A compact battery module layered arrangement and energy equalization management system

Abstract

The application discloses a compact battery module layered arrangement and energy equalization management system, which comprises a layered stacked battery module and an energy equalization management system, the battery module is composed of M battery layers stacked along the height direction, and an insulating baffle assembly is arranged between adjacent battery layers, and an equalization circuit is integrated in the baffle.The energy equalization management system comprises an intra-layer equalization module, an inter-layer equalization module and a control unit, and the intra-layer equalization module is used for energy equalization between single units in the same battery layer.In the application, the control unit executes a hierarchical control strategy according to the single unit terminal voltage, preferentially eliminates a small pressure difference in the layer, and then processes a larger deviation between layers.The insulating baffle assembly simultaneously has multiple functions of structural support, electrical insulation, circuit carrier and heat dissipation channel, so that the module structure is compact, the equalization path is short, the heat management capability is good, and the overall consistency and space utilization are improved.

Description

Technical Field

[0001] This invention belongs to the field of battery energy storage technology, specifically relating to a compact battery module layered arrangement and energy balance management system. Background Technology

[0002] In battery energy storage systems, battery modules are typically composed of a large number of individual battery cells connected in series and parallel. With the increasing demand for energy density, how to rationally arrange battery cells within a limited space to reduce module size, while effectively managing energy inconsistencies between individual cells caused by factors such as manufacturing processes, self-discharge rates, and temperature gradients, has become a technical problem that needs to be solved.

[0003] Traditional battery modules often employ a planar array arrangement or a simple unidirectional stacking structure. Their energy balancing management system is typically placed outside the module as an independent module, connected to each individual cell via numerous wires. This arrangement results in dense and complex wiring inside the module, low space utilization, and the electrical connection between the balancing circuit and the individual battery cells is susceptible to vibration and temperature changes, making long-term contact reliability difficult to guarantee.

[0004] In terms of balancing strategies, when dealing with multi-layer and multi-string battery structures, a single balancing topology requires energy to be transferred back and forth between distant cells. The balancing path is long and the losses are large. Heat loss is concentrated on a few power devices, which is not conducive to the long-term stable operation of the system and cannot respond quickly to local differences in state of charge. Summary of the Invention

[0005] The purpose of this invention is to provide a compact battery module layered layout and energy balance management system to solve the technical problems of traditional battery modules having dense and complex internal wiring, low space utilization, and concentrated heat loss, which are not conducive to the long-term stable operation of the system.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A compact battery module layered arrangement and energy balance management system, comprising:

[0008] A layered battery module, comprising M battery layers stacked along the height direction, where M≥2, with an insulating separator assembly between adjacent battery layers, and an equalization circuit integrated within the insulating separator assembly;

[0009] An energy balance management system, comprising:

[0010] An intra-layer balancing module is electrically connected to the individual cells in each battery layer and is used to balance the energy of the individual cells in the same battery layer.

[0011] Interlayer equalization module, which includes an interlayer equalization circuit in the equalization circuit and an interlayer energy bus, is electrically connected to each battery layer and is used to transfer energy between different battery layers.

[0012] The control unit is connected to the intra-layer equalization module and the inter-layer equalization module respectively. It is used to acquire the status parameters of each battery cell and control the working status of the intra-layer equalization module and the inter-layer equalization module according to the status parameters.

[0013] As a further aspect of the present invention, each battery layer includes Ns battery cells connected in series, where Ns ≥ 2, and M battery layers are connected in series to form the total output of the battery module.

[0014] As a further aspect of the present invention, the insulating separator assembly includes an equalization circuit board corresponding to each battery layer, and at least some circuit elements of the in-layer equalization module are arranged on the equalization circuit board; the thickness of the insulating separator assembly is 0.5 mm to 3 mm.

[0015] As a further aspect of the present invention, a heat dissipation channel is formed inside the insulating partition assembly, and the heat dissipation channel is connected to an external cooling fluid source.

