Energy control system, method, device and vehicle

Abstract

The present application relates to an energy control system, method, device and vehicle, and relates to the technical field of vehicles, and aims to control thermal runaway arc ignition from the source and dynamically determine safe ignition energy, comprising: obtaining the volume concentration of each component gas of a mixed gas in an electrical system and the transient energy in the electrical system; determining the safe ignition energy from a mapping relationship according to the volume concentration, the mapping relationship being used to associate the volume concentration of different component gases in the mixed gas and the corresponding safe ignition energy; judging whether there is an arc explosion risk according to the transient energy and the safe ignition energy; and in the case that there is an arc explosion risk, suppressing the transient energy in the electrical system.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically to an energy control system, method, device, and vehicle. Background Technology

[0002] With the large-scale application of new energy vehicles and energy storage power stations, the safety of lithium-ion battery systems has become a key challenge for the industry. In actual operation, when batteries encounter extreme conditions such as internal short circuits, overcharging, or external impacts, thermal runaway can easily be triggered. Once thermal runaway occurs, a large amount of flammable mixed gases (such as hydrogen, carbon monoxide, and hydrocarbons) produced by the decomposition of the electrolyte will be rapidly released inside the battery. These flammable and explosive gases accumulate rapidly in the sealed battery pack or energy storage chamber, easily forming a mixed atmosphere with an explosion risk. Related technical solutions to address this problem mainly rely on electric shock protection or heat source cutoff after physical insulation failure.

[0003] However, current technical solutions still have the problem of being unable to control thermal runaway arcing and ignition at the source, and the ignition energy is inaccurate. Summary of the Invention

[0004] This invention provides an energy control system, method, device, and vehicle, which aims to control thermal runaway arcing and ignition at the source and dynamically determine the safe ignition energy.

[0005] In a first aspect, this application provides an energy control method, comprising: obtaining the volume concentration of each component gas in a mixed gas in an electrical system and determining the transient energy in the electrical system; determining a safe ignition energy from a mapping relationship based on the volume concentration, wherein the mapping relationship is used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy; determining whether there is a risk of electric arc explosion based on the transient energy and the safe ignition energy; and suppressing the transient energy in the electrical system in the event of a risk of electric arc explosion.

[0006] Based on the aforementioned technical means, this application obtains the volume concentration of each component gas in the mixed gas of an electrical system and determines the transient energy in the electrical system, enabling real-time monitoring of the gas composition and the current stored transient energy level within the electrical system. The safe ignition energy is determined from a mapping relationship based on the volume concentration. This mapping relationship is used to correlate the volume concentration of different component gases in the mixed gas with their corresponding safe ignition energy, thus allowing for dynamic calculation of the required safe ignition energy for the actual mixed gas environment. The presence of an arcing / explosion risk is determined based on the transient energy and the safe ignition energy, dynamically identifying whether the transient energy has approached or exceeded the ignition limit of the mixed gas, achieving early warning of arcing / explosion risks. In the event of an arcing / explosion risk, the transient energy in the electrical system is suppressed, directly reducing the spark energy that may generate arcing in the electrical system, thereby reducing or eliminating the energy source sufficient to ignite the mixed gas, and effectively preventing arcing and fire caused by the release of transient energy during thermal runaway.

[0007] Furthermore, transient energy includes capacitive energy and inductive energy. Capacitive energy in an electrical system is discharged, and capacitive energy is the energy stored in a capacitor. Inductive energy in an electrical system is dissipated, and inductive energy is the energy stored in an inductor.

[0008] Based on the aforementioned technical methods, capacitive energy in the electrical system is discharged and inductive energy is dissipated, respectively. Capacitive energy refers to the energy stored in capacitors, and inductive energy refers to the energy stored in inductors. This approach suppresses the energy stored in both types of energy storage components, avoiding the risk of ignition from the other energy source while only addressing one form of energy. By discharging capacitive energy, the electric field energy stored across the capacitor is directly reduced, thereby lowering the spark energy that could trigger an arc when the contacts separate due to voltage maintenance. By dissipating inductive energy, the magnetic field energy stored in the inductor is directly reduced, preventing the release of inductive energy as a high-voltage backflow and the generation of a strong arc when the circuit is broken.

[0009] Furthermore, the voltage of the electrical system bus is reduced to an intermediate value at a first preset rate. The intermediate value is the median between the bus voltage and the preset safe voltage. The relationship between the safe ignition energy and the capacitive energy is determined. If the safe ignition energy is greater than or equal to the capacitive energy, the discharge is stopped.

[0010] Based on the aforementioned technical means, by reducing the voltage of the electrical system's bus to an intermediate value at a first preset rate—the intermediate value being the midpoint between the bus voltage and a preset safe voltage—the bus voltage can smoothly transition from its initial value to the intermediate value, avoiding transient current spikes or arcs caused by voltage surges. This continuously suppresses the spark energy that could ignite the gas mixture during the venting process. By determining the relationship between the safe ignition energy and the capacitive energy, it is possible to assess in real time whether the remaining capacitive energy is below the safe ignition energy threshold in the gas mixture environment, providing an accurate quantitative criterion for stopping the venting. When the safe ignition energy is greater than or equal to the capacitive energy, the venting is stopped, ensuring timely termination of the venting operation when the capacitive energy no longer poses an ignition risk, avoiding unnecessary energy consumption and excessive heating of the venting circuit.

[0011] Furthermore, if the safe ignition energy is less than the capacitive energy, the voltage of the electrical system bus continues to decrease at a first preset rate until a first preset condition is met. The first preset condition is that the safe ignition energy is greater than or equal to the capacitive energy, or the bus voltage is less than a preset safe voltage.

[0012] According to the aforementioned technical means, by continuing to reduce the voltage of the electrical system's bus at a first preset rate when the safe ignition energy is less than the capacitive energy, until a first preset condition is met, the first preset condition being that the safe ignition energy is greater than or equal to the capacitive energy, or the bus voltage is less than a preset safety voltage, the discharge process can continue to run until either of the two independent termination conditions is met first. Discharge stops when the safe ignition energy is greater than or equal to the capacitive energy, indicating that the capacitive energy has been reduced to below the safe ignition energy threshold in the current mixed gas environment, eliminating the risk of arcing and fire caused by capacitive energy release at the source. Discharge stops when the bus voltage is less than the preset safety voltage. At this point, even if the safe ignition energy is still less than the capacitive energy, continued discharge would lead to unnecessary energy loss since the bus voltage is already below the preset safety voltage. Therefore, discharge is terminated early to save energy and avoid excessive heating of the discharge circuit.

[0013] Furthermore, the relationship between electrical energy and safe ignition energy is determined. Electrical energy includes capacitive energy, inductive energy, and the energy generated by the separation of relay contacts in the electrical system. If the electrical energy is greater than or equal to the safe ignition energy, the capacitive energy continues to be released.

[0014] Based on the aforementioned technical methods, by determining the relationship between electrical energy and safe ignition energy—including capacitive energy, inductive energy, and the energy generated by the separation of relay contacts in the electrical system—the potential arc energy generated at the moment of relay contact separation can be comprehensively included in the assessment of the total electrical energy, avoiding misjudgment of actual ignition risk due to the omission of contact separation energy. When the electrical energy is greater than or equal to the safe ignition energy, continued release of capacitive energy indicates that the current total electrical energy is approaching or exceeding the safe ignition energy threshold in a mixed gas environment. Continuously releasing capacitive energy reduces the electric field energy stored in the bus capacitor, thereby reducing the total energy source that can be converted into an arc when the relay subsequently disconnects, eliminating the possibility of arcing and fire caused by excessive energy during relay disconnection.

[0015] Furthermore, the loop current in the electrical system is reduced to 0 at a second preset rate.

[0016] According to the above technical means, by reducing the circuit current in the electrical system to 0 at a second preset rate, the rate of change of the circuit current can be controlled, avoiding the generation of excessively high induced electromotive force due to sudden current changes, thereby suppressing the release of inductive energy stored in the inductor in the form of a high-voltage backlash arc at the moment of current drop.

[0017] Furthermore, the mapping relationship is determined based on the following method: the minimum ignition energy of each component gas is determined based on the volume concentration of each component gas in the mixed gas; the safe ignition energy is determined based on the minimum ignition energy of each component gas and the binary interaction coefficient between each pair of component gases, thus obtaining the mapping relationship.

