Battery pack in-situ repair method

Abstract

The application discloses a battery pack in-situ maintenance method, and relates to the technical field of power battery maintenance, wherein the battery pack in-situ maintenance method comprises the following steps: hoisting and placing a battery pack to be maintained into a box body of an environmental test box and locking and fixing the battery pack through a fixing platform; closing a top cover of the environmental test box, starting a temperature control unit to perform refrigeration treatment on the environment in the box; opening the top cover, enabling a maintenance device or a maintenance personnel to enter the inside of the box body from the top, taking out a failed battery cell and installing a new battery cell; closing the top cover, starting the temperature control unit to perform heating treatment on the environment in the box, and solidifying a heat conduction structure adhesive of the new battery cell; and taking out the battery pack from the box body after the battery pack is warmed up. The technical effect of the technical scheme provided by the application is that the all-processes of the battery pack are completed in the same work station through full-process closed-loop control of the temperature and humidity of the environment in the box, and the battery pack does not need to be moved at all.

Description

Technical Field

[0001] This invention relates to the field of power battery repair technology, and in particular to a method for in-situ repair of a battery pack. Background Technology

[0002] Currently, power battery packs generally use thermally conductive structural adhesive to bond and fix the battery cells to the liquid cooling plate. When repairing or replacing the battery cells, the adhesive layer must be deactivated before disassembly. There are three main methods for treating the adhesive layer: one is to use the battery pack's own liquid cooling channels to inject high-temperature or low-temperature media for temperature control; the second is to place the battery pack in a low-temperature chamber or refrigeration equipment for overall freezing; and the third is to use vibration or mechanical force to cause the adhesive layer to crack and fall off.

[0003] However, all of the above methods have obvious drawbacks: the method relying on liquid cooling channels cannot be implemented when the liquid cooling plate is damaged or the pipeline leaks; the battery packs processed by the freezing equipment need to be removed from the freezing equipment and transported to the disassembly station. When exposed to room temperature after removal, the surface condensation problem is prominent, posing a safety hazard; the cryo-degumming and heating curing are in different equipment, requiring multiple transfers, which is cumbersome, inefficient, and lacks closed-loop temperature and humidity control throughout the process. Summary of the Invention

[0004] The main objective of this invention is to propose an in-situ battery pack repair method. This method aims to achieve closed-loop control of the temperature and humidity inside the battery pack throughout the entire process, enabling the entire process of freezing and debonding, cell disassembly, new cell installation, and heating and curing to be completed in the same workstation, without requiring the battery pack to be moved at all times.

[0005] To achieve the above objectives, the present invention proposes a method for in-situ repair of a battery pack, comprising the following steps: The battery pack to be repaired is hoisted into the interior of the environmental test chamber and locked in place by the fixing platform inside the chamber. Close the top cover of the environmental test chamber and start the temperature control unit to freeze the environment inside the chamber, causing the thermally conductive structural adhesive inside the battery pack to enter a brittle state. Open the top cover to open the top of the box, and the maintenance equipment or personnel can enter the box from above to remove the failed battery cell and install a new battery cell; Close the top cover and start the temperature control unit of the environmental test chamber to heat the environment inside the chamber, so that the thermally conductive structural adhesive of the new battery cell can be cured. After the battery pack has cooled down, remove the battery pack from the casing. Throughout the entire processing, the battery pack remained inside the environmental test chamber without any relocation of the workstation.

[0006] In one embodiment, the environmental test chamber includes a box body with an opening at the top, a top cover movably installed on the top of the box body and capable of being opened or closed, and a fixed platform disposed inside the box body; the top cover is provided with a lifting ring at the top, or the top cover is a split structure, and the top cover is slidably connected to the opening of the box body in the horizontal direction through a translation mechanism; The step of hoisting the battery pack to be repaired into the environmental test chamber and locking it in place using the fixing platform inside the chamber includes: The top cover is lifted and removed entirely using a crane or industrial robot, or the top cover is pushed from the opening of the box to the side, so that the opening of the box is fully open; The battery pack is hoisted and placed inside the housing; Positioning is achieved by the positioning pins on the fixed platform engaging with the positioning holes at the bottom of the battery pack, and then the battery pack is clamped and fixed by the quick clamping device on the fixed platform.

[0007] In one embodiment, the environmental test chamber further includes a temperature control unit for adjusting the temperature and humidity inside the chamber, and a control system for controlling the operation of the temperature control unit and monitoring the environmental parameters inside the chamber. The temperature control unit includes a refrigeration device, a circulating fan, a humidity sensor, and a humidity control device electrically connected to the control system. The steps of closing the top cover of the environmental test chamber and starting the temperature control unit to freeze the environment inside the chamber, causing the thermally conductive structural adhesive inside the battery pack to enter a brittle state, include: After the battery pack is placed into the enclosure, the process parameters required for this maintenance are set through the touch screen of the control system, including the target freezing temperature, freezing duration, target heating temperature, heating duration, and humidity control target. Start the refrigeration unit and circulating fan of the temperature control unit to cool down the environment inside the box, so as to reduce the temperature inside the box to the embrittlement temperature range of the adhesive layer; During the freezing process, the control system monitors the relative humidity inside the chamber through the humidity sensor of the temperature control unit, and controls the humidity inside the chamber within a preset range through the humidity control device of the temperature control unit.

[0008] In one embodiment, the step of opening the top cover to expose the top of the enclosure, allowing maintenance equipment or personnel to enter the enclosure from above, remove the failed battery cell, and install a new battery cell includes: Once the adhesive layer has become sufficiently brittle, the control system will issue a warning signal. The top cover can be lifted and removed entirely using a crane or industrial robot, or the top cover can be pushed horizontally to fully open the opening of the box. Through the fully open opening at the top of the enclosure, a crane or industrial robot is used to vertically enter the enclosure and lift the failed battery cells vertically upwards. After the bottom of the new battery cell is coated with thermally conductive structural adhesive, it is vertically hoisted into the original empty battery cell position by a crane or industrial robot through the open opening at the top of the box. After confirming that the new battery cell is installed in place, return the top cover to the closed position and cover the opening at the top of the enclosure, then lock the top cover in place using the mechanical locking device.

[0009] In one embodiment, the temperature control unit includes a heating device and a temperature sensor electrically connected to the control system; The steps of closing the top cover and starting the temperature control unit of the environmental test chamber to heat the environment inside the chamber, thereby curing the thermally conductive structural adhesive of the new battery cell, include: After the control system confirms that the top cover is locked, it starts the heating device and circulating fan of the temperature control unit to heat the environment inside the chamber and raise the temperature inside the chamber to the preset heating and curing temperature range. During the heating and curing process, the control system monitors the temperature inside the box and the surface temperature of the battery pack in real time through temperature sensors; The humidity inside the chamber is monitored by a humidity sensor, and the humidity is controlled within a preset range by a humidity control device.