[0016] As a further preferred embodiment of the present invention, the intra-layer equalization module includes multiple equalization units, each equalization unit being connected between two adjacent battery cells. The equalization unit includes a switching device and an energy storage element for bidirectional energy transfer between two adjacent battery cells.

[0017] As a further aspect of the present invention, the balancing current range during energy transfer by the balancing unit is 0.05C to 0.5C, where C is the capacity ratio of the battery cell.

[0018] As a further preferred embodiment of the present invention, the interlayer energy bus is a DC bus, and the interlayer equalization module includes M isolated DC / DC converters. The primary side of each isolated DC / DC converter is connected to the positive and negative terminals of a battery layer, and the secondary side is connected in parallel to the DC bus.

[0019] As a further aspect of the present invention, the rated transmission power of the inter-layer equalization module is configured to be 1.5 to 3 times the total equalization power of the intra-layer equalization module within a battery layer.

[0020] As a preferred embodiment of the present invention, the control unit is configured to execute the following control logic:

[0021] The terminal voltage of each battery cell is obtained, and the maximum voltage difference between cells in each battery layer is calculated. When the maximum voltage difference in any battery layer exceeds the first threshold, the intra-layer equalization module of the corresponding battery layer is activated until the maximum voltage difference in the battery layer is less than the first threshold.

[0022] Calculate the average cell voltage of each battery layer. When the maximum deviation of the average cell voltage of different battery layers exceeds the second threshold, activate the inter-layer equalization module to transfer energy between the battery layer with the highest average cell voltage and the battery layer with the lowest average cell voltage until the maximum deviation is less than the second threshold.

[0023] As a further aspect of the present invention, the first threshold value ranges from 10mV to 40mV, and the second threshold value ranges from 50mV to 200mV.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] In this invention, the battery cells are arranged in a layered stacking manner, with adjacent cells staggered in the horizontal direction. The upper cell is partially embedded in the gap between the lower cells, which effectively utilizes the natural recessed space generated by the cylindrical battery shape, compresses the overall size of the module in the height direction, and enhances the overall structural rigidity of the module by interlocking between layers, reducing the need for additional positioning components and improving the volumetric energy density.

[0026] The insulating partition assembly integrates electrical insulation, structural support, equalization circuitry, and heat dissipation channels into a single unit, eliminating the space occupied by an external equalization module and its connecting harness, resulting in a more compact internal structure. The equalization circuit is positioned adjacent to the individual battery cells, significantly shortening the paths for signal acquisition and energy transfer, thus reducing voltage drop and electromagnetic interference. Conductive elastic contacts achieve elastic contact with the individual cell electrodes through clamping force, eliminating numerous welding or screwing processes, making assembly and disassembly more convenient. Even under vibration and temperature fluctuation conditions, the contact remains stable due to elastic deformation.

[0027] The two-level balancing system, with its hierarchical structure, is functionally decoupled. Intra-layer balancing is handled by the nearest balancing units distributed across each partition, allowing for short-distance energy transfer between adjacent cells, resulting in fast response and low loss. Inter-layer balancing utilizes isolated converters and a DC bus for cross-layer energy dispatch. Electrical isolation between battery layers eliminates inter-layer circulating currents, and energy, after being transferred via the bus, directly applies to the two battery layers with the largest energy deviations, eliminating the need for layer-by-layer transfer and reducing the number of energy transfer stages and conversion losses. The power capacity of the inter-layer converters is proportionally higher than the total power of intra-layer balancing, ensuring that inter-layer allocation does not become a limiting factor in the overall balancing speed.

[0028] The control strategy prioritizes handling minor intra-layer differences, addressing larger inter-layer deviations only after each layer has largely stabilized. This avoids localized fluctuations triggering global equalization, reducing ineffective switching of power devices and energy turnover losses. The intra-layer equalization start-up thresholds and inter-layer equalization start-up thresholds are numerically completely offset, with no overlap between the two levels of judgment. This eliminates the possibility of equalization conflict and repeated oscillations, resulting in stable system operation and extended device lifespan.

