A boost type vertical lithium iron phosphate energy storage battery system and an independent maintenance method thereof

Abstract

The present application relates to a kind of vertical lithium iron phosphate battery systems of boost type energy storage and independent maintenance method thereof, system is stacked from top to bottom by top cover, bus box, battery unit and base;Battery unit includes N vertically stacked battery module, each module side panel integrates battery management control board and boost converter, the low-voltage end of boost converter is directly connected with battery group, and the high-voltage end is outputted with floating connector after boost DC;Adjacent battery module realizes separable electrical plug-in by male and female floating plug-in terminal.The present application distributes boost unit in each battery module, realizes module level boost and fault isolation, compared with centralized boost architecture, system is more reliable, and line loss is smaller;With the help of floating connector and positioning structure, module independent maintenance is realized, solve the problem that traditional energy storage system overhaul needs whole machine disassembly, maintenance difficulty, cost and reconstruction difficulty.

Description

Technical Field

[0001] This invention relates to the field of energy storage battery technology, and in particular to a boost-type vertical lithium iron phosphate energy storage battery system and its independent maintenance method. Background Technology

[0002] As distributed energy storage applications extend from centralized power stations to residential and small-scale commercial and industrial applications, high-voltage energy storage systems face more stringent requirements in terms of integration density, operational safety, and maintenance efficiency. Currently, mainstream high-voltage energy storage battery systems mainly adopt the following two architectures: The first architecture is a direct long-string series architecture of cells, which directly outputs high voltage (such as 400V-800V) by connecting dozens or even hundreds of cells in series inside the battery pack. Although this architecture is simple in structure, the performance degradation or failure of a single cell will trigger the protection of the entire string, causing the entire equipment to shut down, making it difficult to guarantee the system's fault tolerance and power supply continuity; at the same time, the large number of cells connected in series leads to stringent requirements for cell consistency, a large battery pack size, and high maintenance costs.

[0003] The second architecture is a centralized boost converter architecture, in which a high-power DC / DC boost converter is centrally located at the top or bottom of the battery cluster or battery pack to boost the low-voltage DC power from the battery cells before output. While this architecture avoids long series connections between battery cells, it still has the following inherent drawbacks: the centralized placement of the boost converter means that a converter failure will paralyze the entire system, highlighting a reliability bottleneck; the low-voltage side cables need to carry high current transmission, resulting in high line losses and limited system efficiency; the separate placement of the boost converter and battery modules requires long low-voltage power lines and signal acquisition harnesses, leading to low integration and complex assembly; and in the event of a single battery module failure, maintenance still requires disassembling the entire battery cluster structure, making true modular independent maintenance impossible.

[0004] In terms of maintenance, when troubleshooting existing energy storage battery systems, operators typically need to disassemble the entire unit or battery cluster, which is difficult to perform, costly to maintain, and challenging to modify. This fails to meet the needs of residential and small-scale commercial and industrial applications for rapid maintenance and on-demand expansion. In terms of scenario adaptation, residential and small-scale commercial and industrial applications have stringent requirements regarding floor space, ease of installation, expansion flexibility, and low-noise operation. Existing centralized boost architectures struggle to simultaneously meet the dual demands of high integration and ease of maintenance.

[0005] The above problems are worth solving. Summary of the Invention

[0006] The main objective of this invention is to provide a boost-type vertical lithium iron phosphate energy storage battery system and its independent maintenance method, aiming to improve the shortcomings of the prior art and solve the problems of low integration, low modularity, poor fault tolerance of existing energy storage battery systems, and the need to disassemble the whole machine for fault repair, which leads to high maintenance difficulty.

