A battery swap station gas path system control method

Abstract

The present application relates to battery swap station gas path control technical field, especially in a kind of battery swap station gas path system control method, including the first fault detection method and the second fault detection method of simultaneous execution, the first fault detection method includes the air pressure of continuously detecting gas path, when the air pressure of gas path is continuously lower than the time length of first preset value reaches second preset value, alarm, the second fault detection method includes the air pressure of continuously detecting gas path, when the air pressure of gas path is lower than the first preset value in time length for fourth preset value Time reaches third preset value, alarm.

Description

Technical Field

[0001] This invention relates to the field of gas circuit control technology for battery swapping stations, and in particular to a control method for a gas circuit system in a battery swapping station. Background Technology

[0002] The pneumatic system of a battery swapping station consists of two main parts: an air source and pneumatic actuators. The air source provides power to the pneumatic actuators, which are used to perform operations such as battery swapping. The most common air source-pneumatic actuator combination is an air compressor-cylinder. Other commonly used pneumatic actuators in battery swapping stations include locking mechanisms and robotic arms. Currently, the maintenance mode for this combination is generally "fault shutdown + manual inspection." That is, when the station-side control system detects a drop in the working air pressure of the air compressor due to overload, motor failure, or pipeline blockage, the station-side control system activates the air compressor overload protection relay to shut it down and restart it.

[0003] However, this maintenance model often only addresses the symptoms, not the root cause. A shutdown and restart may not resolve the problem. Even after following the standard procedure of "abnormality - shutdown and restart," subsequent vehicles entering the battery swapping station may still encounter issues such as insufficient working air pressure causing the robotic arm to malfunction or the locking mechanism to jam, preventing successful battery replacement. In other words, the station's control system lacks the ability to detect the root cause of the fault, making it prone to recurring problems. When faults recur, they often only become apparent after customer complaints or station staff inspections. Since battery swapping stations typically have many pneumatic actuators, stopping all actuators and manually checking them one by one results in a long average response time and a poor customer experience. Furthermore, faults in the pneumatic system are sometimes "micro-leaks," such as loose connections or aging seals. Long-term "micro-leaks" lead to frequent system shutdowns and restarts, increasing energy consumption, causing frequent equipment start-ups and shutdowns, and shortening equipment lifespan. Summary of the Invention

[0004] This invention provides a control method for a gas circuit system in a battery swapping station, including a first fault detection method and a second fault detection method executed simultaneously. The first fault detection method includes continuously detecting the gas pressure in the gas circuit and triggering an alarm when the gas pressure in the gas circuit is continuously lower than a first preset value for a duration that reaches a second preset value. The second fault detection method includes continuously detecting the gas pressure in the gas circuit and triggering an alarm when the gas pressure in the gas circuit is lower than the first preset value a certain number of times within a time period that is lower than the first preset value for a duration that reaches a third preset value.

[0005] Furthermore, the first fault detection method includes the following steps: The pressure signal of the gas path is collected in real time. If the gas pressure in the gas path is detected to be lower than the first preset value, a low-pressure timing is executed. If the duration of the low-pressure timing reaches the second preset value, it will determine whether a power swap is currently in progress. If a power swap is in progress, an alarm will be triggered after the power swap is completed, citing a pneumatic mechanism malfunction. If a power swap is not in progress, an alarm will be triggered citing a low-pressure air source malfunction.

[0006] Furthermore, the second fault detection method includes the following steps: The pressure signal of the gas path is collected in real time. If the gas pressure in the gas path is detected to be lower than the first preset value, a low pressure count is performed. If the low-pressure counter value reaches the third preset value within a time period of the fourth preset value, an alarm will be triggered on the grounds of gas leakage fault.

[0007] Furthermore, the second fault detection method also includes: if the system alarms due to a pneumatic mechanism malfunction during the low-pressure counting process, the execution of the second fault detection method is stopped.

[0008] Furthermore, the first fault detection method also includes: after an alarm is triggered, the system is prevented from automatically resetting, and the low-pressure timer is reset after the gas pressure in the gas circuit returns to normal.

[0009] Furthermore, the second fault detection method also includes: after an alarm is triggered, the system is prevented from automatically resetting, and the low-pressure counter is reset after the gas pressure in the gas path returns to normal.

[0010] Furthermore, the low-pressure timing in the first fault detection method includes: when the PLC receives a low-pressure signal, it continuously detects the air pressure in the air circuit and starts timing until the timing duration reaches the second preset value.