[0029] The internal heat dissipation channels of the insulating separator work in conjunction with the edge thermal management components to allow the cooling fluid to flow directly through the interlayer area of ​​the battery. The heat generated by the equalization circuit and individual battery cells is absorbed nearby and quickly dissipated, effectively suppressing the temperature difference between the cells and preventing the inconsistency of electrochemical parameters caused by temperature difference. The thermal management and equalization management work together to maintain the uniformity of the battery module in terms of electrical characteristics and temperature. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only examples of embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the connection relationship provided in an embodiment of the present invention. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention.

[0033] See Figure 1 As shown in the figure, an embodiment of the present invention provides a compact battery module layered arrangement and energy balance management system, which includes layered battery modules and an energy balance management system.

[0034] The battery module includes M battery layers stacked along the height direction, where M≥2, and an insulating separator assembly is provided between adjacent battery layers. The insulating separator assembly integrates an equalization circuit.

[0035] The energy balancing management system includes an intra-layer balancing module, an inter-layer balancing module, and a control unit. The intra-layer balancing module is electrically connected to the individual cells within each battery layer and is used to perform energy balancing on the individual cells within the same battery layer. The inter-layer balancing module includes an inter-layer balancing circuit and an inter-layer energy bus in the balancing circuit. The inter-layer balancing module is electrically connected to each battery layer and is used to transfer energy between different battery layers. The control unit is signal-connected to both the intra-layer and inter-layer balancing modules and is used to acquire the status parameters of each individual cell and control the operating status of the intra-layer and inter-layer balancing modules based on the status parameters.

[0036] In the above scheme, the battery cells are arranged in a layered stacking manner, and the equalization circuit is directly integrated in the insulating partition between the layers. This reduces the additional wiring harnesses and independent circuit boards within the module, making the overall structure more compact. Separate modules are set up for equalizing cells within the same layer and for energy scheduling between different layers, allowing inconsistencies to be handled locally and shortening the equalization path. The control unit coordinates the two-level equalization modules based on the acquired cell status parameters, achieving automatic adaptive energy management and avoiding blind equalization actions.

[0037] Each battery layer consists of Ns series-connected battery cells, where Ns ≥ 2. M battery layers are connected in series to form the total output of the battery module. The total output is constructed by first connecting cells in series within each layer, and then connecting all layers in series. This allows for flexible matching of required voltage levels and capacity scales without significantly increasing connection complexity. The intra-layer series structure enables individual cell voltage monitoring and equalization management to be deployed on a layer-by-layer basis, facilitating the centralized arrangement of equalization circuitry within each layer and reducing the difficulty of system expansion.

[0038] The insulating separator assembly includes equalization circuit boards corresponding to each battery layer, on which at least some circuit elements of the in-layer equalization module are arranged; the thickness of the insulating separator assembly is 0.5mm to 3mm. By directly arranging the circuit elements of the in-layer equalization module on the equalization circuit board of the insulating separator, the separator simultaneously undertakes multiple functions: electrical insulation, structural support, and circuit carrier. This eliminates the need for separate installation space and connecting conductors for the equalization circuit, further reducing unnecessary gaps within the module. The separator thickness is limited to a reasonable range, ensuring reliable insulation withstand voltage and sufficient mechanical strength between layers without wasting space in the height direction due to excessive separator thickness.

[0039] The insulating separator assembly has internal heat dissipation channels that connect to an external cooling fluid source. By directly constructing these channels within the insulating separator, cooling fluid can flow between the battery layers, absorbing heat generated by individual cells and the equalization circuit during operation. The heat dissipation structure is integrated with the separator, eliminating the need for separate heat dissipation components. This short heat transfer path helps reduce temperature differences between cells and prevents localized overheating.

