of the above embodiments, it has the same effect, namely, the judgment of the damage risk of the battery pack 100b is more direct and reliable, thereby improving the safety performance of the battery pack 100c.

[0216] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the monitoring method provided in any of the above embodiments.

[0217] This application provides a computer program product that, since it is used to implement the monitoring method provided in any of the above embodiments, has the same effect, namely, that the judgment of the damage risk of the battery pack 100b is more direct and reliable, thereby improving the safety performance of the battery pack 100b.

[0218] This application also provides a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, implement the monitoring method provided in any of the above embodiments.

[0219] This application provides a computer-readable storage medium that, since it is used to implement the monitoring method provided in any of the above embodiments, has the same effect: the assessment of the damage risk of the battery pack 100b is more direct and reliable, thereby improving the safety performance of the battery pack 100b.

[0220] The aforementioned readable storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk. The readable storage medium can be any available medium accessible to a general-purpose or special-purpose computer.

[0221] An exemplary readable storage medium is coupled to a processor, enabling the processor to read information from and write information to the readable storage medium. Of course, the readable storage medium can also be a component of the processor. The processor and the readable storage medium can reside in an Application Specific Integrated Circuit (ASIC). Alternatively, the processor and the readable storage medium can exist as discrete components in the device.

[0222] The division of units is merely a logical functional division; in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0223] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0224] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0225] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0226] Those skilled in the art will understand that all or part of the steps of the above-described method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When executed, the program performs the steps of the above-described method embodiments; and the aforementioned storage medium includes various media capable of storing program code, such as ROM, RAM, magnetic disks, or optical disks.

[0227] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application 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 this application.

[0228] In the description of this application, it should be understood that the terms “comprising” and “having” as used herein, and any variations thereof, are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units that are expressly listed, but may include other steps or units that are not expressly listed or that are inherent to such process, method, product, or apparatus.

[0229] Unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the connection within two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances. 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 technical features indicated.

[0230] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A battery pack expansion monitoring system, characterized in that, include: A battery pack (100) includes a battery group (110) and a battery pack housing, wherein the battery group (110) is located inside the battery pack housing and the battery pack housing has a sealed end; The detection element (200) is used to monitor the displacement of the sealed end in the battery pack (100) from its initial position in real time and output displacement data; the displacement data is used to determine the structural damage risk of the battery pack (100).

2. The battery pack expansion monitoring system according to claim 1, characterized in that, It also includes a battery management system (300), which includes a data analysis module (310) and a risk determination module (320). The data analysis module (310) is used to receive the displacement data and compare the displacement data with a preset threshold. The risk determination module (320) is used to determine the structural damage risk of the battery pack (100) based on the comparison results of the data analysis module (310).

3. The battery pack expansion monitoring system according to claim 2, characterized in that, It also includes a controller (400), and the risk determination module (320) is further configured to issue a warning command when the battery pack (100) has a risk of structural damage; The controller (400) or the battery management system (300) is used to execute a warning action according to the warning instruction.

4. The battery pack expansion monitoring system according to claim 3, characterized in that, The preset threshold includes a safety threshold and a first risk threshold, wherein the first risk threshold is greater than the safety threshold; The data analysis module (310) is also used to compare the displacement data with the safety threshold and the first risk threshold; The risk determination module (320) is further configured to issue a first-level warning instruction when the displacement data is greater than the safety threshold and less than or equal to the first risk threshold, the warning instruction including the first-level warning instruction; And / or, the preset threshold further includes the first risk threshold and the second risk threshold, wherein the second risk threshold is greater than the first risk threshold; The data analysis module (310) is also used to compare the displacement data with the second risk threshold; The risk determination module (320) is further configured to issue a secondary warning instruction when the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold, and the warning instruction further includes the secondary warning instruction; And / or, the preset threshold further includes the second risk threshold and the third risk threshold, wherein the third risk threshold is greater than the second risk threshold; The data analysis module (310) is also used to compare the displacement data with the third risk threshold; The risk determination module (320) is also used to issue a three-level warning instruction when the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, and the warning instruction further includes the three-level warning instruction.

5. The battery pack expansion monitoring system according to claim 4, characterized in that, The battery management system (300) is used to execute a first warning action according to the first warning instruction. The first warning action includes reducing the current of the battery pack (100), and the current of the battery pack (100) includes charging current and / or discharging current. And / or, the battery management system (300) is further configured to execute a second warning action according to the secondary warning instruction, the second warning action including reducing the current of the battery pack (100), and the reduction of the current in the second warning action is greater than the reduction of the current in the first warning action; And / or, the controller (400) is also configured to execute a third warning action according to the three-level warning instruction, the third warning action including controlling the display device to issue a risk warning that the battery pack (100) needs to be repaired.

6. The battery pack expansion monitoring system according to claim 4, characterized in that, The risk determination module (320) is also used to issue a level 4 warning instruction when the displacement data is greater than the third risk threshold, and the warning instruction further includes the level 4 warning instruction; The controller (400) is also used to execute a fourth warning action according to the fourth warning instruction, the fourth warning action including controlling the display device to issue a risk warning that the battery pack (100) needs to be replaced.