[0010] In one embodiment, the step of removing the battery pack from the casing after it has cooled down includes: After heating and curing, the control system lowers the temperature inside the enclosure to room temperature at a controlled rate according to a preset rewarming program to prevent rapid cooling from causing thermal stress inside the battery pack. During the rewarming process, the control system continuously monitors the humidity inside the enclosure to ensure that no condensation forms on the surface of the battery pack. After the battery pack has returned to room temperature, the quick clamping device on the fixed platform is released, and the repaired battery pack is lifted out of the box by a crane or industrial robot, thus completing the entire repair process.

[0011] In one embodiment, the side wall of the housing is provided with a quick-connect interface panel, which is electrically connected to the control system; the battery pack is provided with a temperature monitoring device. After the step of locking and securing the battery pack via the fixing platform, the method further includes: The electrical interface of the battery pack and the temperature monitoring device are connected via the quick-connect interface panel; The temperature signal collected by the temperature monitoring device is transmitted to the control system via the quick-connect interface panel, and is used as the basis for temperature control decisions.

[0012] In one embodiment, a mechanical locking device is provided between the top cover and the housing, and the mechanical locking device is equipped with a position sensor; the control system further includes a safety interlock circuit; After closing the top cover of the environmental test chamber, the following is also included: The position sensor is used to detect whether the top cover is in a locked state. When the position sensor indicates that the top cover is locked, the safety interlock circuit controls the temperature control unit to start operation.

[0013] In one embodiment, the temperature sensor is an adhesive layer temperature sensor disposed inside the housing, and the adhesive layer temperature sensor is located in the edge region adjacent to the adhesive layer of the battery pack; Following the step of starting the refrigeration unit and circulating fan of the temperature-controlled unit, the following is also included: The temperature of the thermally conductive structural adhesive of the battery pack is monitored in real time by the adhesive layer temperature sensor. When the temperature of the adhesive layer reaches the embrittlement temperature zone of the adhesive layer, the duration of freezing is started.

[0014] In one embodiment, after the heat curing is completed, the process further includes: Keep the battery pack inside the box, allow it to return to room temperature, connect the control system to an airtightness testing device to perform an airtightness test on the battery pack, and remove the battery pack from the box only after confirming that it is qualified.

[0015] This invention achieves temperature control of the entire internal environment without relying on the battery pack's own liquid cooling channels. It integrates the entire process of cryogenic debonding, cell disassembly, new cell installation, and heat curing within a single environmental testing chamber. From the start of freezing to the completion of repair, the battery pack remains within a controlled environment inside the chamber, eliminating the need for any transfer operations. This fundamentally avoids cold loss during transport, ensuring the adhesive layer is disassembled at the optimal embrittlement temperature and eliminating the safety hazard of condensation caused by the battery pack being exposed to room temperature at low temperatures. Furthermore, the highly integrated process significantly shortens the repair cycle, and the closed-loop temperature and humidity control throughout the process ensures repair quality and the long-term reliability of the battery pack. With the top cover open, the top of the chamber is completely exposed, allowing for vertical lifting of the cells directly from above using a crane or industrial robot, making the operation simple and efficient. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 A perspective view of the first embodiment of the environmental test chamber provided by the present invention; Figure 2An exploded view of the structure of the first embodiment of the environmental test chamber provided by the present invention; Figure 3 A perspective view of the second embodiment of the environmental test chamber provided by the present invention; Figure 4 This is a flowchart illustrating the steps of the battery pack in-situ repair method provided by the present invention.

[0018] Explanation of icon numbers: 1. Cabinet; 1a. Opening; 2. Top cover; 2a. Lifting ring; 3. Temperature control unit; 4. Fixed platform.

[0019] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0022] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0023] Traditional existing power battery pack repair methods generally have limitations when dealing with the thermally conductive structural adhesive between the battery cells and the liquid cooling plate. These limitations include reliance on the battery pack's own liquid cooling system, which limits the applicable scenarios; separation of freezing and disassembly operations, resulting in cold loss and surface condensation; and the fact that freezing debonding and heating curing are done in different equipment, leading to cumbersome procedures and low efficiency.

[0024] In response, this application proposes a method for in-situ repair of a battery pack, comprising the following steps: Please see Figures 1 to 4 S1: The battery pack to be repaired is hoisted into the chamber 1 of the environmental test chamber and locked in place by the fixing platform 4 inside the chamber 1; S2: Close the top cover 2 of the environmental test chamber and start the temperature control unit 3 to freeze the environment inside the chamber, so that the thermally conductive structural adhesive inside the battery pack enters a brittle state. S3: Open the top cover 2 to open the top of the box 1. The maintenance equipment or maintenance personnel can enter the box 1 from above, remove the failed battery cell and install a new battery cell. S4: Close the top cover 2 and start the temperature control unit 3 of the environmental test chamber to heat the environment inside the chamber, so that the thermally conductive structural adhesive of the new battery cell can be cured. S5: After the battery pack has cooled down, remove the battery pack from the housing 1; From the time the battery pack is placed into the chamber 1 in step S1 until it is removed in step S5, it remains inside the chamber 1 of the environmental test chamber and does not undergo any positional transfer.

[0025] A battery pack is an energy storage unit that integrates multiple battery cells, a battery management system, a cooling system, a casing, and other components. It is typically used in electric vehicles and other fields.

[0026] An environmental test chamber is a testing device with an openable top cover 2. Its internal environment allows for temperature and humidity control to simulate different environmental conditions. The top cover 2 design allows operation of the interior of the chamber 1 from above. A fixed platform 4 is a support structure located inside the environmental test chamber 1, used to support and stably secure the battery pack to be repaired, preventing movement during maintenance. A temperature control unit 3 refers to the equipment system integrated into the environmental test chamber, used to regulate and control the internal temperature and humidity of the chamber 1. This temperature control unit 3 includes subsystems for refrigeration, heating, humidification, and air circulation.

[0027] Thermally conductive structural adhesives are adhesives that combine thermal conductivity and structural bonding properties. They are used to bond and fix battery cells to components such as liquid cooling plates within a battery pack, while simultaneously conducting heat. The embrittlement state refers to the change in material properties of thermally conductive structural adhesives at low temperatures, transforming them from a viscoelastic state with some toughness to a glassy state with increased brittleness. This reduces bond strength and facilitates disassembly. A battery cell refers to the basic energy storage unit in a battery pack, typically a single lithium-ion battery cell.

[0028] First, at the start of the maintenance work, the battery pack to be repaired is hoisted into the chamber 1 of the environmental test chamber. This operation can be performed using conventional lifting equipment, such as an electric hoist or forklift, to smoothly lift the battery pack into chamber 1. Subsequently, the battery pack is locked and secured using a fixing platform 4 located inside chamber 1. This fixing platform 4 can employ a mechanical clamping mechanism, such as manually tightening bolts or lever-type clamps, to ensure the battery pack remains stable during maintenance and prevents shaking.

[0029] Next, close the top cover 2 of the environmental test chamber. The top cover 2 can be operated manually by pushing or pulling or using a simple hinge structure, ensuring it completely covers the opening 1a at the top of the chamber 1. After the top cover 2 is closed, start the temperature control unit 3 to freeze the environment inside the chamber. The temperature control unit 3 can use a conventional refrigeration cycle system, such as cooling the air inside the chamber through a compressor and evaporator, to cause the thermally conductive structural adhesive inside the battery pack to enter a brittle state. Under low temperature, the physical properties of the thermally conductive structural adhesive change from a viscoelastic state to a more brittle glassy state, thereby reducing its adhesive strength and facilitating subsequent disassembly.