[0007] This invention proposes a boost-type vertical lithium iron phosphate energy storage battery system, comprising a top cover, a combiner box, battery units, and a base stacked sequentially from top to bottom; each battery unit comprises N battery modules stacked sequentially in a vertical direction, where N≥2, adjacent battery modules are detachably connected, and adjacent battery modules are electrically connected separately via floating connectors; each floating connector comprises a male floating terminal and a female floating terminal, one of which is disposed on a battery module, and the other of which is disposed on a... On another battery module, the male floating terminal and the female floating terminal are vertically connected and engaged. Each battery module includes a first housing, a cell assembly disposed within the first housing, and a first side panel mounted on one side of the first housing. A boost converter is fixedly mounted on the first side panel of each battery module. The low-voltage input terminal of the boost converter is directly electrically connected to the positive and negative output terminals of the cell assembly, and the high-voltage output terminal of the boost converter is electrically connected to the floating connector. This is used to boost the low-voltage DC power output by the cell assembly and then output high-voltage DC power through the floating connector.

[0008] Preferably, the battery module further includes a second side panel installed on the other side of the first housing and a cover covering the top of the first housing; a battery management control board is also fixedly installed on the first side panel, and the battery management control board is electrically connected to the battery cell group through a data acquisition harness for collecting the voltage, temperature and charging / discharging current of the battery cell group.

[0009] Preferably, the male floating connector is fixedly installed at the lower end of the battery module, and the female floating connector is fixedly installed at the upper end of the battery module; the male floating connector is provided with a power pin and a communication pin extending in the vertical direction, and the female floating connector is provided with a power socket and a communication socket extending in the vertical direction. The power pin is plugged into the power socket for electrical connection, and the communication pin is plugged into the communication socket for communication connection; the floating connector has a radial floating margin to absorb radial position deviation when two adjacent battery modules are stacked.

[0010] Preferably, each of the four corner areas of the top surface of the battery module is provided with an assembly positioning pin, and each of the four corner areas of the bottom surface of the battery module is provided with an assembly positioning hole. Each assembly positioning pin and each assembly positioning hole are arranged in a one-to-one correspondence in the vertical direction. When two adjacent battery modules are stacked, the four assembly positioning pins of the lower battery module are respectively inserted into the four assembly positioning holes of the upper battery module to form a four-corner positioning constraint.

[0011] Preferably, an explosion-proof valve is provided on the side of the first housing, which is used to open and release pressure when the internal pressure of the first housing reaches a preset threshold; a battery cell is provided inside the first housing, the battery cell includes a second housing, and the battery cell assembly is housed in the second housing.

[0012] Furthermore, a foamed silicone pad is disposed above the battery cell, a first epoxy plate is disposed between the inner sidewall of the second housing and the cell assembly, a second epoxy plate is disposed between the inner bottom wall of the second housing and the cell assembly, and a heating film is disposed between the second epoxy plate and the cell assembly; wherein, the foamed silicone pad is pressed between the cover and the battery cell to apply vertical clamping force to the cell assembly and absorb the cyclic expansion deformation of the cell assembly, the first epoxy plate and the second epoxy plate together cover the periphery and bottom surface of the cell assembly to form an electrical isolation layer, and the heating film is used to conduct heat to the cell assembly through the second epoxy plate in a low-temperature environment.

[0013] Furthermore, both the first epoxy board and the second epoxy board are epoxy fiberglass boards, and both the second epoxy board and the heating film cover the entire bottom surface of the battery cell assembly; the second epoxy board is used to electrically isolate the battery cell assembly from the metal bottom wall of the second housing, and the heating film is attached to the bottom surface of the battery cell assembly and separated from the second housing by the second epoxy board.

[0014] Preferably, the first housing has a first mounting hole, a first locking hole, and a second locking hole; the first mounting hole is used to install the explosion-proof valve, the first locking hole is used for a locking screw to pass through, so as to fix the fixing bracket to the first housing; the second locking hole is used for a locking screw of a lifting handle to pass through, so as to fix the lifting handle to the first housing, and the lifting handle is used to provide a vertically upward lifting force point when the battery module is pulled out.

