Intelligent liquid adding device for lead-acid storage battery

Abstract

The application discloses a kind of lead-acid battery intelligent liquid adding device, comprising: host computer, execution module and at least one liquid adding unit interface are arranged on host computer;At least one liquid adding unit, detachably connected on the liquid adding unit interface of host computer and with host computer communication connection;Liquid adding unit is equipped with fixed module and sensing module;Control module is set on host computer, the control module is used to control liquid adding logic, the control module is according to the detection data of sensing module, through execution module and liquid adding unit realizes the dynamic adjustment of battery electrolyte parameter.The application can greatly improve detection and liquid adding precision: solve the precision problem of traditional single parameter control, through sensing module synchronous detection electrolyte level, density, temperature and other multi-dimensional parameters, avoid the misjudgment of mechanical float affected by environmental vibration, electrolyte viscosity, while eliminating the electrolyte mixing error between batteries when using hydrometer continuously.

Description

Technical Field

[0001] This invention relates to the field of battery technology, and more specifically to an intelligent lead-acid battery electrolyte filling device. Background Technology

[0002] Lead-acid batteries are widely used in electric vehicles, energy storage systems, and other fields. The stability of their electrolyte level and density directly affects battery performance and lifespan. During use, the electrolyte level in lead-acid batteries drops due to evaporation and chemical reactions, requiring the periodic addition of distilled water or demineralized water to maintain normal battery performance and lifespan. Current automatic electrolyte filling devices mostly use single-parameter control, such as floats or pressure sensors, but these methods have the following problems: Insufficient accuracy: Traditional mechanical structures (such as buoys) are easily affected by environmental vibration or electrolyte viscosity, leading to misjudgment. When measuring manually, hydrometers are generally used, which have the problem of measurement error due to the mixing of electrolyte between batteries when measuring continuously. Summary of the Invention

[0003] In view of this, the present invention provides an intelligent lead-acid battery filling device to solve the problem of measurement error in existing automatic filling devices.

[0004] This invention provides an intelligent lead-acid battery electrolyte filling device, comprising: The host computer is equipped with an execution module and at least one liquid dispensing unit interface, and the execution module is used to perform liquid dispensing operations. At least one electrolyte filling unit is provided, which is detachably connected to the electrolyte filling unit interface of the host and communicates with the host; the electrolyte filling unit is equipped with a fixing module and a sensing module, the fixing module is used to fix it to the electrolyte filling port of the battery, and the sensing module is used to detect the electrolyte status of the battery. The control module is located on the host and is used to control the electrolyte filling logic. Based on the detection data of the sensor module, the control module dynamically adjusts the electrolyte parameters of the battery through the execution module and the electrolyte filling unit.

[0005] In one optional implementation, the fixing module includes: Retractable stopcock; A mechanical adjustment mechanism is mounted on a retractable rotary valve, and the controlled end of the mechanical adjustment mechanism is connected to the output end of the control module; The identification unit is located at the lower part of the retractable valve, and its output is connected to the input of the control module. The identification unit obtains the position and size information of the battery filler neck through image recognition, laser positioning or infrared sensing, and feeds the information back to the control module. The control module drives the mechanical adjustment mechanism to adjust the size of the retractable valve.

[0006] In one optional embodiment, the sensing module is a multi-parameter sensor module, which includes at least one of a liquid level sensor, a temperature sensor, a density sensor, an ultrasonic sensor, a conductivity sensor, or a pressure sensor.

[0007] In one optional implementation, the execution module includes: Water supply interface, for connecting to a water source; Electrolyte interface, for connecting to the electrolyte source; The main delivery pipe is where the output ends of the water supply interface and the electrolyte interface converge. A peristaltic pump is installed on the main delivery pipe; At least one conduit, one end of which is connected to the main delivery pipe and the other end of which is connected to the liquid dispensing unit interface; A flow control assembly is disposed on each of the aforementioned conduits; A mixing unit is installed on the main delivery pipe. The mixing unit is used to mix the electrolyte and distilled water in a preset ratio according to the real-time parameters detected by the sensor module to generate an electrolyte of target concentration.

[0008] In one optional embodiment, the liquid filling unit interface is provided with multiple liquid filling units, and the conduit is provided with multiple conduits, each conduit being connected to one liquid filling unit interface.

[0009] In one optional implementation, the control module has a built-in processor and storage unit, pre-stores a database of liquid filling parameters for at least one battery model, and performs multi-dimensional analysis of the detection data from the sensor module through a parameter fusion algorithm to generate a liquid filling strategy.

[0010] In one optional embodiment, the liquid dispensing unit includes a liquid dispensing unit body, which is provided with a branch pipe, a delivery chamber and a liquid dispensing nozzle. The branch pipe is connected to the liquid dispensing unit interface, and the branch pipe, the delivery chamber and the liquid dispensing nozzle are connected to each other. The liquid dispensing nozzle is an adaptive liquid dispensing nozzle, and the controlled end of the liquid dispensing nozzle is connected to the output end of the control module.

[0011] In one alternative implementation, it further includes: A storage unit, wherein the storage unit is provided with a host storage compartment and at least one liquid dispensing unit storage compartment; The liquid addition unit is equipped with a sensor module storage space and / or a heat dissipation and drying hole.