[0018] Based on the aforementioned technical methods, by determining the minimum ignition energy of each component gas in the gas mixture based on its volume concentration, the ignition difficulty of each gas component in the gas mixture can be assessed individually, avoiding misjudgment of the overall energy threshold due to changes in the proportion of gas components. The safe ignition energy is determined based on the minimum ignition energy of each component gas and the binary interaction coefficient between each pair of component gases, resulting in a mapping relationship. This allows for the introduction of the mutual influence between different gas components when calculating the safe ignition energy, correcting deviations caused by nonlinear interactions between components, and ensuring that the final safe ignition energy accurately reflects the ignition characteristics of the actual gas mixture environment. The mapping relationship obtained by correcting the minimum ignition energy of each component gas with the binary interaction coefficient can accurately determine the safe ignition energy of the gas mixture under any combination of volume concentrations.

[0019] Furthermore, the minimum ignition energy of the corresponding component gas is determined based on the volume concentration, most explosive concentration, and lower explosive limit concentration of each component gas.

[0020] Based on the aforementioned technical means, the minimum ignition energy of the corresponding component gas can be determined based on the volume concentration, most explosive concentration, and lower explosive limit concentration of each component gas, enabling the independent calculation of the minimum ignition energy value for each gas component in the mixed gas.

[0021] Furthermore, the main relay may be disconnected if the transient energy is less than the safe ignition energy and the voltage in the bus circuit is less than the preset safe voltage.

[0022] Based on the aforementioned technical means, when the transient energy is less than the safe ignition energy, it indicates that the sum of the capacitive and inductive energy currently stored in the electrical system is below the ignition threshold in a mixed gas environment. Even if an arc is generated during the relay contact separation process, the arc energy is insufficient to ignite the surrounding combustible gas. When the voltage in the electrical system is less than the preset safe voltage, it indicates that the bus voltage has entered the safe extra-low voltage range, further reducing the possibility of contact breakdown and the generation of a continuous arc. Once both of these conditions are met simultaneously, the main relay can be disconnected, eliminating the risk of arcing and fire caused by relay disconnection at the source.

[0023] Furthermore, the internal power supply of the electrical system is cut off; an external optocoupler-isolated power supply is established, which transmits energy through a withstand voltage optocoupler or optical fiber, and transmits the control signals of the electrical system through optical fiber.

[0024] Based on the aforementioned technical methods, by cutting off the internal power supply to the electrical system, the risk of the internal power supply continuously outputting electrical energy and becoming a source of arcing and fire energy during thermal runaway can be eliminated. Establishing an external optocoupler-isolated power supply, which transmits energy through withstand voltage optocouplers or optical fibers and transmits the electrical system's control signals through optical fibers, can electrically isolate the external power supply from the electrical system, while preventing control signals from conducting electric sparks or induced voltages through metal wires.

[0025] Secondly, this application provides an energy control device, including an acquisition module and a processing module; the acquisition module is used to acquire the volume concentration of each component gas in a mixed gas in an electrical system and determine the transient energy in the electrical system; the processing module is used to determine the safe ignition energy from a mapping relationship based on the volume concentration, the mapping relationship being used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy; the processing module is also used to determine whether there is a risk of electric arc explosion based on the transient energy and the safe ignition energy; the processing module is also used to suppress the transient energy in the electrical system when there is a risk of electric arc explosion.

[0026] Furthermore, transient energy includes capacitive energy and inductive energy. The processing module is specifically used to discharge capacitive energy in the electrical system, which is the energy stored in the capacitor; and to dissipate inductive energy in the electrical system, which is the energy stored in the inductor.

[0027] Furthermore, the processing module is specifically used to reduce the voltage of the electrical system bus to an intermediate value at a first preset rate, the intermediate value being the median between the bus voltage and the preset safe voltage; determine the relationship between the safe ignition energy and the capacitive energy; and stop the discharge when the safe ignition energy is greater than or equal to the capacitive energy.

[0028] Furthermore, the processing module is also used to continue reducing the voltage of the electrical system bus at a first preset rate when the safe ignition energy is less than the capacitive energy, until a first preset condition is met. The first preset condition is that the safe ignition energy is greater than or equal to the capacitive energy, or the voltage of the bus is less than a preset safe voltage.

[0029] Furthermore, the processing module is also used to determine the magnitude relationship between electrical energy and safe ignition energy. Electrical energy includes capacitive energy, inductive energy, and energy generated by the separation of relay contacts in the electrical system. If the electrical energy is greater than or equal to the safe ignition energy, the capacitive energy continues to be discharged.

[0030] Furthermore, the processing module is specifically used to reduce the loop current in the electrical system to 0 at a second preset rate.

[0031] Furthermore, the mapping relationship is determined based on the following method: the minimum ignition energy of each component gas is determined based on the volume concentration of each component gas in the mixed gas; the safe ignition energy is determined based on the minimum ignition energy of each component gas and the binary interaction coefficient between each pair of component gases, thus obtaining the mapping relationship.

[0032] Furthermore, the processing module is specifically used to determine the minimum ignition energy of the corresponding component gas based on the volume concentration, most explosive concentration, and lower explosive limit concentration of each component gas.

[0033] Furthermore, the processing module is also used to allow the main relay to be disconnected when the transient energy is less than the safe ignition energy and the voltage in the electrical system is less than the preset safe voltage.

[0034] Furthermore, the processing module is also used to cut off the internal power supply of the electrical system; establish an external optocoupler isolated power supply, which transmits energy through a withstand voltage optocoupler or optical fiber, and transmits the control signals of the electrical system through optical fiber.

[0035] Thirdly, this application provides an electronic device comprising: a processor and a memory; the memory storing processor-executable instructions. When the processor is configured to execute the instructions, the electronic device implements the method described in the first aspect.

[0036] Fourthly, this application provides a computer-readable storage medium storing computer program instructions that, when executed by a processor, implement the method described in the first aspect.

[0037] Fifthly, this application provides a computer program product including computer program instructions that, when executed by a processor, implement the method described in the first aspect.

[0038] Sixthly, this application provides a vehicle that uses the energy control method provided in the first aspect to control the energy of its electrical system.

[0039] It should be noted that the technical effects of any of the implementation methods in aspects two through six can be found in the technical effects of the corresponding implementation methods in aspect one, and will not be repeated here.

[0040] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0041] Figure 1 A schematic diagram of the architecture of an energy control system provided by the present invention; Figure 2 A flowchart illustrating an energy control method provided by the present invention; Figure 3 A schematic flowchart illustrating another energy control method provided by the present invention; Figure 4 A flowchart illustrating a transient energy suppression method provided by the present invention; Figure 5 A schematic diagram of the composition of an energy control device provided by the present invention; Figure 6 This is a schematic diagram of the structure of an electronic device provided by the present invention. Detailed Implementation

[0042] The embodiments of the present invention will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are only for illustrating the present invention and not for limiting the scope of protection of the present invention.

[0043] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0044] The energy control system, method, apparatus, and vehicle provided in this application will now be described in detail with reference to the accompanying drawings.

[0045] In this article, the term "and / or" is merely a description of the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can represent three situations: A exists alone, A and B exist simultaneously, and B exists alone.

[0046] The terms "first" and "second," etc., used in the specification and drawings of this application are used to distinguish different objects or to distinguish different treatments of the same object, rather than to describe a specific order of objects.

[0047] Furthermore, the terms "comprising" and "having," and any variations thereof, used in the description of this application 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 limited to the steps or units listed, but may optionally include other steps or units not listed, or may optionally include other steps or units inherent to such process, method, product, or apparatus.

[0048] It should be noted that in the embodiments of this application, the words "exemplarily" or "for example" are used to indicate examples, illustrations, or explanations. Any embodiment or design scheme described as "exemplarily" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design schemes. Specifically, the use of the words "exemplarily" or "for example" is intended to present the relevant concepts in a specific manner.

[0049] To facilitate a clear description of the technical solutions of the embodiments of this application, the terms "first" and "second" are used in the embodiments of this application to distinguish the same or similar items with essentially the same function and effect. Those skilled in the art can understand that the terms "first" and "second" are not intended to limit the quantity or execution order.

[0050] In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0051] The embodiments provided in this application will now be described in detail with reference to the accompanying drawings.

[0052] The energy control method provided in this application can be applied to electronic devices.

[0053] For example, the electronic device can be a server, such as a single server or a server cluster consisting of multiple servers. In some embodiments, the server cluster can also be a distributed cluster.

[0054] For example, the electronic device can be a terminal device, such as a mobile phone, tablet computer, desktop computer, laptop computer, handheld computer, notebook computer, ultra-mobile personal computer (UMPC), netbook, cellular phone, personal digital assistant (PDA), augmented reality (AR) / virtual reality (VR) device, etc. This application embodiment does not impose any special limitations on the specific form of the terminal device.