[0015] Preferably, the combiner box constitutes a primary structural level independent of the battery unit. The combiner box includes a box body, a box cover, a first side cover plate, and a second side cover plate. The lower end of the box body is provided with a male floating plug terminal for plugging into and cooperating with the female floating plug terminal located on the upper end of the battery module below the combiner box, so as to establish a power channel and a communication channel between the combiner box and the battery unit. The box cover is installed on the upper end of the box body and is detachably connected to the box body. The first side cover plate is installed on one side of the box body and is detachably connected to the box body. The second side cover plate is installed on the other side of the box body and is detachably connected to the box body. The box body and the battery module are detachably connected through the fixing bracket. The bottom of the box body is provided with an assembly positioning hole for plugging into and cooperating with the assembly positioning pin on the battery module. By adopting this technical solution, the combiner box and the battery module can be separated in terms of mechanical positioning, detachable connection and electrical connection. The combiner box can be detached as a whole without affecting the structural integrity of the top cover, the base and the battery unit.

[0016] Furthermore, an MC4 negative terminal interface, an MC4 positive terminal interface, a low-voltage switch, a circuit breaker, and a waterproof cover mounted on the circuit breaker are installed on one side wall of the enclosure. One end of both the MC4 negative terminal interface and the MC4 positive terminal interface protrudes from the outer surface of the enclosure for connection to the DC power cable of external equipment; the other end of the MC4 negative terminal interface and the MC4 positive terminal interface penetrates into the interior of the enclosure and is electrically connected to the main circuit of the system; the operating terminal of the low-voltage switch protrudes from the outer surface of the enclosure.

[0017] The other side wall of the enclosure is equipped with a pressure relief valve, a signal receiving antenna, a communication input port, a communication output port, a debugging interface, and an inverter communication port. The pressure relief valve is used to open when the internal air pressure of the enclosure reaches the opening threshold. The signal receiving antenna is used to receive wireless signals. The communication input port is used to receive parallel communication signals output by adjacent battery clusters, and the communication output port is used to output parallel communication signals to adjacent battery clusters. The debugging interface is used for connecting external debugging equipment to read BMS data and configure parameters. The inverter communication port is a composite communication interface that supports CAN bus and RS485 dual protocol communication and is used to connect the communication cable of the external inverter.

[0018] Furthermore, the front end of the enclosure is equipped with a status indicator module, an infrared sensor, and a main control board. The status indicator module includes a display screen and a battery status indicator light, both of which are electrically connected to the main control board. The battery status indicator light includes multiple LED beads, and the main control board drives each LED bead to light up and turn off sequentially along the arrangement direction to create a flowing dynamic effect. The infrared sensor is electrically connected to the main control board, which controls the status indicator module to turn off in standby mode when no personnel are approaching, and keeps the infrared sensor operating in low-power mode. The infrared sensor outputs a high-level wake-up signal when it detects personnel activity, and the main control board responds to the wake-up signal by lighting up the display screen and activating the battery status indicator light, so that the status indicator module only lights up as needed when personnel are approaching.

[0019] Furthermore, the top of the base is provided with the assembly positioning pin and the female floating plug terminal. The assembly positioning pin is used to insert into the assembly positioning hole on the bottom surface of the battery module located above the base. The female floating plug terminal is used to connect and cooperate with the male floating plug terminal at the bottom of the battery module. The base is provided with a grounding connection hole for connecting a grounding cable. The bottom of the base is provided with a base foot for raising the base so that a heat dissipation gap is formed between the bottom surface and the mounting surface.

[0020] Preferably, the device further includes a mounting bracket, which includes a first hook and a second hook, the first hook and the second hook being connected to form an L-shaped structure, the first hook being connected to the battery unit and / or the combiner box, and the second hook being provided with a second mounting hole for an expansion bolt to pass through, so as to anchor the second hook to the building wall.