[0012] In one alternative implementation, it further includes: The liquid storage module includes a first liquid storage tank and a second liquid storage tank, which are respectively connected to the execution module. The first liquid storage tank is connected to a distilled water or demineralized water pipeline in the plant. The first liquid storage tank is used to store distilled water / demineralized water, and the second liquid storage tank is used to store electrolyte; and / or The safety protection module is equipped with a liquid level over-limit detection, pressure abnormality alarm, overcurrent protection, and anti-crystallization and blockage unit. When an abnormal state is detected, it automatically cuts off the liquid addition process and triggers an audible and visual warning; and / or The self-cleaning module cleans the actuator and liquid filling unit regularly or as needed through ultrasonic cleaning, backflushing, or chemical cleaning.

[0013] The technical solution of this invention has the following advantages: The aforementioned intelligent electrolyte filling device for lead-acid batteries significantly improves the accuracy of detection and filling: it solves the problem of insufficient accuracy in traditional single-parameter (buoy / pressure sensor) control by simultaneously detecting multiple parameters such as electrolyte level, density, and temperature through a sensing module. This avoids misjudgments caused by environmental vibrations and electrolyte viscosity affecting mechanical buoys, and eliminates mixing errors between batteries when using a hydrometer for continuous manual measurement. The control module dynamically adjusts the filling logic based on real-time sensor data, precisely controlling the filling volume and ensuring that electrolyte parameters are always within the optimal range, significantly reducing the error rate.

[0014] The aforementioned intelligent lead-acid battery filling device enhances the device's versatility and adaptability: the filling unit 200 adopts a detachable design, and the fixed module can be adapted to the filling ports of different models and specifications of batteries, solving the problem of poor versatility of traditional devices, eliminating the need to configure separate equipment for different batteries, and reducing maintenance costs.

[0015] The aforementioned intelligent lead-acid battery filling device can improve filling efficiency and automation: the main unit supports the connection of multiple filling units, and the control module realizes the synchronous filling operation of multiple sets of batteries, replacing the tedious process of manually adding liquid one by one, and greatly improving maintenance efficiency.

[0016] The aforementioned intelligent lead-acid battery filling device can automatically detect and add electrolyte throughout the entire process, reducing human error and avoiding the impact of overfilling or underfilling on battery performance.

[0017] The aforementioned intelligent electrolyte filling device for lead-acid batteries can effectively extend the service life of batteries by dynamically adjusting the electrolyte level, density, temperature and other core parameters in real time to maintain the stability of the electrolyte state. This addresses the battery performance degradation caused by electrolyte abnormalities at its root, significantly extending the cycle life and service life of lead-acid batteries. It is especially suitable for scenarios with high battery reliability requirements, such as electric vehicles and energy storage systems.

[0018] The main unit communicates and works in tandem with the electrolyte filling unit. The control module can adjust its strategy in real time based on dynamic changes in the electrolyte, such as evaporation and chemical reactions, during battery use. Compared to the traditional fixed electrolyte filling method, this better matches the actual operating conditions of the battery. This lays the foundation for subsequent intelligent operation and maintenance functions such as remote monitoring and data traceability, facilitating the management of the battery's entire life cycle. Attached Figure Description

[0019] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the main unit of an intelligent lead-acid battery liquid filling device provided by the present invention; Figure 2 A schematic diagram of the filling unit of an intelligent lead-acid battery filling device provided by the present invention; Figure 3 A schematic diagram of the storage unit of an intelligent lead-acid battery filling device provided by the present invention; Figure 4 This is a schematic diagram of the structure of the liquid filling unit storage space of an intelligent liquid filling device for lead-acid batteries provided by the present invention; Figure 5 This is a schematic diagram of the mechanical adjustment mechanism of an intelligent lead-acid battery liquid filling device provided by the present invention.

[0021] Explanation of reference numerals in the attached figures: 100. Main unit; 101. Main unit body; 102. Peristaltic pump; 103. Solenoid valve; 104. Battery module; 105. AI chip; 106. Conduit; 107. PLC controller; 108. Communication module; 109. Water supply interface; 110. Electrolyte interface; 111. Liquid addition unit interface; 112. Proportioning unit; 113. First wireless transmission module. 200. Liquid filling unit; 201. Identification unit; 202. Capacitive probe; 203. Density sensor; 204. Ultrasonic sensor; 205. Ultrasonic cleaning device; 206. Second wireless transmission module; 207. Temperature sensor; 208. Conductivity sensor; 209. Mechanical adjustment mechanism; 2091. Airbag; 210. Telescopic valve; 211. Sealing strip; 212. Pressure sensor; 213. Liquid filling nozzle; 214. Branch pipe. 300, storage unit; 301, host storage location; 302, liquid filling unit storage location; 3021, thread; 3022, sensor module storage location; 3023, heat dissipation and drying hole. 400. Control module; 401. Acquisition module; 402. Analysis module; 403. Airbag adjustment module; 404. Wireless communication module. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Lead-acid batteries are widely used in electric vehicles, energy storage systems, and other fields. The stability of their electrolyte level and density directly affects battery performance and lifespan. During use, the electrolyte level in lead-acid batteries drops due to evaporation and chemical reactions, requiring the periodic addition of distilled water or demineralized water to maintain normal battery performance and lifespan. Current automatic electrolyte filling devices mostly use single-parameter control, such as floats or pressure sensors, but these methods have the following problems: 1. Insufficient accuracy: Traditional mechanical structures (such as buoys) are easily affected by environmental vibration or electrolyte viscosity, leading to misjudgment. When measuring manually, hydrometers are generally used. However, when measuring batteries continuously, there is a problem of measurement error due to the mixing of electrolytes between batteries.