[0055] The energy control method provided in this application can be applied to emergency safety handling scenarios following thermal runaway-induced flammable gas leaks in electrical systems, particularly lithium-ion battery systems. Specifically, this includes electric vehicle battery packs, energy storage containers, and various lithium-ion battery energy storage power stations. When a battery enters a thermal runaway state due to internal short circuits, overcharging, or mechanical abuse, it rapidly releases a large amount of flammable gas mixture, primarily hydrogen. Hydrogen has an extremely wide explosion limit and a very low minimum ignition energy. Furthermore, the battery pack or energy storage compartment contains multiple potential ignition sources, such as relay contacts and equalization circuit switches. Once the flammable gas accumulates to an explosive concentration, even a small electrical spark can ignite the gas, leading to a fire or explosion.

[0056] The energy control system 10 of this application includes: a main relay, a dissipation resistor, a bleeder resistor, a capacitor, an inductor, a gas concentration sensor, and a controller. In some embodiments, a gas concentration sensor is used to determine the volume concentration of each component gas in an electrical system.

[0057] In some embodiments, a gas concentration sensor refers to a precision instrument capable of detecting the presence of a specific gas in a specific area and continuously measuring the content of that gas component. In a battery management system, a gas concentration sensor can be installed inside the battery pack or at the vent of the battery system to monitor in real time the volume concentration of combustible gases (such as hydrogen, carbon monoxide, methane, etc.) generated by the battery due to thermal runaway, electrolyte leakage, or abnormal chemical reactions.

[0058] In some embodiments, an electrical system refers to an overall network consisting of a power source, electrical equipment, control devices, and connecting wires, capable of transmitting, distributing, storing, and converting electrical energy.

[0059] In some embodiments, each component gas refers to each individual gas species that constitutes the mixed gas, such as hydrogen, carbon monoxide, methane, ethylene, etc., and each gas is independently referred to as a component.

[0060] In some embodiments, volume concentration refers to the volume fraction of each component gas in the gas mixture, usually expressed as a percentage or parts per million. For example, a hydrogen volume concentration of 4% means that hydrogen accounts for four percent of the total volume of the gas mixture.

[0061] In some embodiments, a gas concentration sensor, such as an electrochemical hydrogen sensor, a non-dispersive infrared carbon monoxide sensor, or a catalytic combustion methane sensor, installed on the internal housing of an electrical system, acquires voltage or current signals in real time, and converts the acquired analog signals into digital quantities via an analog-to-digital converter, thereby determining the volume concentration of each component gas in the mixed gas.

[0062] In some embodiments, the controller is configured to obtain the volume concentration of each component gas in the mixed gas in the electrical system from the gas concentration sensor, and determine the safe ignition energy from a mapping relationship based on the volume concentration, wherein the mapping relationship is used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy.

[0063] In some embodiments, the mapping relationship refers to a functional relationship or data correspondence rule used to map the volume concentration of each component gas in a gas mixture to a safe ignition energy threshold. The mapping relationship is not an instantaneous result derived through real-time calculation, but rather a fixed correspondence rule predetermined through experimental calibration, theoretical calculation, or numerical fitting.

[0064] For example, the mapping relationship may include an empirical curve that maps the volume concentration of a single gas to the safe ignition energy of that gas. The empirical curve outputs a minimum value when the gas concentration is near the lower explosive limit or stoichiometric concentration, and outputs a monotonically increasing larger value when the gas concentration is far below the lower explosive limit or far above the stoichiometric concentration. The mapping relationship may also include a multidimensional data table that maps the combination of volume concentrations of two or more combustible gas components to safe ignition energy. Each dimension of the multidimensional data table corresponds to a volume concentration range of a combustible gas component, and each cell in the table stores a pre-calculated or experimentally calibrated safe ignition energy.

[0065] In some embodiments, safe ignition energy refers to the maximum spark energy that the electrical system is allowed to generate in the current mixed gas environment. Exceeding this limit poses a risk of igniting the mixed gas or causing an electric arc explosion.

[0066] In some embodiments, a controller refers to the core electronic component in a battery management system responsible for performing logical operations, data processing, and instruction output. Physically, it typically takes the form of a microcontroller, microprocessor, digital signal processor, or field-programmable gate array (FPGA). The controller executes a preset firmware program through its internally integrated central processing unit, reads analog or digital signals output from the gas concentration sensor, voltage sampling circuit, and current sampling circuit via an analog-to-digital converter interface, and sends control commands to the electronic switches in the discharge circuit, the switching transistors in the equalization circuit, and the main relay drive circuit via a general-purpose input / output interface or a pulse width modulation interface.

[0067] In some embodiments, a mixed gas refers to a gas mixture within the electrical system's internal environment consisting of two or more flammable gases and air or other inert gases. During battery thermal runaway, the mixed gas may include hydrogen, carbon monoxide, methane, and organic vapors from the electrolyte.

[0068] In some embodiments, the volume concentration of each component gas in the mixed gas, which is detected in real time, can be used as an index to directly read the safe ignition energy threshold corresponding to the volume concentration by means of a lookup table.

[0069] In some embodiments, the voltage V across the bus capacitor is acquired by a voltage sampling circuit, the main circuit current I is acquired by a current sampling circuit, and the pre-calibrated bus capacitance value C and line inductance value L are read. Then, the voltage V and capacitance value C are substituted into formula E. cap =0.5 C V 2 We obtain capacitive energy, where E cap To represent capacitive energy, substitute the current I and the inductance L into the formula E. ind =0.5 L I 2 Obtaining sensory energy, of which E ind This represents inductive energy, and the capacitive energy is added to the inductive energy to form the transient energy in the electrical system.

[0070] In some embodiments, the controller is further configured to determine transient energy in the electrical system, the transient energy including capacitive energy in the capacitor and inductive energy in the inductor.

[0071] In some embodiments, transient energy refers to the energy released or converted by energy storage elements during the transient process of an electrical system transitioning from one steady state to another. Transient energy includes capacitive energy stored in capacitors and inductive energy stored in inductors. Capacitive energy is determined by the bus capacitor voltage, and inductive energy is determined by the loop current and line inductance.

[0072] In some embodiments, capacitive energy refers to the energy stored in the internal electric field of a capacitor element when it is in a charging state. The magnitude of capacitive energy is determined by the capacitance of the capacitor and the voltage across the capacitor.

[0073] In some embodiments, inductive energy refers to the energy stored in the surrounding magnetic field of an inductor when it is energized, and the magnitude of the inductive energy is determined by both the inductance and the current flowing through the inductor.

[0074] In some embodiments, the controller is further configured to determine whether there is a risk of electric arc explosion based on the transient energy and the safe ignition energy; and to suppress the transient energy in the electrical system if there is a risk of electric arc explosion.

[0075] In some embodiments, the risk of arcing and explosion refers to the possibility that when a relay contact in an electrical system separates, a switch is turned off, or a wire is accidentally disconnected, the stored transient energy is released in the form of an arc or spark. If the released energy exceeds the safe ignition energy in the current mixed gas environment, the arc or spark is sufficient to ignite the mixed gas and cause an explosion or fire.

[0076] In some embodiments, if the transient energy is greater than or equal to the safe ignition energy, it is determined that there is a risk of arc explosion; if the transient energy is less than the safe ignition energy, it is determined that there is no risk of arc explosion.

[0077] In some embodiments, suppressing transient energy in an electrical system may include discharging capacitive energy in the electrical system and dissipating inductive energy in the electrical system.

[0078] In some embodiments, the capacitor is used to store energy to obtain capacitive energy; the inductor is used to store energy to obtain inductive energy.

[0079] In some embodiments, a capacitor is a passive component in an electrical system capable of storing charge and establishing an electric field between two plates. Capacitors include specially manufactured capacitor elements and parasitic capacitances generated by circuit layout.

[0080] In some embodiments, an inductor is a component in an electrical system that can convert electrical energy into magnetic field energy and store it, including coils wound on a magnetic core or hollow frame and distributed inductance formed by a layout of wires. An inductor generates an induced electromotive force that opposes the change in current when the current changes.

[0081] In some embodiments, the bleed resistor is used to bleed the capacitive energy in the electrical system; the dissipation resistor is used to dissipate the inductive energy in the electrical system.

[0082] In some embodiments, a bleed resistor is a resistive element connected across a capacitor in an electrical system to release the electric field energy stored in the capacitor as heat. During normal operation, the bleed resistor is connected in parallel with the bus capacitor. When the voltage across the capacitor is high, the charge stored in the capacitor forms a current loop through the bleed resistor. As the current flows through the bleed resistor, heat is generated due to the Joule effect of the resistor, and the electric field energy in the capacitor is gradually converted into heat and dissipated. The function of the bleed resistor is to reduce the voltage across the capacitor, thereby reducing or eliminating the discharge arc energy that may be generated during subsequent circuit switching. Bleed resistors are typically power resistors, such as metal oxide film power resistors, wire-wound power resistors, or thick-film power resistors.