[0040] The intra-layer equalization module comprises multiple equalization units, each bridging two adjacent battery cells. Each equalization unit includes switching devices and energy storage elements, enabling bidirectional energy transfer between adjacent cells. By using equalization units bridging adjacent cells, energy only needs to be moved a short distance between adjacent cells, avoiding the additional voltage drop and losses associated with long circuits. The switching devices and energy storage elements work together to achieve bidirectional buck-boost conversion, moving energy from higher-voltage cells to lower-voltage cells, and vice versa. This makes the equalization process independent of a fixed direction, allowing energy to be directly reused rather than dissipated as heat, thus improving equalization efficiency.

[0041] The balancing current ranges from 0.05C to 0.5C during energy transfer in the balancing unit, where C is the capacity ratio of the individual battery cells. The balancing current is set according to a certain proportion of the battery capacity, and can automatically match an appropriate balancing capability based on the actual battery capacity used. This effectively reduces the charge difference between individual cells within the allowable time, without causing additional temperature rise or accelerating battery aging due to excessive current, and the balancing process remains stable.

[0042] The inter-layer energy bus is a DC bus. The inter-layer equalization module includes M isolated DC / DC converters. The primary side of each isolated DC / DC converter is connected to the positive and negative terminals of a battery layer, and the secondary side is connected in parallel to the DC bus. Using the DC bus as a common energy transfer node between battery layers, each layer connects through an isolated DC / DC converter, achieving electrical isolation between layers and eliminating circulating currents that might be introduced by direct parallel connection. Energy is collected via the bus before being distributed. Energy flow between any two battery layers can be completed without directly establishing a conversion channel, avoiding multiple conversion losses caused by layer-by-layer transmission. Inter-layer energy scheduling is more flexible and safer.

[0043] The rated transmission power of the inter-layer equalization module is configured to be 1.5 to 3 times the total equalization power of the intra-layer equalization module within a single battery layer. This significantly increases the power capacity for inter-layer energy transfer compared to the total rated capacity of intra-layer equalization. When significant state-of-charge (POC) deviations occur between different battery layers, the inter-layer channel has sufficient power margin for rapid adjustment, preventing the equalization process from being slowed down due to insufficient power in the inter-layer converter. This matching relationship ensures that intra-layer and inter-layer equalization are coordinated in terms of response time, guaranteeing a fast overall recovery speed.

[0044] The control unit is configured to execute the following control logic:

[0045] The terminal voltage of each battery cell is obtained, and the maximum voltage difference between cells in each battery layer is calculated. When the maximum voltage difference in any battery layer exceeds the first threshold, the intra-layer equalization module of the corresponding battery layer is activated until the maximum voltage difference in the battery layer is less than the first threshold.

[0046] The average cell voltage of each battery layer is calculated. When the maximum deviation of the average cell voltage between different battery layers exceeds a second threshold, the inter-layer equalization module is activated. Energy transfer occurs between the battery layer with the highest average cell voltage and the battery layer with the lowest average cell voltage until the maximum deviation is less than the second threshold. A layer-based equalization control strategy is established, prioritizing the elimination of small voltage differences between cells within each layer. Larger deviations between layers are addressed only after the voltage within each layer is basically consistent, avoiding system-wide equalization actions triggered by minor voltage fluctuations. During inter-layer equalization, only the two battery layers with the highest and lowest average voltages are selected for directional energy transfer, concentrating power conversion resources on the most unbalanced areas. This reduces unnecessary switching actions and energy turnover losses, contributing to system stability and extending device lifespan.

[0047] The first threshold ranges from 10mV to 40mV, and the second threshold ranges from 50mV to 200mV. The intra-layer and inter-layer equalization start-up thresholds are numerically completely staggered, ensuring that the equalization judgments at the two levels are independent and do not overlap, preventing conflicts or oscillations in the equalization actions. Based on battery characteristics, an appropriate threshold can be selected within this range to avoid frequent start-up and shutdown of the equalization circuit due to an excessively low threshold, while also preventing excessively high thresholds from accumulating voltage differences and affecting the battery pack's usable capacity and safety.