[0024] 2. Poor adaptability: Existing devices have difficulty controlling liquid level and density simultaneously, and cannot dynamically adjust the amount of liquid added according to temperature changes.

[0025] 3. Complex maintenance: Adding electrolyte to multiple battery packs requires individual operation, resulting in low efficiency.

[0026] 4. Large error in manual electrolyte addition: Traditional electrolyte addition methods are mostly manual, which has the following problems: First, it is impossible to accurately detect the actual electrolyte level in the battery, which can easily lead to overfilling or underfilling; second, the position and size of the electrolyte inlet vary for different models and specifications of batteries, resulting in poor versatility; third, the electrolyte addition process is cumbersome, and manual operation is inefficient and prone to errors.

[0027] Based on this, the present invention provides an intelligent electrolyte filling device for lead-acid batteries. This device integrates intelligent sensing, automatic adjustment, and data traceability functions to achieve dynamic balance of electrolyte parameters during battery charging and discharging. Its main structure includes a host unit, at least one electrolyte filling unit, and a control module. The host unit is configured with an interface between the execution module and the electrolyte filling unit. The electrolyte filling unit is connected to the host unit via an acid- and alkali-resistant hose and establishes wireless communication. The control module drives the electrolyte filling logic based on multi-sensor data, and can adapt to the electrolyte filling requirements of different battery models.

[0028] According to an embodiment of the present invention, in a first aspect, a smart lead-acid battery electrolyte filling device is provided, combined with... Figures 1 to 5 As shown, it includes a main unit 100, a liquid dispensing unit 200, and a control module 400.

[0029] The host 100 is equipped with an execution module and at least one liquid addition unit interface 111. The execution module is used to perform liquid addition operations.

[0030] At least one electrolyte filling unit 200 is provided. The electrolyte filling unit 200 is detachably connected to the electrolyte filling unit interface 111 of the host 100 and communicates with the host 100. The electrolyte filling unit 200 is equipped with a fixing module and a sensing module. The fixing module is used to fix it to the electrolyte filling port of the battery, and the sensing module is used to detect the electrolyte status of the battery.

[0031] The control module 400 is mounted on the main unit 100. The control module controls the electrolyte filling logic. Based on the detection data from the sensor module, the control module dynamically adjusts the parameters of the battery electrolyte through the execution module and the electrolyte filling unit 200. These parameters include the electrolyte level, density, and temperature.

[0032] The aforementioned intelligent electrolyte filling device for lead-acid batteries significantly improves the accuracy of detection and filling: it solves the problem of insufficient accuracy in traditional single-parameter (buoy / pressure sensor) control by simultaneously detecting multiple parameters such as electrolyte level, density, and temperature through a sensing module. This avoids misjudgments caused by environmental vibrations and electrolyte viscosity affecting mechanical buoys, and eliminates mixing errors between batteries when using a hydrometer for continuous manual measurement. The control module dynamically adjusts the filling logic based on real-time sensor data, precisely controlling the filling volume and ensuring that electrolyte parameters are always within the optimal range, significantly reducing the error rate.

[0033] The aforementioned intelligent lead-acid battery filling device enhances the device's versatility and adaptability: the filling unit 200 adopts a detachable design, and the fixed module can be adapted to the filling ports of different models and specifications of batteries, solving the problem of poor versatility of traditional devices, eliminating the need to configure separate equipment for different batteries, and reducing maintenance costs.

[0034] The aforementioned intelligent lead-acid battery filling device can improve filling efficiency and automation: the main unit supports the connection of multiple filling units, and the control module realizes the synchronous filling operation of multiple sets of batteries, replacing the tedious process of manually adding liquid one by one, and greatly improving maintenance efficiency.

[0035] The aforementioned intelligent lead-acid battery filling device can automatically detect and add electrolyte throughout the entire process, reducing human error and avoiding the impact of overfilling or underfilling on battery performance.

[0036] The aforementioned intelligent electrolyte filling device for lead-acid batteries can effectively extend the service life of batteries by dynamically adjusting the electrolyte level, density, temperature and other core parameters in real time to maintain the stability of the electrolyte state. This addresses the battery performance degradation caused by electrolyte abnormalities at its root, significantly extending the cycle life and service life of lead-acid batteries. It is especially suitable for scenarios with high battery reliability requirements, such as electric vehicles and energy storage systems.