[0030] Subsequently, the top cover 2 is opened, exposing the top of the housing 1. The top cover 2 can be manually lifted and placed to the side of the housing 1, or manually pushed open using a simple sliding mechanism, thus creating an unobstructed top operating space. Maintenance equipment or personnel can enter the housing 1 from above to remove failed battery cells and install new ones. For example, maintenance personnel can directly remove the failed battery cells from the battery pack through the top opening 1a of the housing 1 using hand tools or small power tools, and manually place the new battery cells in their original positions.

[0031] After installing the new battery cell, the top cover 2 is closed again. The top cover 2 can be manually repositioned or pushed back onto the top of the chamber 1, covering the opening 1a. Subsequently, the temperature control unit 3 of the environmental test chamber is activated to heat the internal environment. The temperature control unit 3 can use conventional heating elements, such as electric heating wires, to heat the air inside the chamber, thereby curing the thermally conductive structural adhesive coated on the bottom of the new battery cell. The purpose of the heat treatment is to accelerate the curing reaction of the thermally conductive structural adhesive, enabling it to achieve the desired bond strength and thermal conductivity.

[0032] Finally, after the battery pack has cooled down, it is removed from the enclosure 1. The cooling process can be achieved through natural heat dissipation, i.e., by stopping the operation of the temperature control unit 3 and allowing the internal temperature to gradually return to ambient temperature. The battery pack can be removed from the enclosure 1 manually by maintenance personnel, or it can be lifted out using simple lifting equipment, thus completing the entire maintenance process.

[0033] It is worth noting that in this method, the battery pack remains inside the environmental test chamber 1 from the time it is placed in chamber 1 in step S1 until it is removed in step S5, without any change in work position. This means that the entire repair process, including cryo-debonding, cell disassembly, new cell installation, and heat curing, is completed within the same environmental test chamber, and the battery pack does not need to be removed from chamber 1.

[0034] This method integrates the entire process of battery pack cryogenic debonding, cell disassembly, new cell installation, and heat curing into a single station within an environmental testing chamber. This effectively solves problems inherent in traditional repair methods, such as reliance on battery pack liquid cooling systems, cold loss and surface condensation due to post-freezing transport, and fragmented and cumbersome procedures. Thus, it achieves integrated "in-situ freezing, in-situ disassembly, and in-situ curing" for battery pack repair, improving both repair efficiency and safety.

[0035] Please see Figures 1 to 4 In the process of hoisting the battery pack to be repaired into the chamber 1 of the environmental test chamber and locking it in place by the fixing platform 4 inside the chamber 1, in order to efficiently, accurately and safely complete the initial loading, positioning and fixing of the battery pack, especially for battery packs that are large in size and heavy in weight, and to ensure the stability and repeatability of the repair process within a limited repair space, this application further proposes specific implementation methods.

[0036] Specifically, the environmental test chamber includes a chamber body 1 with an opening 1a at the top, a top cover 2 movably mounted on the top of the chamber body 1 and capable of being opened or closed, and a fixed platform 4 located inside the chamber body 1. The chamber body 1, as the main structure of the entire environmental test chamber, is responsible for providing a sealed space to achieve precise control of environmental parameters such as temperature and humidity. Its top opening 1a is the main passage for the battery pack to enter and exit, and for maintenance personnel or equipment to enter the chamber body 1 for operation. The top cover 2, movably mounted on the top of the chamber body 1 and capable of being opened or closed, seals the chamber body 1 in the non-maintenance state, ensuring the stability of the internal environment and energy efficiency; in the maintenance state, the top cover 2 can be opened, facilitating the loading and maintenance of the battery pack. The fixed platform 4 located inside the chamber body 1 primarily provides a stable support surface for the battery pack to be repaired and integrates positioning and clamping mechanisms to ensure the battery pack's position is fixed throughout the maintenance process, preventing positional displacement due to vibration, impact, or improper operation.

[0037] To adapt to different maintenance environments and operational needs, the opening method of the top cover 2 can be diversified. One implementation involves a lifting ring 2a at the top of the top cover 2. A crane or industrial robot (such as a gantry crane) hooks onto the lifting ring 2a, vertically lifting the entire top cover 2 off the top of the housing 1, thus fully opening the opening 1a of the housing 1. This method is suitable when there is sufficient clearance above the maintenance space. Another implementation involves a split structure for the top cover 2, which is slidably connected to the opening 1a of the housing 1 in the horizontal direction via a translation mechanism. This design allows the top cover 2 to move horizontally, for example, to the side of the housing 1, thereby opening the opening 1a of the housing 1. The translation mechanism can be implemented using mechanical structures such as guide rails and rollers, suitable for scenarios with limited clearance above the maintenance space but ample lateral space, improving the adaptability of the equipment.

[0038] In the process of hoisting the battery pack to be repaired into the chamber 1 of the environmental test chamber and locking it in place using the fixing platform 4 inside the chamber 1, firstly, the top cover 2 is lifted and removed entirely using a crane or industrial robot, or the top cover 2 is pushed horizontally from the opening 1a of the chamber 1 to the side, so that the opening 1a of the chamber 1 is fully open. This step aims to provide an unobstructed passage for the smooth hoisting of the battery pack, ensuring operational safety and efficiency. Subsequently, the battery pack is hoisted into the chamber 1. After the opening 1a of the chamber 1 is fully open, the battery pack to be repaired is placed smoothly and vertically into the chamber 1 using a crane or industrial robot (such as a crane, forklift, etc.), so that it sits on the fixing platform 4. To ensure the precise position of the battery pack, positioning is achieved by the positioning pins on the fixing platform 4 engaging with the positioning holes on the bottom of the battery pack. The engagement of the positioning pins and positioning holes is a high-precision, repeatable positioning method, ensuring that the battery pack is accurately placed in the preset position each time it is loaded, providing a reliable reference for subsequent precision maintenance operations such as cell removal and installation. Finally, the battery pack is clamped and secured using the quick-clamping device on the fixed platform 4. The quick-clamping device can be in the form of a pneumatic clamp, a hydraulic clamp, or a mechanical quick-locking mechanism. Its function is to quickly and firmly fix the battery pack on the fixed platform 4 after positioning, preventing any displacement during freezing, heating, maintenance operations, etc., thereby ensuring the accuracy and safety of maintenance.

[0039] Through the above technical solution, this application provides a battery pack loading and fixing method that is structurally reasonable, easy to operate, and precise in positioning. The coordinated design of the environmental test chamber body 1, top cover 2, and fixing platform 4, combined with the flexible and diverse opening mechanism of the top cover 2 (lifting or sliding), greatly improves the efficiency and adaptability of battery pack loading. In particular, the precise cooperation between the positioning pin on the fixing platform 4 and the positioning hole on the bottom of the battery pack ensures the accurate position of the battery pack inside the chamber 1, providing a reliable benchmark for subsequent precision maintenance operations such as cell removal and installation. In addition, the application of a quick-clamping device allows the battery pack to be firmly fixed, effectively avoiding displacement that may occur during temperature cycling and maintenance, thereby ensuring the stability and safety of the maintenance process and significantly improving maintenance quality and efficiency.