[0011] Furthermore, the low-pressure counting in the second fault detection method includes: when the PLC receives a low-pressure signal, it continuously detects the air pressure in the air circuit. The low-pressure count is a logical count variable with an initial value of 0. Whenever the PLC receives a low-pressure signal, the value of the low-pressure count is increased by 1 until the value of the low-pressure count reaches the third preset value.

[0012] Furthermore, the low-voltage counting in the second fault detection method also includes: whenever the low-voltage count increases from 0 to 1, the PLC starts timing until the timing duration reaches the fourth preset value.

[0013] Furthermore, the air circuit system of the battery swapping station includes a PLC, an air source, an air source processing component, a sensor, and a pneumatic actuator. The PLC is connected to the air source, the air source processing component, the sensor, and the pneumatic actuator. The air source is used to provide power, the air source processing component is used to process the power provided by the air source and convert it into a working medium usable by the pneumatic actuator, the pneumatic actuator is used to perform operations such as battery swapping, and the sensor is used to collect pressure information of the air circuit.

[0014] The gas circuit system control method for battery swapping stations provided by this invention uses a first fault detection method and a second fault detection method that can operate simultaneously to detect faults in the gas circuit from two different dimensions: the duration of low pressure and the number of times low pressure occurs per unit time. This achieves accurate fault diagnosis, avoids wasted effort in manual maintenance and repeated faults, further avoids the loss of manpower and material resources caused by repeated start-ups and shutdowns of the gas circuit system, and extends the life of equipment and system. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the first fault detection method provided by the present invention.

[0016] Figure 2 This is a schematic diagram of the second fault detection method provided by the present invention. Detailed Implementation

[0017] To further illustrate the technical means and effects adopted by the present invention in order to achieve the intended purpose, the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments.

[0018] It should be noted that the terms "first," "second," "third," "fourth," etc., in the specification and claims of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0019] Please see Figures 1 to 2The present invention provides a control method for a gas circuit system of a battery swapping station, including a first fault detection method and a second fault detection method executed simultaneously. The first fault detection method includes continuously detecting the gas pressure in the gas circuit and alarming when the gas pressure in the gas circuit is continuously lower than a first preset value for a period of time reaching a second preset value. The second fault detection method includes continuously detecting the gas pressure in the gas circuit and alarming when the gas pressure in the gas circuit is lower than the first preset value a certain number of times within a period of time reaching a fourth preset value. Specifically, in a preferred embodiment of the present invention, the air circuit system of the battery swapping station includes a PLC (Programmable Logic Controller), an air source, an air source processing component, sensors, and pneumatic actuators. The PLC is used to collect, filter, calculate, and analyze various information of the battery swapping station, and also to issue commands to control the air source, air source processing component, and pneumatic actuators respectively. The air source provides power, the air source processing component processes the power provided by the air source and converts it into a working medium usable by the pneumatic actuators, and the pneumatic actuators perform operations such as battery swapping. The sensors collect pressure information of the air circuit. The PLC is connected to the air source, air source processing component, sensors, and pneumatic actuators respectively. The air source, air source processing component, and pneumatic actuators constitute the air circuit. In a preferred embodiment of the present invention, the air source is preferably an air compressor, the air source processing component is preferably a triple unit including a filter, a pressure reducing valve, and an oil mist lubricator, or a dual unit including a filter and a pressure reducing valve, the sensor is preferably a digital display pressure sensor, and the pneumatic actuator is preferably a combination of a cylinder, a locking mechanism, and a solenoid valve. In this invention, the first, second, third, and fourth preset values ​​are all preset parameters that can be adjusted according to the actual configuration of the battery swapping station. The first preset value is a preset air pressure value; when the air pressure is lower than the first preset value, it indicates an abnormally low pressure in the air circuit. The second preset value is a preset duration value; when the air pressure remains lower than the first preset value for a duration equal to the second preset value, it indicates that the air circuit has been under low pressure for an extended period, and there may be a malfunction in the air source or pneumatic actuator. The third preset value is a preset counting variable, and the fourth preset value is a preset duration value. When the air pressure is lower than the first preset value, counting begins. If the accumulated count reaches the third preset value within the fourth preset duration, it indicates that the air circuit experiences frequent low pressure within a short period, and there may be an air leak. In essence, the first fault detection method detects the air pressure in the air circuit and times the low pressure to confirm whether there is a prolonged low pressure situation, thereby determining whether there is a malfunction in the air source or pneumatic actuator. The second fault detection method, on the other hand, detects the air pressure in the air circuit and counts the low pressure to confirm whether there is a frequent low pressure situation within a short period, thereby determining whether there is a leak in the air circuit.The first fault detection method and the second fault detection method in this invention can operate simultaneously, respectively detecting faults in the gas circuit from two different dimensions: the duration of low pressure and the number of times low pressure occurs per unit time. This achieves accurate fault diagnosis, avoids wasted effort in manual maintenance and repeated faults, further avoids the loss of manpower and resources caused by repeated start-ups and shutdowns of the gas circuit system, and extends the life of equipment and system.