[0037] The main unit communicates and works in tandem with the electrolyte filling unit. The control module can adjust its strategy in real time based on dynamic changes in the electrolyte, such as evaporation and chemical reactions, during battery use. Compared to the traditional fixed electrolyte filling method, this better matches the actual operating conditions of the battery. This lays the foundation for subsequent intelligent operation and maintenance functions such as remote monitoring and data traceability, facilitating the management of the battery's entire life cycle.

[0038] Different models and specifications of batteries have varying positions and sizes of filling ports, making current filling devices incompatible with different battery specifications and lacking versatility. To address this issue, in some embodiments, the fixing module includes a retractable valve 210, a mechanical adjustment mechanism 209, and an identification unit 201. The mechanical adjustment mechanism 209 is mounted on the retractable valve 210, and its controlled end is connected to the output of the control module. The identification unit 201 is located at the lower part of the retractable valve 210, and its output is connected to the input of the control module. The identification unit 201 acquires the position, shape, and size information of the battery filling port through image recognition, laser positioning, or infrared sensing, and feeds this information back to the control module. The control module then drives the mechanical adjustment mechanism 209 to adjust the size of the retractable valve 210. Specifically, the identification unit 201 can be a camera. This embodiment can automatically identify and accurately adapt to the electrolyte filling ports of different models and specifications of batteries, effectively solving the problem of poor universality of traditional filling devices. It eliminates the need for manual adjustment of adaptation parameters, reducing operational complexity and reliance on manual labor. It is applicable to a variety of battery specifications, improving universality and adaptability. At the same time, precise filling port docking can reduce the risk of electrolyte leakage, ensuring the sealing and safety of the filling process, further enhancing the practicality and reliability of the device, enabling it to be widely used in filling scenarios of various lead-acid batteries such as electric vehicles and energy storage systems.

[0039] The mechanical adjustment mechanism 209 specifically includes an airbag 2091 and an airbag control unit 215. The airbag 2091 is positioned around the retractable valve 210. When the airbag 2091 inflates, it exerts a radial compressive force on the retractable valve 210, causing the valve to contract radially and reduce its opening. When the airbag 2091 deflates, the retractable valve 210 expands radially under its own elastic force, increasing its opening.

[0040] The control module 400 includes a data acquisition module 401, an analysis module 402, an airbag adjustment module 403, and a wireless communication module 404. The output of the identification unit 201 is connected to the input of the data acquisition module 401. The analysis module 402 controls the airbag adjustment module 403 based on the data acquired by the data acquisition module 401. The airbag adjustment module 403 controls the inflation or deflation of the airbag 2091 and can control the inflation or deflation amount. When the identification unit 201 identifies the battery filler neck information, it feeds back the detection information to the data acquisition module 401, which then feeds it back to the analysis module 402. The analysis module 402 confirms the size of the battery filler neck. When the filler neck is confirmed to be large, the airbag adjustment module 403 controls the airbag 2091 to deflate; when the filler neck is confirmed to be small, the airbag adjustment module 403 controls the airbag 2091 to inflate. Therefore, the mechanical adjustment structure can adjust the size of the retractable valve 210. That is, when encountering battery filler necks of different sizes, it can adjust itself according to the size of the battery filler neck. When the position is sufficient, the retractable valve 210 is tightened to ensure airtightness.

[0041] Furthermore, a sealing strip 211 is provided at the bottom of the side wall of the retractable valve 210, which can be sealed when the retractable valve 210 is installed in the battery.

[0042] In some embodiments, the sensing module is a multi-parameter sensor module, which includes at least one of a liquid level sensor, a temperature sensor 207, a density sensor 203, an ultrasonic sensor 204, a conductivity sensor 208, or a pressure sensor 212.

[0043] The sensing module enables multi-dimensional, real-time, and accurate monitoring of the electrolyte state and the process of adding electrolyte to lead-acid batteries. The level sensor dynamically tracks changes in the electrolyte level, ensuring the amount added accurately matches the battery's needs and preventing overflow due to excessively high levels or impact on battery performance due to excessively low levels. Ultrasonic sensors and integrated level sensors measure the electrolyte level. Temperature sensors monitor the electrolyte temperature in real time; combining this data allows for accurate determination of whether electrolyte addition is needed and the required amount. Density sensors quickly detect electrolyte density, ensuring the electrolyte concentration meets standards after addition, thus protecting the battery's electrochemical performance and lifespan. Conductivity sensors reflect the purity and ion concentration of the electrolyte, providing data support for electrolyte quality control. Density and conductivity sensors determine the electrolyte concentration and state. Pressure sensors monitor the sealing pressure during the addition process, ensuring the sealing and safety of the addition system. Through multi-parameter collaborative monitoring, the sensing module can provide the control module with comprehensive decision-making basis, realize intelligent closed-loop control of the liquid addition process, further improve the automation level and liquid addition quality of the device, and reduce the risk of battery failure caused by improper liquid addition.

[0044] Furthermore, both the sensing module and the liquid filling unit are detachable and replaceable to accommodate different battery models.