[0083] In some embodiments, a dissipative resistor is a resistive element connected across an inductor in an electrical system or in series with a freewheeling diode to release the magnetic field energy stored in the inductor as heat. When the inductive load is disconnected, the dissipative resistor and the freewheeling diode form a closed freewheeling circuit. The magnetic field energy stored in the inductor generates an induced electromotive force (EMF) at the moment the circuit is opened. This EMF drives current through the freewheeling diode and the dissipative resistor to form a freewheeling current. As the current flows through the dissipative resistor, heat is generated due to the Joule effect, and the magnetic field energy in the inductor is gradually converted into heat and dissipated. The core function of the dissipative resistor is to absorb the recoil energy generated by sudden current changes in the inductor, limiting the inductive energy within a safe range and preventing the generation of high-voltage recoil arcs. Dissipative resistors are typically non-inductive wire-wound resistors or metal film resistors to avoid the parasitic inductance of the resistor itself affecting the response characteristics of the freewheeling circuit.

[0084] In some embodiments, the main relay, the capacitor, and the inductor constitute a bus circuit.

[0085] In some embodiments, a main relay refers to a high-power electromagnetic switching device connected between the battery pack and an external high-voltage load (such as a motor controller, DC-DC converter, air conditioning compressor, etc.) to connect or disconnect the high-voltage main circuit according to control commands. The main relay is the core actuator in the battery management system for realizing high-voltage safety on / off control. It typically includes two independent devices: a main positive relay and a main negative relay, connected in series on the high-voltage busbars at the positive and negative output terminals of the battery pack, respectively. When both relays are closed simultaneously, the high-voltage circuit is connected, and the battery pack supplies electrical energy. When either relay is open, the high-voltage circuit is disconnected, and the battery pack is electrically isolated from the external high-voltage load.

[0086] In some embodiments, the bus circuit refers to the main conductive path used to transmit electrical energy between the battery pack and an external high-voltage load (such as a motor controller, DC-DC converter, air conditioning compressor, etc.). The bus circuit typically includes a positive bus (positive bus) and a negative bus (negative bus). The positive bus connects the positive output terminal of the battery pack to the positive input terminal of the load, and the negative bus connects the negative output terminal of the battery pack to the negative input terminal of the load.

[0087] In some embodiments, the controller is further configured to allow the main relay to be disconnected when the transient energy is less than the safe ignition energy and the voltage in the bus circuit is less than a preset safe voltage.

[0088] It should be noted that the system architecture described in the embodiments of this application is for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and does not constitute a limitation on the technical solutions provided in the embodiments of this application. As those skilled in the art will know, with the evolution of system architecture, the technical solutions provided in the embodiments of this application are also applicable to similar technical problems.

[0089] The energy control method provided in this application embodiment can be applied to energy control systems, such as... Figure 2 As shown, the energy control method includes the following steps S201~S204: S201. Obtain the volume concentration of each component gas in the mixed gas in the electrical system, and determine the transient energy in the electrical system.

[0090] In some embodiments, an electrical system refers to an overall network consisting of a power source, electrical equipment, control devices, and connecting wires, capable of transmitting, distributing, storing, and converting electrical energy.

[0091] For example, an electrical system may include a battery pack, a high-voltage bus, relays, bus capacitors, line inductors, balancing circuits, and load devices. The electrical system may generate a flammable gas mixture due to thermal runaway. A key characteristic of an electrical system is the presence of voltage, current, and transient energy stored in capacitors and inductors, which may be released as an arc or spark during relay disconnection or circuit switching.

[0092] In some embodiments, a mixed gas refers to a gas mixture within the electrical system's internal environment consisting of two or more flammable gases and air or other inert gases. During battery thermal runaway, the mixed gas may include hydrogen, carbon monoxide, methane, and organic vapors from the electrolyte.

[0093] In some embodiments, each component gas refers to each individual gas species that constitutes the mixed gas, such as hydrogen, carbon monoxide, methane, ethylene, etc., and each gas is independently referred to as a component.

[0094] In some embodiments, volume concentration refers to the volume fraction of each component gas in the gas mixture, usually expressed as a percentage or parts per million. For example, a hydrogen volume concentration of 4% means that hydrogen accounts for four percent of the total volume of the gas mixture.

[0095] In some embodiments, transient energy refers to the energy released or converted by energy storage elements during the transient process of an electrical system transitioning from one steady state to another. Transient energy includes capacitive energy stored in capacitors and inductive energy stored in inductors. Capacitive energy is determined by the bus capacitor voltage, and inductive energy is determined by the loop current and line inductance.

[0096] In some embodiments, voltage or current signals are acquired in real time by an electrochemical hydrogen sensor, a non-dispersive infrared carbon monoxide sensor, and a catalytic combustion methane sensor installed on the internal housing of the electrical system, and the acquired analog signals are converted into digital quantities by an analog-to-digital converter to obtain the volume concentration of each component gas in the mixed gas.

[0097] In some embodiments, the voltage V across the bus capacitor is acquired by a voltage sampling circuit, the main circuit current I is acquired by a current sampling circuit, and the pre-calibrated bus capacitance value C and line inductance value L are read. Then, the voltage V and capacitance value C are substituted into formula E. cap =0.5 C V 2 We obtain capacitive energy, where E cap To represent capacitive energy, substitute the current I and the inductance L into the formula E. ind =0.5 L I 2Obtaining sensory energy, of which E ind This represents inductive energy, and the capacitive energy is added to the inductive energy to form the transient energy in the electrical system.

[0098] S202. Determine the safe ignition energy from the mapping relationship based on the volume concentration.

[0099] The mapping relationship is used to associate the volume concentration of different component gases in the gas mixture with the corresponding safe ignition energy.

[0100] In some embodiments, the mapping relationship refers to a functional relationship or data correspondence rule used to map the volume concentration of each component gas in a gas mixture to a safe ignition energy threshold. The mapping relationship is not an instantaneous result derived through real-time calculation, but rather a fixed correspondence rule predetermined through experimental calibration, theoretical calculation, or numerical fitting.

[0101] For example, the mapping relationship may include an empirical curve that maps the volume concentration of a single gas to the safe ignition energy of that gas. The empirical curve outputs a minimum value when the gas concentration is near the lower explosive limit or stoichiometric concentration, and outputs a monotonically increasing larger value when the gas concentration is far below the lower explosive limit or far above the stoichiometric concentration. The mapping relationship may also include a multidimensional data table that maps the combination of volume concentrations of two or more combustible gas components to safe ignition energy. Each dimension of the multidimensional data table corresponds to a volume concentration range of a combustible gas component, and each cell in the table stores a pre-calculated or experimentally calibrated safe ignition energy.

[0102] In some embodiments, safe ignition energy refers to the maximum spark energy that the electrical system is allowed to generate in the current mixed gas environment. Exceeding this limit poses a risk of igniting the mixed gas or causing an electric arc explosion.

[0103] In some embodiments, the volume concentration of each component gas in the mixed gas, which is detected in real time, can be used as an index to directly read the safe ignition energy threshold corresponding to the volume concentration by means of a lookup table.

[0104] S203. Determine whether there is a risk of electric arc explosion based on transient energy and safe ignition energy.

[0105] In some embodiments, the risk of arcing and explosion refers to the possibility that when a relay contact in an electrical system separates, a switch is turned off, or a wire is accidentally disconnected, the stored transient energy is released in the form of an arc or spark. If the released energy exceeds the safe ignition energy in the current mixed gas environment, the arc or spark is sufficient to ignite the mixed gas and cause an explosion or fire.

[0106] In some embodiments, if the transient energy is greater than or equal to the safe ignition energy, it is determined that there is a risk of arc explosion; if the transient energy is less than the safe ignition energy, it is determined that there is no risk of arc explosion.

[0107] S204. In situations where there is a risk of electric arc explosion, transient energy in the electrical system shall be suppressed.

[0108] In some embodiments, after the main relay is disconnected, the transient energy remaining in the bus capacitor and line inductance may generate an arc at the break point, and the reverse electromotive force of the inductive load will generate a high-voltage backlash, the energy of which often exceeds the safe ignition energy at the current gas concentration, leading to secondary combustion and explosion.

[0109] In some embodiments, suppression refers to reducing, limiting, consuming, or absorbing transient energy in an electrical system by means of active or passive methods, thereby reducing the transient energy to a level below the safe ignition energy level, thereby eliminating or mitigating the risk of arc explosion.

[0110] In some embodiments, suppressing transient energy in an electrical system may include discharging capacitive energy in the electrical system and dissipating inductive energy in the electrical system. Exemplarily, suppressing transient energy in an electrical system may be implemented by the following steps a1-a3.