[0040] Please see Figures 1 to 4 The environmental test chamber also includes a temperature control unit 3 for adjusting the temperature and humidity inside the chamber, and a control system for controlling the operation of the temperature control unit 3 and monitoring the environmental parameters inside the chamber. The temperature control unit 3 includes a refrigeration device, a circulating fan, a humidity sensor, and a humidity control device that are electrically connected to the control system.

[0041] The steps of closing the top cover 2 of the environmental test chamber and starting the temperature control unit 3 to freeze the environment inside the chamber, causing the thermally conductive structural adhesive inside the battery pack to enter a brittle state, include: after the battery pack is placed in the chamber 1, setting the process parameters required for this maintenance through the touch screen of the control system, including the target freezing temperature, freezing duration, target heating temperature, heating duration, and humidity control target; starting the cooling device and circulating fan of the temperature control unit 3 to cool the environment inside the chamber, so as to reduce the temperature inside the chamber to the brittleness temperature range of the adhesive layer; during the freezing process, the control system monitors the relative humidity inside the chamber through the humidity sensor of the temperature control unit 3, and controls the humidity inside the chamber within the preset range through the humidity control device of the temperature control unit 3.

[0042] Specifically, the temperature control unit 3 is the core component of the environmental test chamber. It integrates functional modules such as a refrigeration unit, a circulating fan, a humidity sensor, and a humidity control device, aiming to precisely regulate and maintain the temperature and humidity environment inside chamber 1. The refrigeration unit typically consists of a compressor, condenser, expansion valve, and evaporator, achieving rapid temperature reduction within the chamber through refrigerant circulation. The circulating fan forces airflow within the chamber, ensuring uniform temperature and humidity distribution and preventing localized overcooling or overheating, thereby ensuring that the thermally conductive structural adhesive in all parts of the battery pack reaches its embrittlement temperature uniformly. The humidity sensor monitors the relative humidity of the air inside the chamber in real time, converting humidity changes into electrical signals that are transmitted to the control system. The humidity control device, according to instructions from the control system, replenishes moisture into the chamber to increase or maintain the relative humidity of the air inside, preventing condensation in low-temperature environments.

[0043] The control system, acting as the "brain" of the temperature control unit 3, typically consists of a programmable logic controller (PLC), an industrial computer, and a touchscreen human-machine interface. It receives various process parameters set by operators via the touchscreen, such as the target freezing temperature, freezing duration, target heating temperature, heating duration, and humidity control target. These parameter settings allow for customization and standardization of the maintenance process based on different battery pack models and maintenance needs. During the freezing process, the control system activates the refrigeration unit and circulating fan of the temperature control unit 3 to cool the internal environment, rapidly and uniformly reducing the temperature to the embrittlement temperature range of the thermally conductive structural adhesive. Simultaneously, throughout the freezing process, the control system continuously monitors the relative humidity inside the unit via the humidity sensor and precisely adjusts it according to the preset humidity control target, ensuring that the humidity inside the unit remains within the preset range.

[0044] Through the above technical solution, this application can achieve precise control of environmental parameters within the environmental test chamber. The coordinated operation of the refrigeration unit and the circulating fan ensures that the temperature inside the chamber can be rapidly and uniformly reduced to the embrittlement temperature range of the thermally conductive structural adhesive, thereby ensuring that the adhesive layer is fully and thoroughly embrittled, greatly facilitating the removal of failed battery cells. Simultaneously, the humidity inside the chamber is monitored in real time by a humidity sensor and precisely adjusted by a humidity control device, effectively preventing condensation on the surface of the battery pack due to water vapor in low-temperature environments, protecting the internal circuitry and connectors of the battery pack from the effects of moisture.

[0045] Please see Figures 1 to 4 The steps proposed in this application, which involve opening the top cover 2 to allow the top of the housing 1 to be open, enabling maintenance equipment or personnel to enter the housing 1 from above, remove the failed battery cells, and install new battery cells, include: After the adhesive layer has fully hardened, the control system issues a warning signal. The top cover 2 is then lifted off entirely by a crane or industrial robot, or the top cover 2 is pushed to move horizontally so that the opening 1a of the housing 1 is fully open. Through the fully open opening 1a at the top of the housing 1, a crane or industrial robot is used to vertically enter the housing 1 and lift the failed battery cell vertically upwards. After applying thermally conductive structural adhesive to the bottom of the new battery cell, it is then lifted vertically into the vacated battery cell position by a crane or industrial robot through the open opening 1a at the top of the housing 1. After confirming that the new battery cell is in place, the top cover 2 is lifted back into position by a crane or industrial robot to cover the opening 1a at the top of the housing 1, and the top cover 2 is locked in place by a mechanical locking device.

[0046] Specifically, once the adhesive layer has become sufficiently brittle, the control system will issue a warning signal. This signal ensures that maintenance operations are performed at the optimal time, i.e., when the thermally conductive structural adhesive has reached a brittle state, facilitating subsequent removal. The control system determines whether the adhesive layer has become sufficiently brittle by using a preset freezing time or by monitoring the adhesive layer temperature in real time. Once the conditions are met, the control system will signal the operator through audible and visual alarms, display screen information prompts, etc., indicating that the next step can be performed, thereby avoiding maintenance operations performed too early or too late, and improving maintenance efficiency and success rate.

[0047] Subsequently, the top cover 2 is lifted and removed entirely using a crane or industrial robot, or the top cover 2 is pushed horizontally to fully open the opening 1a of the housing 1. This step aims to provide a flexible and efficient solution for opening the top cover 2. When using a crane or industrial robot to lift and remove the top cover 2 entirely, it is suitable for situations where the top cover 2 is heavy or needs to be completely removed to provide maximum operating space. The crane or industrial robot, connected to the lifting ring 2a on the top of the top cover 2, lifts the top cover 2 vertically upwards and moves it to a predetermined position beside the housing 1. This method fully exposes the top opening 1a of the housing 1, facilitating the operation of large maintenance equipment or multiple maintenance personnel simultaneously. When pushing the top cover 2 horizontally, it is suitable for situations where the top cover 2 has a split structure or is designed with a translation mechanism. The top cover 2 is connected to the opening 1a of the housing 1 via a translation mechanism such as guide rails or rollers, and slides horizontally to the side of the opening 1a of the housing 1 under motor drive or manual pushing, thereby fully opening the top opening 1a of the housing 1. Both methods ensure that the top opening 1a of the enclosure 1 is fully open, providing an unobstructed vertical passage for subsequent cell replacement.

[0048] After the top of housing 1 is fully opened, a crane or industrial robot is used to vertically enter the interior of housing 1 through opening 1a, and the failed battery cell is lifted vertically upwards and removed. This step emphasizes vertical operation and the use of automated or semi-automated equipment. The crane or industrial robot can precisely extend the gripping tool or lifting device vertically into the interior of housing 1 from above, aligning it with the failed battery cell. By lifting vertically upwards, horizontal movement or tilting operations inside housing 1 can be avoided, reducing potential damage to surrounding intact battery cells or the structure of housing 1, while ensuring the stability of the battery cell during removal and preventing secondary damage.