[0045] In some embodiments, the execution module includes a water supply interface 109, an electrolyte interface 110, a delivery main pipe, a peristaltic pump 102, a conduit 106, and a proportioning unit 112. The water supply interface 109 is located at the end of the main body 101 and is connected to a water source. The electrolyte interface 110 is located at the end of the main body 101 and is connected to an electrolyte source. The output ends of the water supply interface 109 and the electrolyte interface 110 converge at the delivery main pipe. The peristaltic pump 102 is mounted on the delivery main pipe. At least one conduit 106 is provided, with one end connected to the delivery main pipe and the other end connected to the liquid addition unit interface 111. A flow control component is mounted on each conduit 106. The proportioning unit 112 is mounted on the delivery main pipe and is used to mix the electrolyte and distilled water according to a preset ratio based on real-time parameters detected by the sensor module to generate an electrolyte of target concentration, solving the problem that traditional devices cannot dynamically adapt to concentration changes.

[0046] In this embodiment, the proportioning unit 112 dynamically adjusts the mixing ratio based on real-time data such as electrolyte density and level fed back by the sensor module, ensuring that the generated target concentration electrolyte perfectly matches the actual needs of the current battery, effectively avoiding the problems of low accuracy and large error in traditional manual proportioning; the peristaltic pump 102 works in conjunction with the flow control component to precisely regulate the electrolyte delivery volume of each conduit, which can meet the differentiated needs of adding electrolyte to single or multiple batteries at the same time, and prevent excessive or insufficient addition from affecting battery performance; the independent setting of the water replenishment interface 109 and the electrolyte interface 110 and the confluence design of the delivery main pipe simplify the pipeline structure and improve the integration and ease of operation of the liquid addition system; the overall execution module realizes intelligent control of the entire process of proportioning, delivery and flow during liquid addition through closed-loop linkage with the sensor module and the control module, which significantly improves the automation level and liquid addition accuracy of the device, further ensuring the electrochemical performance and service life of the battery, and reducing the probability of battery failure caused by improper liquid addition parameters.

[0047] The mixing unit 112 includes at least two mixing proportion valves, which control the liquid output of the water supply interface 109 and the electrolyte interface 110 respectively. The valve opening can be dynamically adjusted according to the electrolyte density, liquid level and other parameters fed back by the sensor module in real time, so as to flexibly adjust the mixing ratio of water supply and electrolyte stock solution. After the mixed liquid is collected by the main delivery pipe, it is accurately delivered to the battery liquid addition end through the peristaltic pump and flow control component, so as to achieve seamless connection between on-demand mixing and quantitative delivery, and ensure that the concentration of generated electrolyte always matches the actual needs of the battery, further improving the intelligence and accuracy of the liquid addition process.

[0048] Furthermore, multiple liquid filling unit interfaces 111 are provided, multiple liquid filling units 200 are provided, and multiple conduits 106 are provided, with each conduit 106 corresponding to a liquid filling unit interface 111.

[0049] Each electrolyte filling unit 200 can independently perform electrolyte filling operations through its corresponding connecting conduit 106 and electrolyte filling unit interface 111, without interfering with each other. This supports simultaneous intelligent electrolyte filling of multiple lead-acid batteries of different models or states, flexibly matching the needs of single-station multi-battery or multi-station parallel electrolyte filling scenarios. Simultaneously, each conduit 106 can be further configured with an independent flow detection submodule (such as a miniature electromagnetic flowmeter). The real-time flow data collected by this submodule is synchronously transmitted to the control module, dynamically compared and calibrated with the target flow parameters output by the proportioning unit 112. This ensures that the electrolyte delivery volume of each electrolyte filling unit 200 accurately matches the actual needs of the corresponding battery, effectively improving the overall accuracy and operational efficiency when multiple batteries are added in parallel, and further enhancing the device's adaptability to batch electrolyte filling scenarios.

[0050] The flow control component is a solenoid valve 103, and the liquid addition unit 200 adopts a combination of a high-precision solenoid valve and a peristaltic pump. Through multi-channel independent control, it supports independent liquid addition for a single battery.

[0051] In some embodiments, the liquid filling unit 200 includes a liquid filling unit body, on which a branch pipe 214, a liquid infusion chamber, and a liquid filling nozzle 213 are disposed. The branch pipe 214 is correspondingly connected to the liquid filling unit interface 111, and the branch pipe 214, the liquid infusion chamber, and the liquid filling nozzle 213 are interconnected. The liquid filling nozzle 213 is an adaptive liquid filling nozzle, and the controlled end of the liquid filling nozzle 213 is connected to the output end of the control module. The adaptive liquid filling nozzle includes a liquid filling nozzle body and a flow regulating valve. The adaptive liquid filling nozzle freely adds liquid to the battery according to instructions and controls the amount of liquid added.

[0052] In some embodiments, the control module has a built-in processor and storage unit, pre-stores a database of liquid filling parameters for at least one battery model, and performs multi-dimensional analysis on the detection data of the sensor module through a parameter fusion algorithm to generate a liquid filling strategy.

[0053] The parameter fusion algorithm is as follows: an electrolyte state model is constructed based on sensor module data, and the electrolyte addition strategy is dynamically adjusted in conjunction with a temperature compensation algorithm. When the liquid level is below the threshold and the density is abnormal, the mixing ratio valve is automatically triggered to replenish electrolyte according to the preset density ratio, thereby achieving synchronous control of liquid level and density.