[0111] a1. To dissipate inductive energy in an electrical system, where inductive energy is the energy stored in the inductor.

[0112] In some embodiments, inductive energy refers to the energy stored in the surrounding magnetic field of an inductor when it is energized, and the magnitude of the inductive energy is determined by both the inductance and the current flowing through the inductor.

[0113] In some embodiments, an inductor is a component in an electrical system that can convert electrical energy into magnetic field energy and store it, including coils wound on a magnetic core or hollow frame and distributed inductance formed by a layout of wires. An inductor generates an induced electromotive force that opposes the change in current when the current changes.

[0114] In some embodiments, dissipation refers to the process of converting the magnetic field energy stored in an inductor into other forms of energy (mainly heat energy) and dissipating it from the electrical system. Dissipation is different from simple energy transfer, and its purpose is to make the inductive energy no longer capable of generating an electric arc or spark.

[0115] In some embodiments, when a main relay disconnection command is detected or there is a risk of electric arc explosion, the electronic switch in the freewheeling diode circuit connected in parallel across the inductor is closed, so that the inductive energy stored in the inductor forms a closed current loop through the freewheeling diode and the series dissipation resistor. The current in the inductor gradually decays in the form of Joule heat on the dissipation resistor, and the inductive energy is then converted into heat energy and dissipated.

[0116] In some embodiments, the loop current in the electrical system can be reduced to 0 at a second preset rate to dissipate inductive energy in the electrical system.

[0117] In some embodiments, the second preset rate refers to a preset rate of change of the loop current over time, which determines the transition time required for the loop current to drop from its current value to zero.

[0118] In some embodiments, loop current refers to the current flowing through the main circuit of the electrical system or the branch where the inductive load is located. The loop current maintains the operation of the load when the switch is turned on, and generates a back electromotive force due to the continuous current characteristic of the inductive element when the switch is turned off.

[0119] In some embodiments, the loop current value can be acquired in real time through a current sampling circuit, while simultaneously reading a pre-set second preset rate parameter. The required total turn-off time is calculated based on the current loop current value and the second preset rate parameter. The total turn-off time is divided into multiple pulse width modulation (PWM) control cycles, and the duty cycle of the drive signal is gradually reduced within each PWM cycle. When the switch is turned on, the loop current rises; when the switch is turned off, the loop current naturally decays through the freewheeling circuit. As the duty cycle gradually decreases, the switch's on-time becomes shorter, and the average value of the loop current gradually decreases according to the second preset rate, eventually dropping to zero. Throughout the soft turn-off process, the actual value of the loop current is continuously monitored and compared with the theoretical decrease curve corresponding to the second preset rate. The decreasing step size of the PWM duty cycle is dynamically adjusted to ensure that the actual current decrease rate remains consistent with the second preset rate.

[0120] For example, when a relay disconnect command is detected, the freewheeling diode circuit is immediately closed, dissipating the inductive energy through a resistor (e.g., 100Ω / 2W) within 10ms. At this time, the inductive energy in the circuit can be calculated to satisfy the following relationship: E ind_line =0.5·L parasitic ·I peak 2 L parasitic For stray inductance of the line, I peak To disconnect the instantaneous current before the interruption, E ind_lineThis refers to the inductive energy in the circuit. PWM control reduces the loop current to zero at a second preset rate, ensuring that the inductive energy in the circuit is below the safe ignition energy before the relay's mechanical contacts separate. The second preset rate can be 100A / ms.

[0121] a2. To release capacitive energy in an electrical system, where capacitive energy is the energy stored in a capacitor.

[0122] In some embodiments, capacitive energy refers to the energy stored in the internal electric field of a capacitor element when it is in a charging state. The magnitude of capacitive energy is determined by the capacitance of the capacitor and the voltage across the capacitor.

[0123] In some embodiments, a capacitor is a passive component in an electrical system capable of storing charge and establishing an electric field between two plates. Capacitors include specially manufactured capacitor elements and parasitic capacitances generated by circuit layout.

[0124] In some embodiments, discharge refers to the process of releasing the electric field energy stored in the capacitor through a conductive path and converting it into other forms of energy (mainly heat energy). The purpose of discharge is to reduce the voltage across the capacitor, thereby reducing or eliminating the discharge arc energy that may be generated by the capacitor during subsequent circuit switching.

[0125] In some embodiments, a conduction signal can be sent to an electronic switch in the discharge circuit connected across the capacitor, causing a discharge resistor to be connected across the capacitor. The charge stored in the capacitor begins to flow through the discharge resistor, and the current generates Joule heating on the resistor. The electric field energy is gradually converted into heat energy and dissipated, causing the voltage across the capacitor to drop.

[0126] In some embodiments, the discharge of capacitive energy in an electrical system can be achieved through the following steps b1 to b4: b1. Reduce the voltage of the electrical system bus to an intermediate value at a first preset rate. The intermediate value is the midpoint between the bus voltage and the preset safe voltage.

[0127] In some embodiments, the first preset rate refers to a preset rate of change of the bus voltage over time, typically expressed in volts per second. The first preset rate determines the transition time required for the bus voltage to drop from its initial value to an intermediate value.

[0128] In some embodiments, controlling the voltage drop rate can ensure that the equivalent spark energy corresponding to the instantaneous power during the discharge process is always less than the safe ignition energy.

[0129] In some embodiments, a busbar refers to the main conductive path in an electrical system used to collect and distribute electrical energy. It typically includes a positive busbar and a negative busbar, with busbar capacitors connected in parallel between the positive and negative busbars to smooth voltage and provide transient current.

[0130] In some embodiments, voltage refers to the potential difference between the positive and negative terminals of the busbar, and the magnitude of the voltage directly determines the capacitive energy stored in the busbar capacitor.

[0131] In some embodiments, the intermediate value refers to a transition voltage value between the current bus voltage and the preset safety voltage. The intermediate value is greater than the preset safety voltage and less than the current bus voltage, and is the arithmetic mean of the current bus voltage and the preset safety voltage.

[0132] In some embodiments, the preset safety voltage refers to a pre-set upper limit of voltage at which it is assumed that no dangerous arc will occur even if contact separation occurs. For example, the preset safety voltage may be the DC safety extra-low voltage of 60 volts as defined by the International Electrotechnical Commission standard IEC 61140, or 36 volts as specified in a particular industry standard, or an upper limit of safety voltage calculated in reverse based on the minimum ignition energy of the gas environment inside the electrical system.

[0133] In some embodiments, when the bus voltage is high, if it drops directly to the preset safe voltage at a first preset rate, the instantaneous power across the bleeder resistor is extremely high, which may exceed the rated power of the bleeder resistor, causing the resistor to burn out or the solder joint to melt. At the same time, an excessively high voltage drop rate will generate a large displacement current between the bus capacitor and the line distributed inductance. The displacement current may be coupled to the low-voltage control circuit through parasitic parameters, causing logic mis-triggering or device damage.

[0134] b2. Determine the relationship between safe ignition energy and capacitive energy.

[0135] b3. Stop releasing energy when the safe ignition energy is greater than or equal to the capacitive energy.

[0136] In some embodiments, stopping discharge means disconnecting the electronic switch connected across the capacitor in the discharge circuit, so that the discharge resistor is no longer connected in parallel with the capacitor, thereby stopping the capacitor charge from passing through the discharge resistor.

[0137] b4. When the safe ignition energy is less than the capacitive energy, continue to reduce the voltage of the electrical system bus at a first preset rate until the first preset condition is met. The first preset condition is that the safe ignition energy is greater than or equal to the capacitive energy, or the voltage of the bus is less than the preset safe voltage.

[0138] In some embodiments, after performing the first comparison between the safe ignition energy and the capacitive energy, if the safe ignition energy is less than the capacitive energy, it is determined that further discharge is necessary. A pre-stored preset rate parameter and preset safe voltage value are read, and a conduction signal (such as a high-level or PWM signal) is sent to the electronic switch in the discharge circuit connected across the bus capacitor via a general-purpose input / output port. This causes the discharge resistor to reconnect across the bus capacitor, and the bus voltage begins to decrease continuously at a preset rate.

[0139] For example, during the discharge process, the following operations can be repeated at fixed time intervals (e.g., every 10 milliseconds): the current bus voltage value is read through a voltage sampling circuit, and the current remaining capacitive energy is calculated; the current mixed gas concentration is obtained through a gas sensor, and the safe ignition energy is updated from the mapping relationship (because the gas concentration may change over time); the updated safe ignition energy is compared with the current remaining capacitive energy; and it is simultaneously determined whether the current bus voltage is less than a preset safe voltage. If the safe ignition energy is greater than or equal to the capacitive energy obtained from the above comparison, the discharge is immediately stopped and the discharge circuit is disconnected; or if the bus voltage is less than the preset safe voltage, the discharge is also immediately stopped and the discharge circuit is disconnected. As soon as either of the two conditions is met first, the discharge process terminates, and the discharge action is no longer performed.