[0049] Next, after applying thermally conductive structural adhesive to the bottom of the new battery cell, it is vertically hoisted into the previously vacated cell position by a crane or industrial robot through the open opening 1a at the top of housing 1. This step also emphasizes vertical operation and the use of automated or semi-automated equipment. Before installing the new battery cell, thermally conductive structural adhesive is pre-applied to its bottom to ensure a good heat conduction path between the new battery cell and the internal heat dissipation structure of the battery pack. Subsequently, the crane or industrial robot vertically hoists the new battery cell, coated with thermally conductive structural adhesive, through the open opening 1a at the top of housing 1 and precisely places it in the vacated position of the previously failed battery cell. Vertical hoisting and precise placement help ensure alignment between the new battery cell and the internal connectors of the battery pack and prevent the thermally conductive structural adhesive from being scratched or contaminated during placement, ensuring installation quality.

[0050] Finally, after confirming that the new battery cell is installed in place, use a crane or industrial robot to return the top cover 2 to the closed position and cover the top opening 1a of the chamber 1, then lock the top cover 2 securely using a mechanical locking device. This step aims to restore the airtightness and safety of the environmental test chamber. After confirming that the new battery cell has been correctly installed and secured, use a crane or industrial robot to precisely return the top cover 2 to the closed position, covering the top opening 1a of the chamber 1. Subsequently, use a mechanical locking device to firmly lock the top cover 2 to the chamber 1, ensuring the airtightness of the chamber 1, creating a stable internal environment for the subsequent heat curing steps, and preventing the top cover 2 from accidentally opening during equipment operation, thus ensuring operational safety.

[0051] Please see Figures 1 to 4 This application further proposes that the temperature control unit 3 includes a heating device and a temperature sensor electrically connected to the control system; the step of closing the top cover 2 and starting the temperature control unit 3 of the environmental test chamber to heat the environment inside the chamber to cure the thermally conductive structural adhesive of the new battery cell includes: After the control system confirms that the top cover 2 is locked, it starts the heating device and circulating fan of the temperature control unit 3 to heat the environment inside the box and raise the temperature inside the box to the preset heating and curing temperature range. During the heating and curing process, the control system monitors the temperature inside the box and the surface temperature of the battery pack in real time through temperature sensors. It also monitors the humidity inside the box through humidity sensors and controls the humidity within the preset range through a humidity control device.

[0052] The heating device is a key component of the temperature control unit 3, providing heat to the interior of the enclosure 1 to cure the thermally conductive structural adhesive for the new battery cells. Specifically, the heating device can take various forms, such as electric heating tubes, PTC heaters, or heat pump systems. Its design should ensure the rapid and stable raising of the enclosure temperature to the required curing temperature range for the thermally conductive structural adhesive. The heating device is electrically connected to the control system, allowing the control system to precisely adjust the heating power and duration to meet the curing process requirements of different thermally conductive structural adhesives. Temperature sensors are used to acquire real-time temperature data of the enclosure environment and the battery pack surface. These sensors can be high-precision temperature sensing elements such as thermocouples, resistance temperature detectors (RTDs) (e.g., Pt100), or semiconductor temperature sensors. They are strategically arranged inside the enclosure 1, for example, to monitor the ambient temperature within the enclosure space and to monitor the battery pack's own heating status near the battery pack surface (especially the new battery cell area). Through these sensors, the control system can obtain accurate temperature feedback, enabling fine-grained temperature control and preventing localized overheating or underheating.

[0053] During implementation, after the control system confirms that the top cover 2 is locked, it activates the heating device and circulating fan of the temperature control unit 3 to heat the environment inside the enclosure, raising the temperature to the preset heating and curing temperature range. This step aims to ensure the safety and effectiveness of the heating process. Before starting heating, the control system receives a signal from the position sensor on the mechanical locking device of the top cover 2 to confirm that the top cover 2 is completely closed and reliably locked. This safety interlock mechanism prevents heating from starting if the top cover 2 is not completely closed, thereby avoiding heat loss and potential safety risks. Once the top cover 2 is confirmed to be locked, the control system instructs the heating device to start working and simultaneously activates the circulating fan. The function of the circulating fan is to force airflow inside the enclosure, ensuring that heat is evenly distributed inside the enclosure 1, avoiding excessive temperature gradients, and thus ensuring uniform heating of the entire battery pack, creating conditions for the full curing of the thermally conductive structural adhesive. The preset heating and curing temperature range is determined based on the chemical properties and curing curve of the thermally conductive structural adhesive used, as well as the heat resistance limit of the battery pack components.

[0054] During the heat curing process, the control system monitors the internal temperature of the enclosure and the surface temperature of the battery pack in real time using temperature sensors. Real-time monitoring is crucial for achieving precise temperature control. The control system continuously receives data from the internal temperature sensors and the battery pack surface temperature sensors. By analyzing this data, the control system can understand the overall temperature trend of the internal environment and the actual heating state of the battery pack. This allows the control system to dynamically adjust the output power of the heating device according to a preset heating curve or target temperature, for example, through a PID control algorithm, to ensure that the internal temperature of the enclosure and the surface temperature of the battery pack are always maintained within the optimal range required for the curing of the thermally conductive structural adhesive, while preventing damage to the battery pack due to overheating. Simultaneously, a humidity sensor monitors the humidity inside the enclosure, and a humidity control device maintains the humidity within a preset range. Humidity control is critical in the curing process of some thermally conductive structural adhesives. The humidity sensor continuously monitors the relative humidity inside the enclosure and feeds the data back to the control system. Based on a preset humidity target value, the control system instructs the humidity control device to operate, for example, by increasing the humidity inside the enclosure through spraying or steam humidification, or by reducing the humidity through dehumidification when necessary. Maintaining a suitable humidity environment helps optimize the curing reaction of thermally conductive structural adhesives, preventing incomplete curing or bubble formation due to excessively dry conditions, or condensation due to excessively high humidity, thereby ensuring curing quality.

[0055] Through the above technical solution, a dedicated heating device and a high-precision temperature sensor were introduced during the heating and curing stage of battery pack repair. Combined with the control system's confirmation of the top cover's locking status, this enabled precise, real-time monitoring and control of the internal ambient temperature and the battery pack surface temperature. This effectively avoided the risks of large temperature fluctuations, uneven heating, or overheating damage to the battery pack during the heating process. Simultaneously, precise humidity control within the enclosure, achieved through a humidity sensor and humidity control device, provided an optimal environment for the curing of the thermally conductive structural adhesive, ensuring its full curing and bonding strength.

[0056] Please see Figures 1 to 4 This application further proposes a step for removing the battery pack from the housing 1 after it has warmed up, including: after heating and curing, the control system lowers the temperature inside the housing to room temperature at a controllable rate according to a preset warming program to prevent rapid cooling from causing thermal stress inside the battery pack. During the warming process, the control system continuously monitors the humidity inside the housing to ensure that no condensation occurs on the surface of the battery pack; after the temperature reaches room temperature, the quick-clamping device of the fixing platform 4 is released, and the repaired battery pack is lifted out of the housing 1 by a crane or industrial robot, completing the entire repair process.