[0048] The battery cells are cylindrical, and the cells within each battery layer are arranged in a row × column matrix. Cells in adjacent battery layers are staggered horizontally, ensuring that each cell within a layer is at least partially embedded in the gaps between cells in adjacent layers. Utilizing the natural gaps created by the cylindrical battery shape, upper-layer cells are embedded into recessed areas between lower-layer cells, effectively reclaiming previously unused space and compressing the overall size of the module in the height direction. The staggered arrangement also ensures that the cells interlock between layers, enhancing the overall structural rigidity of the module, reducing reliance on external positioning components, and further improving volumetric energy density.

[0049] This embodiment also includes end plates and pull rods. The end plates are located at both ends of the battery module, and the pull rods connect the end plates and apply a clamping force to the battery module, pressing the insulating separator assembly between adjacent battery layers. The insulating separator assembly has multiple conductive elastic contacts on its surface facing the individual battery cells. These contacts are electrically connected to the equalization module within the layer and, under clamping conditions, elastically contact the electrodes of the corresponding battery cells. The end plates and pull rods apply a clamping force to the battery module, firmly clamping the insulating separator assembly between the battery layers. Simultaneously, the conductive elastic contacts on the separator surface form a pressure contact connection with the battery cell electrodes, eliminating the need for extensive welding or screwing operations. The elastic contacts can follow the slight displacement of the individual cells during vibration or temperature changes, maintaining contact reliability. Furthermore, when maintenance is required, separation is achieved simply by releasing the clamping force, making disassembly and assembly convenient.

[0050] This embodiment also includes a thermal management component, which is integrated into the edge region of the insulating separator assembly and communicates with the heat dissipation channels within the insulating separator assembly. Integrating the thermal management component into the edge region of the insulating separator allows for a more direct connection between the external cooling circuit and the internal heat dissipation channels, reducing the space occupied by pipe connections. Edge integration does not interfere with the cell arrangement within the battery layer, and the cooling fluid has a short inlet and outlet path. Combined with the flow channels within the separator, this forms a complete heat dissipation cycle, effectively controlling the module's operating temperature and maintaining battery performance and cycle life.

[0051] The battery module is composed of multiple battery layers stacked along its height. Each layer contains several battery cells connected in series, and the layers are further connected in series to form the total output. An insulating separator assembly is installed between adjacent battery layers. This separator serves as both interlayer insulation and load-bearing structure, as well as the physical carrier of the balancing circuit. An balancing circuit board is embedded within the separator, on which the circuit elements of the intralayer balancing module and the interlayer balancing circuit are arranged. Conductive elastic contacts are provided on the surface of the insulating separator facing the battery cells. Under the clamping force applied by the end plates and pull rods at both ends of the module, the elastic contacts form a pressure bond with the individual cell electrodes, thereby establishing an electrical connection between the balancing circuit and each individual cell, eliminating the need for soldering wires.

[0052] Energy balancing management is divided into two levels: intra-layer balancing and inter-layer balancing. The intra-layer balancing module consists of multiple balancing units connected between adjacent cells within the same battery layer. Each balancing unit includes switching devices and energy storage elements, directly transferring energy between adjacent cells via bidirectional buck-boost converters. The inter-layer balancing module contains isolated DC / DC converters corresponding to each battery layer. The primary side of each converter is connected to the output of the corresponding battery layer, and the secondary side is connected in parallel to a common DC bus. The rated transmission power of the inter-layer balancing module is designed to be higher than the total intra-layer balancing power within a single layer, reserving sufficient power margin for inter-layer energy dispatch.