[0054] The control module pre-stores a database of electrolyte filling parameters for different battery models. Combined with real-time data from temperature sensors, it uses algorithms to correct the impact of temperature on electrolyte density and dynamically adjusts the electrolyte filling amount. For example, when the electrolyte expands at high temperatures, the system automatically reduces the filling amount to prevent overflow; at low temperatures, it appropriately adds concentrated electrolyte based on density changes to ensure parameter stability.

[0055] The processor is an AI chip supporting edge computing. Based on a PLC (Programmable Logic Controller) control system, it pre-stores electrolyte filling parameters and standard electrolyte level data for different battery models. Through collaboration with a sensing module and an adaptive dispensing nozzle, and combined with a PID algorithm, it dynamically adjusts the electrolyte filling volume. This prevents overfilling or underfilling and automatically closes the valve after filling, ensuring the accuracy and reliability of the filling process.

[0056] Closed-loop control process: Initialization: Set the target liquid level and density range.

[0057] Real-time monitoring: The sensor collects data every 10 seconds.

[0058] Decision execution: The main control module calculates the required liquid replenishment volume and drives the peristaltic pump and solenoid valve to complete the liquid addition.

[0059] Feedback calibration: After adding liquid, the parameters are checked again. If they do not meet the standard, a second fine-tuning is performed.

[0060] In some embodiments, the host 100 is further provided with a battery module 104, which powers the host 100 as a whole.

[0061] In some embodiments, the device also includes a storage unit 300, which is provided with a main unit storage location 301 and at least one liquid filling unit storage location 302. This allows for the categorized and organized storage of the main unit and liquid filling units, effectively improving space utilization efficiency and reducing the risk of damage or loss of components due to cluttered placement. At the same time, the categorized storage location design facilitates operators to quickly find, retrieve, and return each component to its designated location, simplifying daily maintenance and repair processes. Furthermore, the integrated storage structure makes the device easier to store and manage during transportation or when not in use.

[0062] Furthermore, the storage unit 300 is a storage rack or positioning plate, and multiple liquid filling unit storage positions 302 are arranged linearly at intervals on the storage rack or positioning plate; both the liquid filling unit storage position 302 and the main unit storage position 301 are grooves.

[0063] A sensing module storage position 3022 and / or a heat-dissipation drying hole 3023 is / are provided on the filling unit storage position 302. Wherein, the sensing module storage position 3022 is an adapting groove tailor-designed for sensing components matched with the filling unit 200 (such as liquid level detection sensors, temperature monitoring probes, etc.), the size of which accurately matches the outer shape of the sensing components, can realize integrated storage of the sensing parts and the filling unit, avoids the problems that the sensing components are easily lost and damaged when stored separately, and at the same time facilitates operators to quickly complete the assembly of the sensing module when taking the filling unit, thereby improving operation efficiency. The heat-dissipation drying hole 3023 is a through hole penetrating through the thickness direction of the positioning plate, the hole wall of which is coated with a hydrophobic and moisture-proof nano-coating, can timely discharge accumulated moisture and heat in the storage position, prevent the metal interface of the filling unit from rusting due to moisture to affect connection reliability, and can also avoid aging and deformation of plastic parts due to long-term exposure to a hot and humid environment, effectively prolonging the storage life and service stability of the filling unit. When both the sensing module storage position 3022 and the heat-dissipation drying hole 3023 are provided on the filling unit storage position 302, the two can cooperate to function, which not only ensures safe storage of the sensing components, but also maintains a dry and ventilated environment inside the storage position, further optimizing the functional integrity of the storage unit.

[0064] Further, a thread 3021 is further provided on the sensing module storage position 3022, which facilitates threaded connection with the retractable plug 210 of the filling unit 200, so that the filling unit 200 can be firmly positioned at the sensing module storage position 3022.

[0065] In some embodiments, a liquid storage module is further included, the liquid storage module comprises a first liquid storage tank and a second liquid storage tank, the first liquid storage tank and the second liquid storage tank are respectively connected with an execution module, the first liquid storage tank is connected with a distilled water or demineralized water pipeline in a plant through a hose, the first liquid storage tank is used for storing distilled water / demineralized water, and the second liquid storage tank is used for storing electrolyte. The first liquid storage tank and the second liquid storage tank adjust electrolyte density through a mixing proportional valve.

[0066] In some embodiments, a safety protection module is further included, the safety protection module is provided with a liquid level over-limit detection unit, a pressure abnormality alarm unit, an overcurrent protection unit and an anti-crystallization blocking unit, which automatically cuts off the filling process and triggers an audible and visual alarm when an abnormal state is detected.

[0067] In some embodiments, a self-cleaning module is also included, which performs regular or on-demand cleaning of the actuator module and the liquid filling unit 200 through ultrasonic cleaning, backflushing, or chemical cleaning. This effectively removes residual electrolyte crystals, impurities, or contaminants from the internal pipelines, valves, and liquid filling unit of the actuator module, avoiding problems such as unstable liquid filling flow and decreased accuracy caused by pipeline blockage, and ensuring the continuity and accuracy of the liquid filling process. It also reduces wear or jamming of key components of the actuator module (such as peristaltic pumps and solenoid valves) caused by contaminant adhesion, extending their service life. Furthermore, it prevents residual contaminants from entering the lead-acid battery with newly injected electrolyte, avoiding corrosion of the battery plates or interference with normal electrochemical reactions, thereby maintaining the battery's performance stability and cycle life. At the same time, the combination of regular and on-demand cleaning can flexibly adapt to different usage frequencies and operating conditions, forming a double protection with the anti-crystallization blockage unit of the safety protection module, further improving the overall reliability and ease of maintenance of the device.