[0057] Specifically, after the heating and curing process is completed, the control system will initiate a preset temperature recovery program. This program aims to reduce the internal temperature of the enclosure 1 at a controlled and gradual rate until it reaches room temperature. The key to this process is to avoid the battery pack being suddenly exposed to a low-temperature environment while it is at a high temperature, thereby effectively preventing the generation of internal thermal stress caused by the difference in thermal expansion coefficients of different materials and protecting the structural integrity of the battery pack. For example, the control system can set a multi-stage cooling curve according to the material characteristics and size of the battery pack, and precisely regulate the internal temperature of the enclosure through the refrigeration device of the temperature control unit 3 and the circulating fan to ensure stable temperature changes.

[0058] Meanwhile, throughout the entire temperature recovery process, the control system continuously monitors the relative humidity inside enclosure 1 using a humidity sensor. This is to ensure that condensation does not form on the battery pack surface due to excessively high ambient humidity during cooling. Condensation can lead to short circuits, corrosion, or decreased insulation performance of internal electrical components in the battery pack. Based on real-time humidity data, the control system can activate the dehumidification function of the temperature control unit 3 or adjust the temperature recovery rate to keep the battery pack surface temperature above the dew point, thereby completely preventing condensation.

[0059] Once the battery pack has fully warmed to room temperature and all temperature and humidity control procedures have been completed, the control system will issue a command to release the quick-clamping device on the fixing platform 4. This clamping device is used to securely fix the battery pack inside the housing 1 during the maintenance process. After releasing the clamp, the repaired battery pack is safely lifted out of the housing 1 using a crane or industrial robot, thus marking the successful completion of the entire in-situ maintenance process for the battery pack.

[0060] Through the above technical solution, after the battery pack has completed heating and curing, the control system can gradually reduce the temperature inside the chamber to room temperature at a controllable rate according to a preset rewarming program. This controlled cooling process effectively avoids excessive thermal stress generated by rapid cooling of the battery pack, thereby protecting the integrity of the internal structural components and preventing deformation or connection failure. Simultaneously, during the rewarming process, the control system continuously monitors and adjusts the humidity inside the chamber to ensure that the surface temperature of the battery pack remains above the dew point temperature, thus preventing condensation and avoiding problems such as short circuits, corrosion, or decreased insulation performance that may be caused by moisture. Finally, after the battery pack has fully rewarmed and been released from its fixation, it can be safely removed using a crane or industrial robot, ensuring the reliability of the repaired battery pack in terms of structure, electrical system, and environmental adaptability, significantly improving the quality and safety of in-situ battery pack repair.

[0061] Please see Figures 1 to 4This application further proposes that after the above-mentioned step of locking the battery pack to be repaired through the fixing platform 4, the electrical interface of the battery pack and the temperature monitoring device inside the battery pack are connected through the quick-connect interface panel provided on the side wall of the housing 1.

[0062] The side wall of enclosure 1 is equipped with a quick-connect interface panel, which is electrically connected to the control system. This quick-connect interface panel is typically located on the exterior of the side wall of enclosure 1 and integrates various electrical connection ports, such as power interfaces, data communication interfaces, and sensor signal interfaces. Its design aims to provide a convenient, fast, and reliable connection method, allowing external devices or internal battery packs to communicate and exchange data with the control system.

[0063] The quick-connect interface panel eliminates the need for complex wiring during each maintenance, improving operational efficiency and safety. A temperature monitoring device is pre-installed in a critical location within the battery pack, such as near the thermally conductive structural adhesive or the battery cells, to monitor the internal temperature in real time. This sensor can be a thermistor, thermocouple, or integrated temperature sensor, depending on the required measurement accuracy, response speed, and operating environment. Its core function is to provide accurate internal temperature data, not just ambient or surface temperature. After the battery pack is secured inside the housing 1, operators or automated equipment connect the battery pack's electrical interfaces (e.g., interfaces for power supply, communication, or diagnostics) and the temperature monitoring device's signal lines to the control system via the quick-connect interface panel. This connection ensures the control system can acquire the battery pack's operating status information and internal temperature data. The temperature signal collected by the temperature monitoring device is transmitted to the control system via the quick-connect interface panel, serving as the basis for temperature control decisions. The temperature monitoring device continuously collects internal temperature data from the battery pack and transmits these analog or digital signals to the control system via the quick-connect interface panel. After receiving these real-time temperature data, the control system compares them with preset process parameters (such as target freezing temperature and heating curing temperature range), and adjusts the operating strategy of the temperature control unit 3 accordingly, such as the power output of the refrigeration or heating device and the speed of the circulating fan, in order to achieve precise control of the internal temperature of the battery pack.

[0064] Through the above technical solution, a quick-connect interface panel is installed on the side wall of the housing 1, and the control system can directly acquire real-time temperature data inside the battery pack by utilizing temperature monitoring devices inside the battery pack. This allows temperature control decisions to no longer rely solely on the ambient temperature inside the housing or the surface temperature of the battery pack, but rather on the actual thermal state inside the battery pack. Therefore, during the freezing process, the control system can more accurately determine whether the thermally conductive structural adhesive has reached the embrittlement temperature zone, avoiding over-freezing or under-freezing, thereby ensuring that the thermally conductive structural adhesive is fully embrittled, facilitating the removal of failed battery cells. Similarly, during the heating and curing process, the control system can monitor the curing temperature of the thermally conductive structural adhesive of the new battery cell in real time, ensuring that it completes curing within the optimal temperature range, improving curing quality and efficiency.

[0065] Please see Figures 1 to 4 This application further proposes that a mechanical locking device is provided between the top cover 2 and the chamber 1, and a position sensor is provided on the mechanical locking device; the control system also includes a safety interlock circuit; after the top cover 2 of the environmental test chamber is closed, the system further includes: detecting whether the top cover 2 is in a locked state through the position sensor; when the position sensor reports that the top cover 2 is locked, the safety interlock circuit controls the temperature control unit 3 to start running.

[0066] Specifically, the mechanical locking device is a mechanism used to securely connect the top cover 2 to the housing 1. Its function is to ensure that the top cover 2 is reliably fixed to the top of the housing 1 when closed, preventing accidental opening or loosening due to internal pressure changes or external vibrations during the operation of the temperature control unit 3. This device can be implemented in various forms. For example, it can be a set of manually operated bolts or clips, which are tightened or fastened manually to achieve locking; or it can be a more automated hydraulic or pneumatic clamping mechanism, which drives a hydraulic cylinder or air cylinder through commands issued by the control system, so that the clamp automatically and tightly binds the top cover 2 to the housing 1. In addition, it can also be an electric screw-driven locking mechanism, in which the screw is rotated by a motor to achieve the fastening of the top cover 2.