[0053] The control unit collects the terminal voltage of all battery cells and performs tiered judgment. First, it calculates the maximum voltage difference between cells within each battery layer. When the maximum voltage difference within any layer exceeds a set first threshold, the intra-layer equalization module for that layer is activated. This module performs bidirectional energy transfer along the paths of adjacent cells with the highest and lowest voltages within the layer, until the intra-layer voltage difference falls below the first threshold. Then, it calculates the average cell voltage of each battery layer. When the deviation between the average voltages of different layers exceeds a second threshold, the inter-layer equalization module is activated. This module controls the isolated converter corresponding to the battery layer with the highest average voltage to release energy to the DC bus, while simultaneously controlling the converter corresponding to the battery layer with the lowest average voltage to absorb energy from the DC bus, until the inter-layer deviation drops below the second threshold. The two thresholds are numerically completely separate, ensuring that the judgments for intra-layer and inter-layer equalization are independent and do not interfere with each other.

[0054] The insulating partition assembly has a heat dissipation channel inside, which is connected to the thermal management component integrated on the edge of the partition. External cooling fluid enters the internal flow channel of the partition through the thermal management component, and carries away the heat generated by the individual units and the equalization circuit nearby.

[0055] During assembly, individual battery cells are arranged in a matrix to form battery layers. Insulating separator assemblies are placed between adjacent battery layers, aligning the conductive elastic contacts on the separator surface with the positive or negative electrodes of each cell. End plates are installed at both ends of the module, pull rods are inserted, and clamping force is applied to tightly hold the insulating separator assemblies between the battery layers. The elastic contacts form reliable elastic contact with the cell electrodes, completing the mechanical assembly and electrical connection of the battery module. The thermal management components are connected to an external cooling circuit, and the control unit is connected to each equalization module and voltage acquisition line.

[0056] During operation, the control unit continuously monitors the terminal voltage of each battery cell. When the maximum voltage difference between cells within a battery layer exceeds a set threshold, intra-layer equalization is automatically initiated. The equalization unit transfers energy between adjacent high and low voltage cells in a bidirectional switching manner until the voltage difference decreases. When the deviation of the average voltage across layers exceeds another threshold, inter-layer equalization is automatically initiated. Energy is transferred between the battery layers with the highest and lowest average voltages via the DC bus and an isolated converter until the deviation is reduced. During equalization, the heat generated by the equalization circuit and the heat accumulated between battery layers are continuously carried away by cooling fluid through the heat dissipation channels inside the insulating separator.

[0057] During maintenance, simply remove the clamping force of the pull rod and end plate, and the insulating separator assembly can be separated from the battery cell, making it easy to inspect and replace the cell or separator.

[0058] In this embodiment, the battery module is composed of M battery layers stacked along the height direction, where M is an integer not less than 2, typically ranging from 2 to 10. Each battery layer contains Ns battery cells connected in series, where Ns is an integer not less than 2, for example, Ns is 4 to 20. After the M battery layers are connected in series, the module's total positive output terminal and total negative output terminal are brought out. The battery cells can be cylindrical lithium-ion batteries with capacities between 1Ah and 100Ah, such as the common 18650, 21700, or larger specifications.

[0059] An insulating separator assembly is installed between two adjacent battery layers. This insulating separator assembly is a multi-layered composite structure, with an embedded equalization circuit board containing equalization circuitry. This equalization circuitry includes at least some circuit elements of the intra-layer equalization module and the inter-layer equalization circuitry of the inter-layer equalization module. The total thickness D of the insulating separator assembly is controlled between 0.5mm and 3mm to balance mechanical strength, insulation performance, and compactness. Multiple conductive elastic contacts are provided on the upper and lower surfaces of the insulating separator assembly facing the battery cells. These contacts are electrically connected to the equalization circuit board via internal wiring. During module assembly, a certain clamping force is applied by end plates and pull rods at both ends, tightly clamping the insulating separator assembly between adjacent battery layers. The conductive elastic contacts then reliably and elastically contact the positive or negative electrode of the corresponding battery cell, achieving electrical connection between the equalization circuitry and each cell. This avoids the need for numerous soldered wires, facilitating assembly and maintenance.

[0060] The insulating separator assembly can also have heat dissipation channels inside, which are connected to thermal management components integrated into the edge area of ​​the separator. These thermal management components can be connected to an external liquid cooling or air cooling system. In this way, the heat generated during the operation of the equalization circuit and the heat transferred between battery layers can be quickly dissipated through the insulating separator assembly, maintaining a uniform internal temperature of the module.