7. The battery pack expansion monitoring system according to any one of claims 3-6, characterized in that, The controller (400) is also used to transmit the expansion data of the battery pack (100) and the warning command to the warning platform (500), wherein the expansion data includes the displacement data and a preset threshold; the expansion data and the warning command are used to determine the remaining lifespan of the battery pack (100).

8. The battery pack expansion monitoring system according to any one of claims 1-7, characterized in that, The battery pack housing includes a baffle (130) located on one side of the battery pack (110), and the baffle (130) has the sealing end.

9. The battery pack expansion monitoring system according to claim 8, characterized in that, The battery pack housing has a sealing element, and the sealing end of the baffle (130) has a connector (600). The sealing element and the baffle (130) are sealed together by the connector (600). The detection element (200) is used to monitor the displacement of the connector (600) in a first direction in real time. In the first direction, the displacement of the connector (600) is the same as the displacement of the sealing end.

10. The battery pack expansion monitoring system according to claim 9, characterized in that, The sealing element includes a cold plate (120), and the connector (600) is used to connect the baffle (130) and the cold plate (120); And / or, the detection element (200) is disposed on the cold plate (120).

11. The battery pack expansion monitoring system according to claim 10, characterized in that, The battery pack (100) also includes a test component (700), at least a portion of which is located on one side of the connector (600) in the first direction; The detection element (200) is used to monitor the displacement of the component to be detected (700) in the first direction in real time. In the first direction, the displacement of the component to be detected (700) is the same as the displacement of the connecting member (600). And / or, the number of baffles (130) is two, the two baffles (130) include a first baffle (131) and a second baffle (132), the first baffle (131) and the second baffle (132) are respectively disposed at opposite ends of the battery pack (110) in the first direction, and the sealing ends of the first baffle (131) and the second baffle (132) are connected to the cold plate (120) through a plurality of connectors (600); The cold plate (120) is provided with the detection element (200) in a region adjacent to the first baffle (131) and / or the second baffle (132), and the detection element (200) is disposed opposite to one of the connectors (600) in the first direction.

12. A monitoring method for a battery pack expansion monitoring system, characterized in that, The monitoring method, applied to the battery pack expansion monitoring system as described in any one of claims 1-11, comprises the following steps: Step S100: Real-time monitoring of the displacement of the battery pack housing at the sealed end in the battery pack (100) and outputting displacement data, wherein the sealed end is connected to the cold plate (120) in the battery pack (100); Step S200: Determine the structural damage risk of the battery pack (100) based on the displacement data.

13. The monitoring method according to claim 12, characterized in that, Step S200 includes: Step S210: Compare the displacement data with a preset threshold; Step S220: Based on the comparison result in step S210, determine whether the battery pack (100) has a structural damage risk, and issue a warning command when the battery pack (100) has a structural damage risk, and execute a warning action according to the warning command.

14. The monitoring method according to claim 13, characterized in that, The preset threshold includes a safety threshold and a first risk threshold, wherein the first risk threshold is greater than the safety threshold; Step S210 includes: The displacement data is compared with the safety threshold and the first risk threshold; Step S220 includes: When the displacement data is greater than the safety threshold and less than or equal to the first risk threshold, a first-level warning instruction is issued to determine that the battery pack (100) has a structural damage risk, and a first warning action is executed according to the first-level warning instruction, the warning action including the first warning action; The first warning action includes reducing the current of the battery pack (100), the current of the battery pack (100) includes the charging current and / or the discharging current, and the warning instruction includes the first-level warning instruction; And / or, the preset threshold further includes the first risk threshold and the second risk threshold, wherein the second risk threshold is greater than the first risk threshold; Step S210 includes: The displacement data is compared with the second risk threshold; Step S220 includes: When the displacement data is greater than the first risk threshold and less than or equal to the second risk threshold, it is determined that the battery pack (100) has a structural damage risk, and a secondary warning instruction is issued. A second warning action is executed according to the secondary warning instruction, and the warning action also includes the second warning action. The second warning action includes reducing the current of the battery pack (100), and the reduction in current in the second warning action is greater than the reduction in current in the first warning action; the warning instruction also includes the secondary warning instruction; And / or, the preset threshold further includes the second risk threshold and the third risk threshold, wherein the third risk threshold is greater than the second risk threshold; Step S210 includes: Compare the displacement data with the third risk threshold; Step S220 includes: When the displacement data is greater than the second risk threshold and less than or equal to the third risk threshold, it is determined that the battery pack (100) has a structural damage risk, and a level three warning instruction is issued. The third warning action is executed according to the level three warning instruction. The warning action also includes the third warning action. The third early warning action includes controlling the display device to issue a risk warning that the battery pack (100) needs maintenance; the early warning instruction also includes the three-level early warning instruction; And / or, the preset threshold further includes the third risk threshold, and step S220 further includes: When the displacement data is greater than the third risk threshold, a level four warning instruction is issued, and a fourth warning action is executed according to the level four warning instruction. The warning action also includes the fourth warning action. The fourth warning action includes controlling the display device to issue a risk warning that the battery pack (100) needs to be replaced. The warning instruction also includes the level four warning instruction.

15. An electrical appliance, characterized in that, Includes the battery pack expansion monitoring system as described in any one of claims 1-11.

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