[0020] The first fault detection method in this invention specifically includes the following steps: Step S1: Determine if the PLC is in automatic mode. If it is in automatic mode, proceed to step S2.

[0021] Specifically, in step S1, it is first necessary to determine whether the gas circuit system of the battery swapping station is in the normal operating mode, i.e., automatic mode. In automatic mode, the gas source, gas source processing component, sensors, and pneumatic actuators work autonomously under the control of the PLC. For example, when a vehicle enters the station for battery swapping, the pneumatic actuator sends a power demand to the PLC. After analysis and calculation, the PLC issues the power demand to the gas source, and the gas source processing component processes the power input from the gas source and outputs it to the pneumatic actuator. When the system alarms, the staff can choose to stop the automatic mode and perform manual maintenance according to the type of alarm or the actual situation.

[0022] Step S2: Real-time acquisition of air pressure signal. If the air pressure in the air circuit is detected to be lower than the first preset value, low pressure timing is executed.

[0023] Specifically, in step S2, the sensor continuously collects the pressure signal of the air path to obtain the air pressure in the air path. When the pressure signal collected by the sensor is lower than a first preset value, the signal is marked as a low-pressure signal. The first preset value is a pressure threshold used to determine that the air pressure in the air path is too low; that is, when the air pressure is lower than the first preset value, it indicates that there is an abnormally low pressure in the air path. In a preferred embodiment of the present invention, the first preset value is set to 0.3 MPa. In particular, the occurrence of abnormally low pressure in the air path does not necessarily mean that the air path is faulty. This is because the air path system of the battery swapping station may experience significant real-time air pressure fluctuations during normal operation due to the simultaneous start and stop of multiple pneumatic actuators or the execution of specific actions. Therefore, after detecting that the air pressure in the air path is lower than the first preset value, a low-pressure timer needs to be started to further confirm whether the cause of the abnormally low pressure is a normal air pressure fluctuation or a fault in the air path.

[0024] Step S3: If the duration of the low-pressure timer reaches the second preset value, determine whether a power swap is currently in progress. If a power swap is in progress, an alarm will be triggered after the power swap is completed, citing a pneumatic mechanism malfunction. If a power swap is not in progress, an alarm will be triggered, citing a low-pressure air source malfunction.

[0025] Specifically, in step S3, when the PLC receives a low-pressure signal, it continuously monitors the air pressure in the air circuit, sets the low-pressure timer to 0 and starts timing until the duration of the low-pressure timer reaches a second preset value. If the duration of the air pressure continuously below the first preset value reaches the second preset value, it indicates that the air circuit has been under low pressure for an extended period, suggesting a possible fault. If the duration of the air pressure continuously below the first preset value does not reach the second preset value, it indicates that the air circuit only experiences occasional low pressure, and the cause of this occasional low pressure is likely normal air pressure fluctuations, indicating no fault in the air circuit. In this case, the low-pressure timer is reset to zero. In a preferred embodiment of the invention, the second preset value is set to 5 seconds. After detecting a possible fault in the air circuit, it is necessary to further trace the cause of the fault to accurately locate the faulty component. Step S3 in this invention further traces the cause of the fault by determining the actions being performed by the air circuit system of the battery swapping station. If a prolonged period of low air pressure occurs during the battery swapping process, it indicates that the air pressure is too low when the pneumatic actuator performs a specific action. The fault is identified as a malfunction in the pneumatic actuator, and an alarm is triggered based on this pneumatic mechanism malfunction. If a prolonged period of low air pressure occurs outside of the battery swapping process, it indicates a malfunction in the air supply. Since the pneumatic actuator is not operating at this time, the fault is also identified as a malfunction in the air supply, and an alarm is triggered based on a low air supply pressure malfunction. Specifically, if an alarm is triggered based on a pneumatic mechanism malfunction, it must be reported to the PLC only after the battery swapping operation is completed, not during the swapping process, to prevent duplicate work orders.

[0026] Step S4: Prohibit subsequent vehicles from entering the station for battery swapping, manually inspect and repair the vehicle, and repeat step S1.

[0027] Specifically, in step S4, regardless of the alarm signal received by the PLC, a fault work order is generated and reported to manual control, prohibiting subsequent vehicles from entering the station for battery swapping and preventing the system from automatically resetting. After accurately locating the faulty component based on the alarm signal, the station staff manually inspects and repairs the designated component until the fault is resolved. Once the air pressure in the air circuit returns to normal, the PLC control system is manually reset. During the system reset, the low-pressure timer and low-pressure counter are reset, returning to automatic mode and re-executing step S1. This prevents the generation of numerous duplicate fault work orders.