[0061] Each battery layer consists of Ns battery cells connected in series to form a battery string. The intra-layer balancing module includes multiple balancing units connected between adjacent battery cells. Each balancing unit employs a bidirectional Buck-Boost or switched-capacitor topology, containing two switching transistors and an energy storage inductor or capacitor, capable of transferring energy from a higher-voltage cell to an adjacent lower-voltage cell. The allowable balancing current range for the balancing unit is 0.05C to 0.5C, where C is the cell capacity ratio. For example, for a 3Ah cell, the balancing current can be 0.15A to 1.5A. The intra-layer balancing module redistributes energy among cells within the same battery layer, effectively eliminating inconsistencies between cells within the layer.

[0062] The inter-layer equalization module comprises M isolated DC / DC converters and a shared inter-layer energy bus, which is a DC bus. The primary side of each isolated DC / DC converter is connected to the positive and negative terminals of the corresponding battery layer, while the secondary side is connected in parallel to the DC bus. The DC / DC converters are preferably bidirectional flyback or full-bridge converters, and their rated transmission power is designed to be 1.5 to 3 times the total equalization power of the intra-layer equalization module within that layer. The total equalization power of the intra-layer equalization module within a battery layer refers to the sum of the power that all equalization units in that layer can transmit simultaneously under rated equalization current. For example, if Ns is 8 and the rated power of each equalization unit is approximately 3W, then the total equalization power is approximately 24W, and the corresponding rated power of the DC / DC converter can be 40W to 70W. This power ratio ensures that inter-layer energy transfer can respond quickly and will not become a bottleneck for equalization speed.

[0063] The control unit includes a microcontroller, a voltage acquisition front-end, and a communication interface. The microcontroller acquires the terminal voltage of each battery cell through a multi-channel, high-precision analog-to-digital converter. This process is either periodic or triggered by individual cell voltage changes.

[0064] Step S1: Collect the voltage of all individual battery cells;

[0065] Step S2: For each battery layer, calculate the difference between the maximum and minimum voltages within the layer;

[0066] Step S3: Determine if the maximum voltage difference within a battery layer exceeds the first threshold. The first threshold can be selected in the range of 10mV to 40mV, for example, 20mV. If so, in step S4, activate the intra-layer equalization module for that layer to perform bidirectional energy transfer on the adjacent cell paths with the highest and lowest voltages until the maximum voltage difference within that layer is reduced to below the first threshold.

[0067] Step S5: Calculate the average cell voltage of each battery layer and determine the deviation between the highest and lowest average voltages;

[0068] Step S6: Determine whether the average voltage deviation between layers exceeds the second threshold. The second threshold can be selected in the range of 50mV to 200mV, for example, 100mV. If so, then in step S7, start the inter-layer equalization module, control the isolated DC / DC converter corresponding to the battery layer with the highest average voltage to release energy to the DC bus, and at the same time control the converter corresponding to the battery layer with the lowest average voltage to absorb energy from the DC bus until the average voltage deviation between layers drops below the second threshold.

[0069] Through the aforementioned two-stage equalization strategy, minor intra-layer differences are rapidly processed by high-efficiency near-field equalization units distributed within the insulating partition assembly, while larger inter-layer differences are handled through global energy scheduling via isolated converters and the DC bus. Since the upper limit of the first threshold is 40mV and the lower limit of the second threshold is 50mV, the two thresholds are numerically completely separated, ensuring that the judgments for intra-layer and inter-layer equalization are independent, thus avoiding conflicts or oscillations between the two levels of equalization actions. The overall system achieves high equalization efficiency and dispersed heat loss.

[0070] To further reduce the overall height of the module, the battery cells are arranged in a row × column matrix within each battery layer, and the cells in adjacent battery layers are staggered on the horizontal plane, meaning that the bottom part of the cells in the upper layer is embedded in the gap between the cells in the lower layer, forming an interleaved stack. This arrangement can effectively reduce the overall size of the module in the height direction and enhance the interlocking force between layers.