[0067] A position sensor is a device used to detect the status of the mechanical locking mechanism in real time, accurately determining whether the top cover 2 is in the fully locked position. This sensor can employ various technologies; for example, it can be a limit switch installed at a key part of the locking mechanism, triggering a switch signal when the locking mechanism is in position; it can also be a proximity switch, such as an inductive or magnetic switch, outputting a signal by sensing the position of the locking component; or it can be a photoelectric sensor, determining the locking status by detecting the obstruction or reflection of a light beam. The position sensor transmits the detected status information (e.g., an electrical signal indicating "locked") to the control system.

[0068] The control system is the central control unit of the entire battery pack in-situ maintenance method, responsible for coordinating and managing the operation of various equipment components. It receives signals from various sensors and sends control commands to actuators (such as temperature control unit 3, mechanical locking device, etc.) according to preset program logic and process parameters. The control system is usually composed of an industrial-grade programmable logic controller (PLC) or an industrial computer, and has data acquisition, processing, logic judgment, and output control functions.

[0069] A safety interlock circuit is a critical safety mechanism within or in conjunction with a control system. Its core function is to determine whether certain high-risk operations (such as starting the temperature control unit 3) are permitted based on specific conditions (such as the locked state of top cover 2). This circuit can exist in the form of hardware logic (e.g., implemented through relays or safety modules) or software logic (interlock conditions are written in the PLC program). Its design goal is to prevent equipment from operating in unsafe conditions, thereby protecting the safety of equipment, products, and operators.

[0070] After the top cover 2 is closed, the control system continuously receives signals from the position sensor. The position sensor monitors the physical state of the mechanical locking device in real time. For example, when the locking mechanism is fully engaged or in place, the position sensor sends a specific signal (such as a closed signal or a high-level signal) indicating that the top cover 2 is in the locked state. Based on the received signal, the control system determines whether the top cover 2 has met the safety locking requirements. Only when the control system confirms through the position sensor that the top cover 2 is fully locked, and this "locked" signal is received and verified by the safety interlock circuit, will the safety interlock circuit release the restriction on starting the temperature control unit 3. At this time, the control system can send a start command to the temperature control unit 3 to begin freezing or heating.

[0071] By employing the aforementioned technical solution, a mechanical locking device and a position sensor are installed between the top cover 2 and the housing 1, and a safety interlock circuit is introduced. This application enables real-time detection of the locking status of the top cover 2. The safety interlock circuit only allows the temperature control unit 3 to start when the position sensor indicates that the top cover 2 is fully locked. This effectively prevents the temperature control unit 3 from starting if the top cover 2 is not fully closed or reliably locked, thereby preventing temperature leakage, energy loss, and potential safety risks to maintenance personnel within the housing.

[0072] Please see Figures 1 to 4 This application further proposes that the temperature sensor is an adhesive layer temperature sensor installed inside the housing 1, and the adhesive layer temperature sensor is located in the edge area adjacent to the adhesive layer of the battery pack; after the step of starting the cooling device and circulating fan of the temperature control unit 3, the application further includes: monitoring the adhesive layer temperature of the thermally conductive structural adhesive of the battery pack in real time through the adhesive layer temperature sensor, and starting the timing of the freezing duration when the adhesive layer temperature reaches the adhesive layer embrittlement temperature zone.

[0073] Specifically, the adhesive layer temperature sensor is a sensor specifically designed to measure the temperature of the thermally conductive structural adhesive layer. It can be a miniature thermocouple, thermistor, or resistance temperature detector (RTD), and its selection should ensure high accuracy and rapid response within the target temperature range. This sensor is strategically placed inside the housing 1, at the edge of the thermally conductive structural adhesive layer adjacent to the battery pack. This edge placement is chosen because it is generally easier to install and position the sensor, avoiding unnecessary interference with the main battery pack structure. Furthermore, under uniform cooling conditions, temperature changes in the edge area can effectively represent or indicate the overall temperature state of the adhesive layer. After the cooling unit and circulating fan of the temperature control unit 3 are activated to cool the environment inside the housing, the adhesive layer temperature sensor continuously and in real-time collects the actual temperature data of the thermally conductive structural adhesive layer of the battery pack and transmits this data to the control system. The control system determines whether the adhesive layer temperature has reached a preset embrittlement temperature range (e.g., -20°C to -30°C). Once the adhesive layer temperature enters the embrittlement temperature range, the control system precisely starts a timer for the freezing duration to ensure the effectiveness of the freezing treatment.

[0074] Through the above technical solution, this application can achieve direct, real-time monitoring of the temperature of the thermally conductive structural adhesive layer inside the battery pack, rather than relying solely on indirect indicators such as the ambient temperature inside the box or the surface temperature of the battery pack. This precise temperature feedback mechanism ensures that the timing of the freezing duration only begins when the thermally conductive structural adhesive itself has reached the required embrittlement temperature range, thereby avoiding insufficient or excessive freezing due to temperature lag or inaccurate measurement.

[0075] Please see Figures 1 to 4 This application further proposes that after the heat curing is completed, the process includes: keeping the battery pack inside the housing 1, returning the battery pack to room temperature, connecting an airtightness testing device through a control system to perform an airtightness test on the battery pack, and removing the battery pack from the housing after confirming that it is qualified.

[0076] Specifically, after completing the cell replacement and the curing of the thermally conductive structural adhesive, the battery pack remains inside the chamber 1 of the environmental test chamber without being transferred to any other station. This measure aims to avoid secondary pollution, mechanical damage or environmental changes that may be introduced by handling during the maintenance process, ensure that the battery pack completes subsequent inspections in a controlled environment, thereby maintaining the continuity of the maintenance process and the stability of the environment. On this basis, the intelligent central control system of the entire maintenance method is responsible for coordinating and managing various operations, and performs electrical connection and data interaction with external air tightness detection equipment. The control system may be a programmable logic controller (PLC), an industrial computer or an embedded system, which realizes automatic control and status monitoring of the maintenance process through preset programs and sensor feedback. The air tightness detection equipment is a professional instrument for evaluating the sealing performance of battery packs, and its working principle usually includes applying a certain pressure or vacuum to the inside or outside of the battery pack, and then monitoring pressure changes or gas leakage conditions. Common detection methods include the pressure decay method, the flow method, the helium mass spectrometer leak detection method, etc. The equipment judges whether the sealing of the battery pack meets the preset standard by accurately measuring the pressure difference or leakage rate inside and outside the battery pack. Connecting the air tightness detection equipment through the control system to perform air tightness detection on the battery pack aims to verify whether the maintained battery pack has good sealing performance. In specific implementation, the air tightness detection equipment is connected to a specific interface of the battery pack (for example, a reserved detection port or connected through a quick-connect interface panel) to pressurize or evacuate the interior of the battery pack, and monitor the change in pressure or vacuum degree within a certain period of time. If the change in pressure or vacuum degree is within the allowable range, the air tightness is considered to be qualified. Only after the air tightness detection confirms qualification will the system execute the subsequent temperature returning and taking-out steps. If the detection result is unqualified, the system will issue an alarm and may guide maintenance personnel to conduct further inspection and repair until the air tightness reaches the standard. This is an effective quality control mechanism aimed at preventing unqualified products from entering subsequent links and ensuring maintenance quality.