[0068] Specifically, the liquid filling pipeline has a built-in ultrasonic cleaning device 205 to prevent crystallization and blockage. More specifically, the ultrasonic cleaning device 205 is located at the liquid filling nozzle 213, and the entire liquid filling pipeline is flushed by ultrasonic cleaning.

[0069] In some embodiments, the host 100 and the liquid filling unit 200 are communicatively connected via a communication module 108. The host 100 is equipped with a first wireless transmission module 113, and the liquid filling unit 200 is equipped with a second wireless transmission module 206. The communication modules support 4G / 5G or LoRa communication, enabling remote monitoring and data upload to a cloud platform. The device has a built-in data storage module that records information such as the time, volume, and battery model of each liquid filling operation, facilitating user query and management. Simultaneously, equipped with a remote monitoring module, users can also remotely view the battery's liquid level and the operation of the liquid filling device via a mobile app or computer, receive liquid filling completion notifications or fault alarms, achieving remote control and early warning, and improving maintenance efficiency and management level.

[0070] The above-mentioned intelligent electrolyte filling device for lead-acid batteries, in a single-cell electrolyte filling scenario: the device is fixed to the battery filling port by a clamp, the sensor probe is immersed in the electrolyte, and the main control module controls the amount of electrolyte added based on real-time data.

[0071] The aforementioned intelligent lead-acid battery refilling device enables collaborative management of multiple battery packs: multiple devices are connected via CAN bus or wireless networking, and a central controller coordinates the process to achieve batch refilling (such as in energy storage power station scenarios).

[0072] The aforementioned intelligent lead-acid battery electrolyte filling device has the following technical advantages: High precision: Combining liquid level, density, and temperature parameters, the error rate is <1%.

[0073] High efficiency and energy saving: Multi-channel synchronous liquid addition efficiency is increased by 50% and power consumption is reduced by 30%.

[0074] Smart Expansion: Supports IoT integration and adapts to the needs of Industry 4.0 smart factories.

[0075] According to an embodiment of the present invention, in a second aspect, a smart electrolyte filling method for lead-acid batteries is provided, specifically including the following steps: S1. Fluid Filling Unit Installation and System Initialization: Before conducting charge / discharge tests on the battery, the original level gauge needs to be replaced with the fluid filling unit. The identification unit 201 identifies the position and size of the battery filling port, and the mechanical adjustment mechanism 209 adjusts the size of the retractable stopcock 210 to achieve a sealed fit. After installation, an airtightness test is performed. If successful, an acid / alkali resistant hose is used to connect the main unit's fluid filling unit interface 111 to the fluid filling unit 200's branch pipe 214, and the distilled water / demineralized water quick connector is connected to the corresponding water replenishment interface 109 on the main unit. After starting the main unit, the fluid filling unit and the main unit establish a communication connection via the communication module, completing the preparation for the charge / discharge process.

[0076] S2. Intelligent Adjustment for High Acidity: When the electrolyte evaporates during charging, causing excessive acidity, the system activates a multi-sensor collaborative monitoring mechanism. Capacitive probe 202, density sensor 203, ultrasonic sensor 204, temperature sensor 207, conductivity sensor 208, and pressure sensor 212 collect electrolyte temperature, density, and other parameters in real time (sensor combinations can be configured as needed), and upload this data to the host computer via the second wireless transmission module 206. After analysis by the AI ​​chip 105, the host computer, in conjunction with the PLC controller 107, executes dual-path control: on one hand, it sends instructions to the liquid addition unit via the first wireless transmission module 113; on the other hand, it starts the peristaltic pump 102 and triggers the corresponding solenoid valve 103 based on real-time feedback signals, controlling the adaptive liquid addition nozzle 213 to precisely replenish distilled water or demineralized water.

[0077] S3. Intelligent Adjustment for Low-Density Conditions: When the sensor detects that the electrolyte density is too low, the host AI chip 105 and PLC controller 107 work together to activate the mixing function. The mixing unit 112 dynamically mixes the liquid input from the water supply interface 109 with the acid input from the electrolyte interface 110, and then distributes it to the corresponding solenoid valve 103 via the peristaltic pump 102, accurately delivering it to the target liquid addition unit to complete the electrolyte concentration adjustment.

[0078] S4. Data Recording and Storage: The system has a full-process data memory and storage function, which automatically records key parameters during the charging and discharging process, including timestamps, electrolyte temperature, density value, single liquid addition volume and cumulative liquid addition volume, and supports data printing or export for analysis.

[0079] S5. System Completion and Maintenance: After charging is complete, release the mechanical adjustment mechanism 209 to remove the liquid filling unit and replace the original liquid level gauge; start the self-cleaning program, and use distilled water or demineralized water in conjunction with the ultrasonic cleaning device 205 to perform deep cleaning on the liquid filling unit. After cleaning, store it in a dedicated fixed tank.