[0071] The above description illustrates the basic principles of the present invention. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. The above embodiments and descriptions in the specification are only for illustrating the principles of the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and scope of the present invention without departing from the scope of the present invention should be included within the protection scope of the present invention.

Claims

1. A compact battery module layered arrangement and energy balance management system, characterized in that... include: A layered battery module, the battery module comprising M battery layers stacked along the height direction, M≥2, an insulating separator assembly is provided between adjacent battery layers, and an equalization circuit is integrated within the insulating separator assembly; An energy balance management system, comprising: An intra-layer balancing module is electrically connected to the individual cells in each battery layer and is used to perform energy balancing on the individual cells in the same battery layer. The inter-layer equalization module includes an inter-layer equalization circuit and an inter-layer energy bus in the equalization circuit. The inter-layer equalization module is electrically connected to each of the battery layers and is used to transfer energy between different battery layers. The control unit is connected to the intra-layer equalization module and the inter-layer equalization module respectively, and is used to acquire the state parameters of each battery cell and control the working state of the intra-layer equalization module and the inter-layer equalization module according to the state parameters.

2. The compact battery module layered arrangement and energy balance management system according to claim 1, characterized in that: Each of the battery layers includes Ns battery cells connected in series, where Ns ≥ 2, and M of the battery layers are connected in series to form the total output of the battery module.

3. The compact battery module layered arrangement and energy balance management system according to claim 2, characterized in that: The insulating separator assembly includes a balancing circuit board corresponding to each of the battery layers, and at least some circuit elements of the in-layer balancing module are arranged on the balancing circuit board; the thickness of the insulating separator assembly is 0.5 mm to 3 mm.

4. The compact battery module layered arrangement and energy balance management system according to claim 3, characterized in that: The insulating partition assembly has a heat dissipation channel inside, which is connected to an external cooling fluid source.

5. A compact battery module layered arrangement and energy balance management system according to claim 2, characterized in that: The intralayer equalization module includes multiple equalization units, each of which is connected between two adjacent battery cells. Each equalization unit includes a switching device and an energy storage element for bidirectional energy transfer between the two adjacent battery cells.

6. A compact battery module layered arrangement and energy balance management system according to claim 5, characterized in that: The equalization current range for energy transfer by the equalization unit is 0.05C to 0.5C, where C is the capacity ratio of the battery cell.

7. A compact battery module layered arrangement and energy balance management system according to claim 2, characterized in that: The interlayer energy bus is a DC bus, and the interlayer equalization module includes M isolated DC / DC converters. The primary side of each isolated DC / DC converter is connected to the positive and negative terminals of one of the battery layers, and the secondary side is connected in parallel to the DC bus.

8. A compact battery module layered arrangement and energy balance management system according to claim 7, characterized in that: The rated transmission power of the inter-layer equalization module is configured to be 1.5 to 3 times the total equalization power of the intra-layer equalization module within one battery layer.

9. A compact battery module layered arrangement and energy balance management system according to any one of claims 2 to 8, characterized in that: The control unit is configured to execute the following control logic: The terminal voltage of each battery cell is obtained, the maximum voltage difference between cells in each battery layer is calculated, and when the maximum voltage difference in any battery layer exceeds a first threshold, the intra-layer equalization module of the corresponding battery layer is activated until the maximum voltage difference in the battery layer is less than the first threshold. Calculate the average cell voltage of each battery layer. When the maximum deviation of the average cell voltage of different battery layers exceeds the second threshold, activate the inter-layer equalization module to transfer energy between the battery layer with the highest average cell voltage and the battery layer with the lowest average cell voltage until the maximum deviation is less than the second threshold.

10. A compact battery module layered arrangement and energy balance management system according to claim 9, characterized in that: The first threshold ranges from 10mV to 40mV, and the second threshold ranges from 50mV to 200mV.

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