[0028] This invention detects the air pressure in the air circuit using a first fault detection method and performs low-pressure timing when low pressure occurs. It also identifies whether the fault is caused by the air source or the pneumatic actuator based on whether the current power supply has been replaced. This achieves accurate fault diagnosis, avoids wasted effort in manual maintenance and repeated faults, further avoids the loss of manpower and resources caused by repeated start-ups and shutdowns of the air circuit system, and extends the lifespan of equipment and systems.

[0029] The second fault detection method in this invention specifically includes the following steps: Step M1: Determine if the PLC is in automatic mode. If it is in automatic mode, proceed to step M2.

[0030] Specifically, in step M1, the reasons and purposes for determining whether the PLC is in automatic mode are the same as in step S1, and will not be repeated here.

[0031] Step M2: Real-time acquisition of air pressure signals. If the air pressure in the air path is detected to be lower than the first preset value, low-pressure counting is performed.

[0032] Specifically, in step M2, the sensor continuously collects the pressure signal of the air path to obtain the air pressure in the air path. When the pressure signal collected by the sensor is lower than a first preset value, the signal is marked as a low-pressure signal. As mentioned above, the first preset value is the air pressure threshold used to determine if the air pressure in the air path is too low. That is, when the air pressure is lower than the first preset value, it indicates that there is an abnormal low pressure in the air path. Steps M2 and S2 use the same first preset value as the air pressure threshold so that the first fault detection method and the second fault detection method can be executed simultaneously to accurately determine the cause of the fault. As mentioned above, the occurrence of abnormal low pressure in the air path does not necessarily mean that there is a fault in the air path. This is because the air path system of the battery swapping station will experience significant real-time air pressure fluctuations during normal operation due to the simultaneous start and stop of multiple pneumatic actuators or the execution of specific actions. Therefore, after detecting that the air pressure in the air path is lower than the first preset value, it is also necessary to start a low-pressure counter to further confirm whether the cause of the abnormal low pressure is a normal air pressure fluctuation or a fault in the air path.

[0033] Step M3: If the low pressure counter value reaches the third preset value within a time period of the fourth preset value, an alarm will be triggered for the reason of gas leakage fault.

[0034] Specifically, in step M3, the low-pressure counter in this invention is a logical counter variable. The initial value of the low-pressure counter is 0. Whenever the PLC receives a low-pressure signal, the value of the low-pressure counter is increased by 1 until the value of the low-pressure counter reaches the third preset value. Furthermore, whenever the low-pressure counter increases from 0 to 1, the PLC starts timing. If the timing duration reaches the fourth preset value and the value of the low-pressure counter has not reached the third preset value, the PLC resets the value of the low-pressure counter to 0. If the value of the low-pressure counter reaches the third preset value within the time period of the fourth preset value, it indicates that the gas pressure has been below the first preset value too many times per unit time, indicating a short-term, high-frequency low-pressure situation in the gas path. The fault is identified as a gas path leak, and an alarm is triggered based on this gas path leak. In a preferred embodiment of this invention, the third preset value is set to 2, and the fourth preset value is set to 180 seconds. That is, if the number of low-pressure signals within 3 minutes is greater than or equal to 2, the system alarms. Specifically, if the first fault detection method and the second fault detection method are executed simultaneously, and the PLC has already alarmed due to the low pressure fault of the gas source in step S3 during the low pressure counting process, then step M3 is stopped because the fault is temporarily locked as the low pressure of the gas source, and there is no need to check whether there is a gas leak in the gas line. After step S4 is executed, the PLC control system is manually reset, and then the second fault detection method is re-executed from step M1.

[0035] Step M4: Manually inspect and repair the faulty parts and repeat step M1.

[0036] Specifically, in step M4, the PLC generates a fault work order and reports it to manual control, preventing the system from automatically resetting. Simultaneously, the PLC further determines the severity of the air leak based on the low-pressure signal. If the level exceeds the fifth-level low-pressure alarm of the air compressor, subsequent vehicles are prohibited from entering the station for battery swapping. After accurately locating the leak in the air circuit based on the alarm signal, the station staff manually inspects and repairs the designated components until the leak is resolved. Once the air pressure in the circuit returns to normal, the PLC is operated to reset the control system. During the system reset, the low-pressure timer and low-pressure counter are reset, returning to automatic mode and re-executing step M1.