[0080] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A smart electrolyte filling device for lead-acid batteries, characterized in that, include: The host (100) is provided with an execution module and at least one liquid addition unit interface (111), the execution module being used to perform liquid addition operations; At least one electrolyte filling unit (200) is provided, wherein the electrolyte filling unit (200) is detachably connected to the electrolyte filling unit interface (111) of the host (100) and is communicatively connected to the host (100); the electrolyte filling unit (200) is provided with a fixing module and a sensing module, wherein the fixing module is used to fix to the electrolyte filling port of the battery, and the sensing module is used to detect the electrolyte state of the battery. The control module is installed on the host (100). The control module is used to control the electrolyte addition logic. The control module dynamically adjusts the electrolyte parameters of the storage battery through the execution module and the electrolyte addition unit (200) based on the detection data of the sensor module.

2. The intelligent lead-acid battery electrolyte filling device according to claim 1, characterized in that, The fixing module includes: Retractable stopcock (210); A mechanical adjustment mechanism (209) is provided on a retractable rotary valve (210), and the controlled end of the mechanical adjustment mechanism (209) is connected to the output end of the control module; The identification unit (201) is located at the lower part of the retractable valve (210). The output end of the identification unit (201) is connected to the input end of the control module. The identification unit (201) obtains the position and size information of the battery filling port through image recognition, laser positioning or infrared sensing, and feeds the information back to the control module. The control module drives the mechanical adjustment mechanism (209) to adjust the size of the retractable valve (210).

3. The intelligent lead-acid battery electrolyte filling device according to claim 1, characterized in that, The sensing module is a multi-parameter sensor module, which includes at least one of a liquid level sensor, a temperature sensor, a density sensor, an ultrasonic sensor, a conductivity sensor, or a pressure sensor.

4. The intelligent lead-acid battery electrolyte filling device according to claim 1, characterized in that, The execution module includes: Water supply interface (109) is connected to a water source; Electrolyte interface (110) is connected to an electrolyte source; The output ends of the water supply interface (109) and the electrolyte interface (110) converge at the main delivery pipe; A peristaltic pump (102) is installed on the main delivery pipe; At least one conduit (106), one end of which is connected to the main delivery pipe and the other end of which is connected to the liquid filling unit interface (111); A flow control component is provided on each of the aforementioned conduits (106).

5. The intelligent lead-acid battery electrolyte filling device according to claim 4, characterized in that, The main delivery pipe is equipped with a mixing unit (112), which is used to mix the electrolyte and distilled water in a preset ratio according to the real-time parameters detected by the sensing module to generate an electrolyte of target concentration.

6. The intelligent lead-acid battery electrolyte filling device according to claim 4, characterized in that, Multiple liquid filling unit interfaces (111) are provided, multiple liquid filling units (200) are provided, and multiple conduits (106) are provided. Each conduit (106) is connected to a liquid filling unit interface (111).

7. The intelligent lead-acid battery electrolyte filling device according to claim 1, characterized in that, The control module has a built-in processor and storage unit, pre-stores a database of liquid filling parameters for at least one battery model, and performs multi-dimensional analysis of the detection data from the sensor module through a parameter fusion algorithm to generate a liquid filling strategy.

8. The intelligent lead-acid battery electrolyte filling device according to claim 1, characterized in that, The liquid dispensing unit (200) includes a liquid dispensing unit body, on which a branch pipe (214), an infusion chamber and a liquid dispensing nozzle (213) are provided. The branch pipe (214) is connected to the liquid dispensing unit interface (111). The branch pipe (214), the infusion chamber and the liquid dispensing nozzle (213) are connected to each other. The liquid dispensing nozzle (213) is an adaptive liquid dispensing nozzle. The controlled end of the liquid dispensing nozzle (213) is connected to the output end of the control module.

9. The intelligent lead-acid battery electrolyte filling device according to claim 1, characterized in that, Also includes: Storage unit (300), wherein the storage unit (300) is provided with a host storage position (301) and at least one liquid filling unit storage position (302); The liquid filling unit storage compartment (302) is provided with a sensor module storage compartment (3022) and / or a heat dissipation and drying hole (3023).

10. The intelligent lead-acid battery electrolyte filling device according to any one of claims 1-9, characterized in that, Also includes: The liquid storage module includes a first liquid storage tank and a second liquid storage tank. The first liquid storage tank and the second liquid storage tank are respectively connected to the execution module. The first liquid storage tank is connected to a distilled water or demineralized water pipeline in the plant. The first liquid storage tank is used to store distilled water / demineralized water, and the second liquid storage tank is used to store electrolyte. and / or The safety protection module is equipped with a liquid level over-limit detection, pressure abnormality alarm, overcurrent protection, and anti-crystallization and blockage unit. When an abnormal state is detected, it automatically cuts off the liquid addition process and triggers an audible and visual warning; and / or The self-cleaning module cleans the actuator and liquid filling unit (200) regularly or as needed by means of ultrasonic cleaning, backflushing or chemical cleaning.

Images