[0140] a3. Determine the relationship between electrical energy and safe ignition energy. Electrical energy includes capacitive energy, inductive energy, and energy generated by the separation of relay contacts in the electrical system. If the electrical energy is greater than or equal to the safe ignition energy, continue to release the capacitive energy.

[0141] In some embodiments, electrical energy refers to the sum of all energy in an electrical system that can be converted into an electric arc or spark. In this step, electrical energy specifically includes three parts: capacitive energy, inductive energy, and energy generated by the separation of relay contacts.

[0142] In some embodiments, the energy generated by relay contact separation refers to the energy released when an electric arc is formed in the contact gap as the relay contacts transition from a closed state to an open state. The energy is related to factors such as the circuit voltage and current at the moment of contact separation, as well as the contact material and separation speed.

[0143] For example, the energy generated by the separation of relay contacts can be a fixed empirical value calibrated through experiments, a value dynamically estimated based on the current bus voltage and loop current, or a real-time calculated value obtained by integrating the voltage and current waveforms at the moment of contact separation.

[0144] In some embodiments, if the comparison result shows that the electrical energy is greater than or equal to the safe ignition energy, it is determined that the current total electrical energy exceeds the safety threshold in a mixed gas environment, and it is necessary to continue reducing the capacitive energy to decrease the total electrical energy. A signal to remain on (e.g., maintain a high level or maintain PWM output) is sent to the electronic switch in the discharge circuit connected across the bus capacitor via a general-purpose input / output port, causing the discharge resistor to remain in parallel with the bus capacitor. The capacitive energy continues to be converted into heat dissipation through the discharge resistor, and the total electrical energy gradually decreases. The above acquisition and comparison steps are repeated continuously or intermittently during the discharge process until the total electrical energy drops below the safe ignition energy.

[0145] In some embodiments, the mapping relationship in step S202 may be determined based on the following: The first step is to determine the minimum ignition energy of each component gas based on the volume concentration of each component gas in the mixed gas.

[0146] In some embodiments, the minimum ignition energy refers to the lowest spark energy required for each component gas to be ignited and cause combustion or explosion in the current mixed gas environment. The value of the minimum ignition energy exhibits certain characteristics as the concentration of the component gas changes.

[0147] For example, the minimum ignition energy of each of the following gases in the mixed gas—hydrogen, methane, carbon monoxide, ethane, propane, ethylene, and acetylene—is determined as an independent component gas.

[0148] In some embodiments, the minimum ignition energy of a corresponding component gas can be determined based on the volume concentration, most explosive concentration, and lower explosive limit concentration of each component gas.

[0149] In some embodiments, the most explosive concentration refers to the gas volume fraction of the mixture that minimizes the minimum ignition energy near the stoichiometric concentration. For example, hydrogen has a minimum ignition energy as low as 0.019 millijoules at a volume concentration of about 28%, and methane explodes most violently at a volume concentration of about 9.5%.

[0150] In some embodiments, the lower explosive limit (LEB) refers to the lowest volume concentration at which a gas can explode. Below this concentration, the gas is too lean to propagate the flame. For example, the LEB of hydrogen is 4.0%, the LEB of methane is 5.0%, and the LEB of carbon monoxide is 12.5%.

[0151] For example, the minimum ignition energy of a single-component gas at different concentrations can be calculated by satisfying the following relationship:

[0152] in, Represents gas At the current volume concentration The minimum ignition energy below, Indicates the current volume concentration of the gas. This indicates the lower explosive limit concentration. Indicates the most explosive concentration. This represents the ignition energy corresponding to the most explosive concentration. and The curve correction factor can be obtained by performing a minimum ignition energy concentration scan experiment that extends the standards of GB / T 16425 or IEC 60079-20-1 (e.g., =0.8, =5.0), σ represents the attenuation coefficient, used to control the steepness of the curve in the low concentration region. This represents the natural exponential function.

[0153] For example, the minimum ignition energy concentration scan experiment can be conducted under constant temperature and pressure conditions, strictly following standard methods and equipment, to intermittently prepare large quantities of fuel-air mixtures of varying concentrations (e.g., hydrogen from 3% to 75% by volume) across a very low to very high concentration range. The newly prepared gases are then attempted to be ignited using an ignition source of specific energy. The minimum spark energy value required to just ignite the mixture at that concentration is recorded. Measurements are repeated at each concentration, and all data points are plotted on graph paper to obtain a curve. After completing the concentration scan experiment, a complete curve formula is fitted from the scatter plot of experimental data using mathematical methods.

[0154] For example, for the minimum ignition energy of a single-component gas at different concentrations, the relationship between the gas volume concentration and the minimum ignition energy exhibits a "U-shaped" curve characteristic: when the volume concentration of the single-component gas is near the stoichiometric ratio (i.e., the concentration range where combustion is most complete, for example, the volume concentration of hydrogen is about 28% to 30%), the minimum ignition energy reaches the minimum value in the entire concentration range (for hydrogen, it can be as low as about 0.017 mJ), and the gas is most easily ignited by a weak spark; however, when the volume concentration deviates towards the lower explosive limit (e.g., 4% for hydrogen) or the upper explosive limit (e.g., 75% for hydrogen), and further extends towards extremely low or extremely high concentrations, the minimum ignition energy will increase sharply, meaning that a stronger spark is required to ignite the gas, and ignition becomes extremely difficult even after the concentration exceeds the explosive limit range.

[0155] The second step is to determine the safe ignition energy based on the minimum ignition energy of each component gas and the binary interaction coefficient between each pair of component gases, thus obtaining the mapping relationship.

[0156] In some embodiments, the binary interaction coefficient is a dimensionless correction parameter used to characterize the strength of the interaction between two different component gases in a gas mixture. Since there are nonlinear interaction effects in the physicochemical processes such as collisions, diffusion, and heat conduction between the molecules of two different gases when they are mixed, the overall ignition characteristics of the gas mixture are not a simple linear superposition of the ignition characteristics of each component. Therefore, it is necessary to introduce a binary interaction coefficient to correct the mutual influence between the components.

[0157] For example, the determination of safe ignition energy can satisfy the following relationship:

[0158] in, Indicates safe ignition of energy. Indicates the first The mole fraction of each component gas in the total component gas. Indicates the quantity of component gases. Indicates the first At the current concentration of the gas The minimum ignition energy below can be achieved by using The minimum ignition energy is obtained by inputting the above calculation method. This represents a synergy factor (e.g., a value between 0.1 and 0.3), used to correct for nonlinear enhancement effects in multi-component gas mixtures. It represents the binary interaction coefficient, characterizing the cooperative explosion effect between gases.

[0159] In some embodiments, the volume concentrations of the various component gases that may appear in the mixed gas can be divided into multiple discrete concentration combinations according to a preset step size (e.g., taking a discrete point every 1% from 0% to 100% for hydrogen volume concentration, and taking a discrete point every 0.5% from 0% to 20% for methane volume concentration). For each discrete concentration combination, the safe ignition energy corresponding to that discrete concentration combination is calculated and sequentially written into a two-dimensional or multi-dimensional data table to obtain the mapping relationship.

[0160] In some embodiments, a safety factor can be taken for the safe ignition energy, the safety factor can be multiplied by the safe ignition energy to obtain a new safe ignition energy, and then the new safe energy can be written into a table to obtain a mapping relationship, ensuring that even within the sensor error range, the electrical energy is still lower than the safe ignition energy.

[0161] In some embodiments, the solution provided in this application may further include allowing the main relay to be disconnected when the transient energy is less than the safe ignition energy and the voltage in the bus circuit is less than the preset safe voltage.

[0162] In some embodiments, the solution provided in this application may further include switching the active balancing topology circuit in the electrical system to a passive balancing topology circuit when the transient energy is greater than the safe ignition energy.

[0163] In some embodiments, conventional battery management systems maintain the operation of the active balancing chip even when the transient energy exceeds the safe ignition energy. The voltage and current changes generated by these high-frequency switching devices during the switching process can easily form electromagnetic pulses and micro-arcs. Although their energy is only at the millijoule level, it is sufficient to ignite the gas mixture near the most explosive concentration.