[0037] This invention detects the air pressure in the gas path using a second fault detection method and counts low pressure when it occurs. This effectively pinpoints the cause of the fault when there is a gas leak, achieving accurate fault diagnosis. Furthermore, if the PLC has already alarmed due to a low-pressure gas source fault identified in the first fault detection method during the execution of the second fault detection method, the second fault detection method is terminated. It is then re-executed after the system is reset, further improving the accuracy of fault identification and avoiding invalid detection.

[0038] In summary, the gas circuit system control method of the battery swapping station in this invention detects gas circuit faults from two different dimensions: the duration of low pressure and the number of times low pressure occurs per unit time, through a first fault detection method and a second fault detection method that can operate simultaneously. This achieves accurate fault diagnosis, avoids wasted effort in manual maintenance and repeated faults, further avoids the loss of manpower and resources caused by repeated start-ups and shutdowns of the gas circuit system, and extends the life of equipment and system.

[0039] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A control method for a gas circuit system in a battery swapping station, characterized in that: The method includes a first fault detection method and a second fault detection method that are executed simultaneously. The first fault detection method includes continuously detecting the air pressure in the air circuit and triggering an alarm when the air pressure in the air circuit is continuously lower than a first preset value for a period of time that reaches a second preset value. The second fault detection method includes continuously detecting the air pressure in the air circuit and triggering an alarm when the air pressure in the air circuit is lower than the first preset value a certain number of times within a period of time that reaches a fourth preset value.

2. The control method for the gas circuit system of a battery swapping station as described in claim 1, characterized in that: The first fault detection method includes the following steps: The pressure signal of the gas path is collected in real time. If the gas pressure in the gas path is detected to be lower than the first preset value, a low-pressure timing is executed. If the duration of the low-pressure timing reaches the second preset value, it is determined whether a power swap is currently in progress. If a power swap is in progress, an alarm is triggered after the power swap is completed, citing a pneumatic mechanism malfunction. If a power swap is not in progress, an alarm is triggered, citing a low-pressure air source malfunction.

3. The control method for the gas circuit system of a battery swapping station as described in claim 2, characterized in that: The second fault detection method includes the following steps: The pressure signal of the gas path is collected in real time. If the gas pressure in the gas path is detected to be lower than the first preset value, a low pressure count is performed. If the low-pressure counter value reaches the third preset value within a time period of the fourth preset value, an alarm will be triggered on the grounds of gas leakage fault.

4. The control method for the gas circuit system of a battery swapping station as described in claim 3, characterized in that: The second fault detection method further includes: if the system alarms due to a pneumatic mechanism malfunction during the low-pressure counting process, the execution of the second fault detection method shall be stopped.

5. The control method for the gas circuit system of a battery swapping station as described in claim 2, characterized in that: The first fault detection method also includes: after an alarm is triggered, the system is prevented from automatically resetting, and the low-pressure timer is reset after the gas pressure in the gas circuit returns to normal.

6. The control method for the gas circuit system of a battery swapping station as described in claim 3, characterized in that: The second fault detection method also includes: after an alarm is triggered, the system is prevented from automatically resetting, and the low-pressure counter is reset after the gas pressure in the gas circuit returns to normal.

7. The control method for the gas circuit system of a battery swapping station as described in claim 2, characterized in that: The low-pressure timing in the first fault detection method includes: when the PLC receives a low-pressure signal, it continuously detects the air pressure in the air circuit and starts timing until the timing duration reaches the second preset value.

8. The control method for the gas circuit system of a battery swapping station as described in claim 3, characterized in that: The low-pressure counting in the second fault detection method includes: when the PLC receives a low-pressure signal, it continuously detects the air pressure in the air circuit. The low-pressure count is a logic count variable with an initial value of 0. Whenever the PLC receives a low-pressure signal, the value of the low-pressure count is increased by 1 until the value of the low-pressure count reaches the third preset value.

9. The control method for the gas circuit system of a battery swapping station as described in claim 8, characterized in that: The low-voltage counting in the second fault detection method further includes: whenever the low-voltage count increases from 0 to 1, the PLC starts timing until the timing duration reaches the fourth preset value.

10. The control method for the gas circuit system of a battery swapping station as described in claim 1, characterized in that: The air circuit system of the battery swapping station includes a PLC, an air source, an air source processing component, a sensor, and a pneumatic actuator. The PLC is connected to the air source, the air source processing component, the sensor, and the pneumatic actuator. The air source provides power, the air source processing component processes the power provided by the air source and converts it into a working medium usable by the pneumatic actuator, the pneumatic actuator performs operations such as battery swapping, and the sensor collects pressure information of the air circuit.

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