[0077] The above description is only an exemplary embodiment of the present invention, and is not intended to limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the specification and accompanying drawings of the present invention under the technical concept of the present invention, or direct / indirect application in other relevant technical fields, are all included in the patent protection scope of the present invention.

Claims

1. A method for in-situ repair of a battery pack, characterized in that, Includes the following steps: The battery pack to be repaired is hoisted into the interior of the environmental test chamber and locked in place by the fixing platform inside the chamber. Close the top cover of the environmental test chamber and start the temperature control unit to freeze the environment inside the chamber, causing the thermally conductive structural adhesive inside the battery pack to enter a brittle state. Open the top cover to open the top of the box, and the maintenance equipment or personnel can enter the box from above to remove the failed battery cell and install a new battery cell; Close the top cover and start the temperature control unit of the environmental test chamber to heat the environment inside the chamber, so that the thermally conductive structural adhesive of the new battery cell can be cured. After the battery pack has cooled down, remove the battery pack from the casing. Throughout the entire processing, the battery pack remained inside the environmental test chamber without any relocation of the workstation.

2. The battery pack in-situ repair method as described in claim 1, characterized in that, The environmental test chamber includes a box body with an opening at the top, a top cover that is movably installed on the top of the box body and can be opened or closed, and a fixed platform set inside the box body; the top cover has a lifting ring at the top, or the top cover is a split structure, and the top cover is slidably connected to the opening of the box body in the horizontal direction through a translation mechanism; The step of hoisting the battery pack to be repaired into the environmental test chamber and locking it in place using the fixing platform inside the chamber includes: The top cover is lifted and removed entirely using a crane or industrial robot, or the top cover is pushed from the opening of the box to the side, so that the opening of the box is fully open; The battery pack is hoisted and placed inside the housing; Positioning is achieved by the positioning pins on the fixed platform engaging with the positioning holes at the bottom of the battery pack, and then the battery pack is clamped and fixed by the quick clamping device on the fixed platform.

3. The battery pack in-situ repair method as described in claim 1, characterized in that, The environmental test chamber also includes a temperature control unit for regulating the temperature and humidity inside the chamber, and a control system for controlling the operation of the temperature control unit and monitoring the environmental parameters inside the chamber. The temperature control unit includes a refrigeration device, a circulating fan, a humidity sensor, and a humidity control device that are electrically connected to the control system. The steps of closing the top cover of the environmental test chamber and starting the temperature control unit to freeze the environment inside the chamber, causing the thermally conductive structural adhesive inside the battery pack to enter a brittle state, include: After the battery pack is placed into the enclosure, the process parameters required for this maintenance are set through the touch screen of the control system, including the target freezing temperature, freezing duration, target heating temperature, heating duration, and humidity control target. Start the refrigeration unit and circulating fan of the temperature control unit to cool down the environment inside the box, so as to reduce the temperature inside the box to the embrittlement temperature range of the adhesive layer; During the freezing process, the control system monitors the relative humidity inside the chamber through the humidity sensor of the temperature control unit, and controls the humidity inside the chamber within a preset range through the humidity control device of the temperature control unit.

4. The battery pack in-situ repair method as described in claim 3, characterized in that, The steps of opening the top cover to expose the top of the enclosure, allowing maintenance equipment or personnel to enter the enclosure from above, remove the failed battery cells, and install new ones include: Once the adhesive layer has become sufficiently brittle, the control system will issue a warning signal. The top cover can be lifted and removed entirely using a crane or industrial robot, or the top cover can be pushed horizontally to fully open the opening of the box. Through the fully open opening at the top of the enclosure, a crane or industrial robot is used to vertically enter the enclosure and lift the failed battery cells vertically upwards. After the bottom of the new battery cell is coated with thermally conductive structural adhesive, it is vertically hoisted into the original empty battery cell position by a crane or industrial robot through the open opening at the top of the box. After confirming that the new battery cell is installed in place, return the top cover to the closed position and cover the opening at the top of the enclosure, then lock the top cover in place using the mechanical locking device.

5. The battery pack in-situ repair method as described in claim 3, characterized in that, The temperature control unit includes a heating device and a temperature sensor that are electrically connected to the control system. The steps of closing the top cover and starting the temperature control unit of the environmental test chamber to heat the environment inside the chamber, thereby curing the thermally conductive structural adhesive of the new battery cell, include: After the control system confirms that the top cover is locked, it starts the heating device and circulating fan of the temperature control unit to heat the environment inside the chamber and raise the temperature inside the chamber to the preset heating and curing temperature range. During the heating and curing process, the control system monitors the temperature inside the box and the surface temperature of the battery pack in real time through temperature sensors; The humidity inside the chamber is monitored by a humidity sensor, and the humidity is controlled within a preset range by a humidity control device.

6. The battery pack in-situ repair method as described in claim 1, characterized in that, The step of removing the battery pack from the casing after it has cooled down includes: After the heating and curing process is completed, the control system lowers the temperature inside the box to room temperature at a controllable rate according to the preset temperature recovery program to prevent rapid cooling from causing thermal stress inside the battery pack. During the temperature recovery process, the control system continuously monitors the humidity inside the box to ensure that no condensation occurs on the surface of the battery pack. After the battery pack has returned to room temperature, the quick clamping device on the fixed platform is released, and the repaired battery pack is lifted out of the box by a crane or industrial robot, thus completing the entire repair process.

7. The battery pack in-situ repair method as described in claim 3, characterized in that, The side wall of the enclosure is provided with a quick-connect interface panel, which is electrically connected to the control system; the battery pack is equipped with a temperature monitoring device. After the step of locking and securing the battery pack via the fixing platform, the method further includes: The electrical interface of the battery pack and the temperature monitoring device are connected via the quick-connect interface panel; The temperature signal collected by the temperature monitoring device is transmitted to the control system via the quick-connect interface panel, and is used as the basis for temperature control decisions.

8. The battery pack in-situ repair method as described in claim 3, characterized in that, A mechanical locking device is provided between the top cover and the housing, and a position sensor is provided on the mechanical locking device; the control system also includes a safety interlock circuit; After closing the top cover of the environmental test chamber, the following is also included: The position sensor is used to detect whether the top cover is in a locked state. When the position sensor indicates that the top cover is locked, the safety interlock circuit controls the temperature control unit to start operation.

9. The battery pack in-situ repair method as described in claim 5, characterized in that, The temperature sensor is an adhesive layer temperature sensor installed inside the housing, and the adhesive layer temperature sensor is located in the edge area adjacent to the adhesive layer of the battery pack; Following the step of starting the refrigeration unit and circulating fan of the temperature-controlled unit, the following is also included: The temperature of the thermally conductive structural adhesive of the battery pack is monitored in real time by the adhesive layer temperature sensor. When the temperature of the adhesive layer reaches the embrittlement temperature zone of the adhesive layer, the duration of freezing is started.

10. The battery pack in-situ repair method as described in claim 1, characterized in that, After the heat curing is completed, the process also includes: Keep the battery pack inside the box, allow it to return to room temperature, connect the control system to an airtightness testing device to perform an airtightness test on the battery pack, and remove the battery pack from the box only after confirming that it is qualified.

Images