[0164] In some embodiments, when the transient energy exceeds the safe ignition energy, the PWM drive signals of all active balancing chips (such as balancing ICs based on flyback converters or switched capacitors) are immediately shut off. The power supply to the converter's switching transistors is cut off to ensure all semiconductor switches are completely off. After the switching transistors are turned off, a static discharge resistor connected in parallel across the switching transistors ensures complete release of the gate charge, preventing false turn-on. Using a relay array or MOSFET switch matrix, the active balancing transformer / capacitor originally connected in parallel across the battery cells is switched to a purely resistive network, such as a ceramic resistor or wire-wound resistor, with the resistance value selected according to the balancing current requirements. The purely resistive network consumes the inter-cell voltage difference only through resistive heating, without switching action or high-frequency electromagnetic radiation; the maximum electrical spark energy it may generate is only at the level of resistive thermal noise (micro-joule level). The passive balancing path is dynamically controlled by the gas volume concentration. When the safe ignition energy is extremely low (e.g., less than 0.1 mJ), passive balancing is cut off by relying on natural pressure difference balance.

[0165] In some embodiments, switching the active equalization topology to the passive equalization topology not only eliminates the potential ignition source of high-frequency switching devices, but also fundamentally changes the energy transfer method (from electromagnetic conversion to pure resistive dissipation).

[0166] In some embodiments, the solution provided in this application may further include cutting off the internal power supply of the electrical system when the transient energy is greater than the safe ignition energy; establishing an external optocoupler isolated power supply, wherein the optocoupler isolated power supply transmits energy through a withstand voltage optocoupler or optical fiber, and transmits the control signals of the electrical system through the optical fiber.

[0167] In some embodiments, the low-voltage system of the battery management system powers the sensors within the pack through an isolated converter. Although voltage isolation is achieved, electrical connections (e.g., common-mode capacitance, leakage current path) still exist. In high-temperature and high-humidity environments, the low-voltage circuit may generate micro-leakage current due to insulation degradation, forming tiny sparks at the connectors (e.g., the induced voltage of the relay coil circuit is released through the low-voltage ground wire).

[0168] In some embodiments, when the transient energy exceeds the safe ignition energy, this application completely disconnects the 5V (sampling chip power supply) and 12V (sensor power supply) power lines from the motherboard to the battery pack via a solid-state relay. This ensures that after disconnection, there is no direct electrical connection (including power lines and signal lines) between all electronic components (voltage sampling lines, temperature sensors, gas sensors) in the battery pack and the motherboard.

[0169] In some embodiments, after the internal power supply is cut off, an external optocoupler-isolated power supply circuit is established. This circuit is powered by an independent external power source (such as a vehicle 12V battery with additional isolation), and the energy is transmitted through a high-voltage optocoupler (e.g., isolation voltage ≥5000Vrms) or optical fiber. For gas sensors that must operate, optical fiber power is used, with the sampling optical signal introduced only through the optical fiber, or an optical sensor powered by an independent battery is used. For single-cell voltage sampling, a fully isolated sampling method is adopted. The signal after voltage division by the sampling resistor is transmitted in isolation through a linear optocoupler (such as HCPL-7840) or a digital optocoupler (such as Si8421), and the primary-side drive power supply of the optocoupler is completely independent of the battery pack.

[0170] In some embodiments, all control signals (such as relay control) are replaced with fiber optic transmission (such as Avago's optically isolated driver), completely eliminating the electrical connection of the control loop. The reference ground of all circuits within the battery pack is forcibly separated from the vehicle ground via a high-impedance connection / disconnect controllable switch, creating an electrical island within the pack. Even in the event of an internal short circuit, current cannot flow through the weak current circuit to generate an external discharge spark.

[0171] In some embodiments, by cutting off the active power supply and introducing a completely electrical-free transmission method using optocouplers / fibers, deep decoupling of the internal chemical environment of the battery pack from the external electrical system is achieved. This not only eliminates the risk of minute sparks but also establishes an inherently safe physical isolation boundary, ensuring that even in extreme cases (such as electrolyte vapor corroding connectors), an explosive atmosphere will not be ignited through a weak electrical circuit.

[0172] For example, Figure 3 This is a schematic flowchart illustrating another energy control method provided by the present invention. Figure 3 As shown, the process involves the following steps: Step S1: Monitor the state of the gas mixture. Step S2: Query the safe ignition energy. Step S3: Calculate the transient energy. Step S4: Determine if the transient energy is greater than the safe ignition energy. If not, proceed to Step S5: Allow the main relay to disconnect; if yes, proceed to Step S6: Prevent the main relay from disconnecting.

[0173] For example, Figure 4 This is a schematic flowchart illustrating a transient energy suppression method provided by the present invention. Figure 4As shown, capacitive energy discharge and inductive energy dissipation occur simultaneously. During capacitive energy discharge, the capacitive energy is calculated in real time, and then it is determined whether the capacitive energy is greater than the safe ignition energy. If not, discharge stops; if so, it is determined whether the bus voltage is less than the preset safe voltage. If not, discharge continues; if so, discharge stops. After discharging stops, electrical energy is calculated. Then, it is determined whether the electrical energy is less than the safe ignition energy. If so, the electrical system is safe and without risk; if not, discharge continues.

[0174] The above primarily describes the solutions provided by the embodiments of this application from a methodological perspective. To achieve the above functions, the energy control device includes hardware structures and / or software modules corresponding to the execution of each function. Those skilled in the art should readily recognize that, in conjunction with the units and algorithm steps of the various examples described in the embodiments disclosed herein, this application can be implemented in hardware or a combination of hardware and computer software. Whether a function is executed in hardware or by computer software driving hardware depends on the specific application and design constraints of the technical solution. Experts may use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0175] like Figure 5 As shown, the energy control device 1000 includes an acquisition module 1001 and a processing module 1002. The acquisition module 1001 is used to acquire the volume concentration of each component gas in the mixed gas of the electrical system and determine the transient energy in the electrical system. The processing module 1002 is used to determine the safe ignition energy from a mapping relationship based on the volume concentration, wherein the mapping relationship is used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy. The processing module 1002 is also used to determine whether there is a risk of electric arc explosion based on the transient energy and the safe ignition energy. The processing module 1002 is also used to suppress the transient energy in the electrical system when there is a risk of electric arc explosion.

[0176] Furthermore, transient energy includes capacitive energy and inductive energy. The processing module 1002 is specifically used to discharge capacitive energy in the electrical system, which is the energy stored in the capacitor; and to dissipate inductive energy in the electrical system, which is the energy stored in the inductor.

[0177] Furthermore, the processing module 1002 is specifically used to reduce the voltage of the bus of the electrical system to an intermediate value at a first preset rate, the intermediate value being the median between the bus voltage and the preset safe voltage; determine the relationship between the safe ignition energy and the capacitive energy; and stop the discharge when the safe ignition energy is greater than or equal to the capacitive energy.

[0178] Furthermore, the processing module 1002 is also used to continue reducing the voltage of the electrical system bus at a first preset rate when the safe ignition energy is less than the capacitive energy, until a first preset condition is met. The first preset condition is that the safe ignition energy is greater than or equal to the capacitive energy, or the voltage of the bus is less than a preset safe voltage.

[0179] Furthermore, the processing module 1002 is also used to determine the magnitude relationship between electrical energy and safe ignition energy, wherein the electrical energy includes capacitive energy, inductive energy and energy generated by the separation of relay contacts in the electrical system; if the electrical energy is greater than or equal to the safe ignition energy, the capacitive energy continues to be discharged.

[0180] Furthermore, the processing module 1002 is specifically used to reduce the loop current in the electrical system to 0 at a second preset rate.

[0181] Furthermore, the mapping relationship is determined based on the following method: the minimum ignition energy of each component gas is determined based on the volume concentration of each component gas in the mixed gas; the safe ignition energy is determined based on the minimum ignition energy of each component gas and the binary interaction coefficient between each pair of component gases, thus obtaining the mapping relationship.

[0182] Furthermore, the processing module 1002 is specifically used to determine the minimum ignition energy of the corresponding component gas based on the volume concentration, most explosive concentration and lower explosive limit concentration of each component gas.

[0183] Furthermore, the processing module 1002 is also used to allow the main relay to be disconnected when the transient energy is less than the safe ignition energy and the voltage in the bus circuit is less than the preset safe voltage.

[0184] Furthermore, the processing module 1002 is also used to cut off the internal power supply of the electrical system; establish an external optocoupler isolated power supply, which transmits energy through a withstand voltage optocoupler or optical fiber, and transmits the control signals of the electrical system through optical fiber.

[0185] like Figure 6 As shown, the electronic device 1100 includes, but is not limited to, a processor 1101 and a memory 1102.

[0186] The memory 1102 described above is used to store the executable instructions of the processor 1101. It is understood that the processor 1101 is configured to execute instructions to implement the energy control method in the above embodiments.

[0187] It should be noted that those skilled in the art will understand that Figure 6 The electronic device structure shown does not constitute a limitation on electronic device 1100; electronic device 1100 may include, but is not limited to, other electronic devices. Figure 6This may indicate more or fewer components, or combinations of certain components, or different component arrangements.

[0188] Processor 1101 is the control center of electronic device 1100. It connects various parts of the electronic device via various interfaces and lines. By running or executing software programs and / or modules stored in memory 1102, and by calling data stored in memory 1102, it performs various functions and processes data of electronic device 1100, thereby providing overall monitoring of electronic device 1100. Processor 1101 may include one or more processing units. Optionally, processor 1101 may integrate an application processor and a modem processor. The application processor mainly handles the operating system, user interface, and applications, while the modem processor mainly handles wireless communication. It is understood that the modem processor may not be integrated into processor 1101.

[0189] The memory 1102 can be used to store software programs and various data. The memory 1102 may primarily include a program storage area and a data storage area. The program storage area may store the operating system, application programs required by at least one functional module (such as a determination unit, processing unit, etc.), etc. Furthermore, the memory 1102 may include high-speed random access memory, and may also include non-volatile memory, such as at least one disk storage device, flash memory device, or other volatile solid-state storage device.

[0190] In an exemplary embodiment, a computer-readable storage medium including instructions is also provided, such as a memory 1102 including instructions, which can be executed by a processor 1101 of an electronic device 1100 to implement the energy control method in the above embodiments.

[0191] In actual implementation, Figure 5 The functions of the acquisition module 1001 and the processing module 1002 can both be provided by Figure 6 The processor 1101 calls the computer program stored in the memory 1102 to implement the process. The specific execution process can be found in the method section of the previous embodiment, and will not be repeated here.

[0192] Optionally, the computer-readable storage medium may be a non-transitory computer-readable storage medium, such as a read-only memory (ROM), random access memory (RAM), CD-ROM, magnetic tape, floppy disk, and optical data storage device.

[0193] In an exemplary embodiment, this application also provides a computer program product including one or more instructions, which can be executed by the processor 1101 of the electronic device 1100 to complete the energy control method in the above embodiments.

[0194] It should be noted that when one or more instructions in the computer-readable storage medium or computer program product are executed by the processor of an electronic device, they implement the various processes of the above method embodiments and achieve the same technical effect as the above method. To avoid repetition, they will not be described again here.

[0195] Through the above description of the embodiments, those skilled in the art can clearly understand that, for the sake of convenience and brevity, only the division of the above functional modules is used as an example. In actual applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above.

[0196] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of modules or units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another apparatus, or some features may be ignored or not executed. Furthermore, the mutual coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0197] The units described as separate components may or may not be physically separate. A component shown as a unit can be one or more physical units; that is, it can be located in one place or distributed in multiple different locations. Some or all of the classified units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0198] Furthermore, the functional units in the various embodiments of this application 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. The integrated unit can be implemented in hardware or as a software functional unit.

[0199] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a readable storage medium. Based on this understanding, the technical solution of the embodiments of this application, essentially, or the part that contributes to the prior art, or a complete or partial classification of the technical solution, can be embodied in the form of a software product. This software product is stored in a storage medium and includes several instructions to cause a device (which may be a microcontroller, chip, etc.) or processor to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, ROM, RAM, magnetic disks, or optical disks.

[0200] The above embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention.

Claims

1. An energy control system, characterized in that, include: Gas concentration sensor and controller; The gas concentration sensor is used to determine the volume concentration of each component gas in the electrical system; The controller is configured to obtain the volume concentration of each component gas in the mixed gas in the electrical system from the gas concentration sensor, and determine the safe ignition energy from a mapping relationship based on the volume concentration. The mapping relationship is used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy. The controller is also configured to determine transient energy in the electrical system, the transient energy including capacitive energy in the capacitor and inductive energy in the inductor; The controller is also used to determine whether there is a risk of electric arc explosion based on the transient energy and the safe ignition energy; In situations where there is a risk of electric arc explosion, transient energy in the electrical system is suppressed.

2. The energy control system according to claim 1, characterized in that, The system also includes capacitors, inductors, dissipation resistors, and bleeder resistors; The capacitor is used to store energy to obtain capacitive energy; The inductor is used to store energy and obtain inductive energy; The bleeder resistor is used to bleed the capacitive energy in the electrical system. The dissipation resistor is used to dissipate the inductive energy in the electrical system.

3. The energy control system according to claim 1, characterized in that, The system also includes a main relay; The main relay, the capacitor, and the inductor constitute a bus circuit; The controller is also configured to allow the main relay to be disconnected when the transient energy is less than the safe ignition energy and the voltage in the bus circuit is less than the preset safe voltage.

4. An energy control method, characterized in that, The method includes: The volume concentrations of each component gas in the mixed gas in the electrical system are obtained, and the transient energy in the electrical system is determined. The safe ignition energy is determined from the mapping relationship based on the volume concentration, wherein the mapping relationship is used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy; The presence of an arc explosion risk is determined based on the transient energy and the safe ignition energy. In situations where there is a risk of electric arc explosion, transient energy in the electrical system is suppressed.

5. The energy control method according to claim 4, characterized in that, The transient energy includes capacitive energy and inductive energy. Suppressing the transient energy in the electrical system in the event of an arc explosion risk includes: The capacitive energy in the electrical system is discharged, and the capacitive energy is the energy stored in the capacitor; The inductive energy in the electrical system is dissipated, and the inductive energy is the energy stored in the inductor.

6. The energy control method according to claim 5, characterized in that, The method of releasing capacitive energy in the electrical system based on the safe ignition energy includes: The voltage of the busbar of the electrical system is reduced to an intermediate value at a first preset rate, the intermediate value being the median value between the voltage of the busbar and the preset safe voltage; Determine the relationship between the safe ignition energy and the capacitive energy; When the safe ignition energy is greater than or equal to the capacitive energy, the discharge is stopped.

7. The energy control method according to claim 6, characterized in that, The method further includes: If the safe ignition energy is less than the capacitive energy, the voltage of the bus of the electrical system continues to decrease at a first preset rate until a first preset condition is met. The first preset condition is that the safe ignition energy is greater than or equal to the capacitive energy, or the voltage of the bus is less than the preset safe voltage.

8. The energy control method according to claim 5, characterized in that, The method further includes: Determine the relationship between electrical energy and the safe ignition energy, wherein the electrical energy includes the capacitive energy, the inductive energy, and the energy generated by the separation of relay contacts in the electrical system; If the electrical energy is greater than or equal to the safe ignition energy, the capacitive energy continues to be released.

9. The energy control method according to claim 5, characterized in that, The dissipation of inductive energy in the electrical system based on the safe ignition energy includes: The loop current in the electrical system is reduced to 0 at a second preset rate.

10. The energy control method according to claim 4, characterized in that, The mapping relationship is determined based on the following method: The minimum ignition energy of each component gas is determined based on the volume concentration of each component gas in the mixed gas. The safe ignition energy is determined based on the minimum ignition energy of each component gas and the binary interaction coefficient between every two component gases, thus obtaining the mapping relationship.

11. The energy control method according to claim 10, characterized in that, The determination of the minimum ignition energy of each component gas based on the volume concentration of each component in the mixed gas includes: The minimum ignition energy of the corresponding component gas is determined based on the volume concentration, most explosive concentration, and lower explosive limit concentration of each component gas.

12. The energy control method according to claim 4, characterized in that, The method further includes: The main relay may be disconnected if the transient energy is less than the safe ignition energy and the voltage in the bus circuit is less than the preset safe voltage.

13. The energy control method according to claim 4, characterized in that, In cases where there is a risk of electric arc explosion, the method further includes: Disconnect the internal power supply to the electrical system; An external optically isolated power supply is established, wherein the optically isolated power supply transmits energy through a withstand voltage optical coupler or optical fiber, and transmits the control signals of the electrical system through the optical fiber.

14. An energy control device, characterized in that, The energy control device includes an acquisition module and a processing module; The acquisition module is used to acquire the volume concentration of each component gas in the mixed gas in the electrical system and to determine the transient energy in the electrical system. The processing module is used to determine the safe ignition energy from the mapping relationship based on the volume concentration, wherein the mapping relationship is used to associate the volume concentration of different component gases in the mixed gas with the corresponding safe ignition energy. The processing module is also used to determine whether there is a risk of electric arc explosion based on the transient energy and the safe ignition energy; The processing module is also used to suppress transient energy in the electrical system in the event of an arc explosion risk.

15. A vehicle, characterized in that, The vehicle employs the energy control method described in any one of claims 4-13 for energy control of its electrical system.

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