[0021] Furthermore, this application also provides an independent maintenance method based on the above-mentioned boost-type vertical lithium iron phosphate energy storage battery system. Each battery module in the boost-type vertical lithium iron phosphate energy storage battery system is equipped with a boost converter. The high-voltage output terminal of the boost converter is connected to the high-voltage bus via the floating connector. The method includes the following steps:

[0022] Step S1: The operating status of each battery module in the battery cell is detected module by module through the battery management control board configured one-to-one with each of the battery modules;

[0023] Step S2: When the performance degradation or failure of the target battery module is detected, the maintenance work is carried out only around the target battery module, and the fixed brackets connected to both sides of the target battery module are disassembled to release the mechanical constraints between the target battery module and its upper and lower adjacent objects.

[0024] Step S3: Pull the target battery module vertically to simultaneously separate the floating connector between the upper end of the target battery module and the adjacent upper battery module, and the floating connector between the lower end of the target battery module and the adjacent lower battery module or the base, so that the high voltage output terminal of the target battery module is disconnected from the high voltage bus.

[0025] Step S4: The target battery module is independently extracted from the stacked system in a horizontal direction. During the extraction process, the mechanical and electrical connections of the top cover, the junction box, the base, and other non-associated battery modules remain unchanged.

[0026] Step S5: Place the backup battery module in the original position of the target battery module, and insert the assembly positioning pin located below it into the assembly positioning hole on the bottom surface of the backup battery module to complete the alignment and guidance. Then, reinstall the fixing bracket to achieve the detachable connection of the backup battery module.

[0027] Step S6: Insert the floating connectors at the upper and lower ends of the backup battery module into place, so that the high voltage output terminal of the boost converter built into the backup battery module is connected to the high voltage bus, thus completing the online replacement of the backup battery module.

[0028] Furthermore, after step S6, the backup battery module completes identification through its built-in battery management control board and connects to the system after completing high-voltage bus voltage matching through its built-in boost converter.

[0029] Compared with the prior art, the present invention has the following main advantages:

[0030] 1. By distributing and integrating the boost converters onto the first side panel of each battery module, each battery module has independent boost and voltage regulation capabilities. When the boost converter of any battery module fails, its impact is limited to the power unit of that module itself and will not affect the combiner box or the boost circuits of other battery modules. The power unit capacity involved in fault handling is reduced from 100% of the whole system to 1 / N. At the same time, since the fault discrimination granularity is refined from the cluster level to the module level, the battery management control board of each module can be used to directly locate the battery module that has degraded. The fault location time is shortened from hours to minutes, and the maintainability of the system is significantly improved.

[0031] 2. Because the low-voltage input terminal of the boost converter is directly connected to the positive and negative output terminals of the battery cell assembly, and the high-voltage output terminal is connected to the high-voltage busbar via a floating connector, the low-voltage high-current loop is completely confined within a single battery module. The length of the low-voltage current-carrying cable is shortened from 1.5m to 2.0m under a centralized boost architecture to less than 0.15m, and the resistance of the cable itself decreases by more than 90%. At the same output power, after the low-voltage DC current of the battery cell assembly is boosted at the module level, the current on the high-voltage side drops to 1 / k of the current on the low-voltage side (k is the boost ratio, and in the preferred implementation, k is approximately 2.3), and the line loss is reduced to approximately 1 / k². Under the combined effect of the above two factors, the measured line loss of the high-voltage busbar circuit of the prototype is reduced by more than 80% compared to the centralized boost architecture, and the overall round-trip efficiency is increased from approximately 92.5% to approximately 95.2%, an increase of approximately 2.7 percentage points.

[0032] 3. By leveraging the precise guidance of the four corner mounting positioning pins and mounting positioning holes, the detachable connection of the fixed brackets, and the rapid insertion and removal of the floating connectors in the vertical direction, the faulty module can be independently extracted. When a single battery module experiences performance degradation or failure, the operator only needs to remove the fixed brackets on both sides of the battery module and separate the floating connectors at both ends of the module in the vertical direction to extract the battery module from the stacked system. There is no need to disassemble the top cover, combiner box, base, or other unrelated battery modules. Taking a six-battery-module stack as an example, the single-module replacement operation is reduced from approximately 120 minutes to approximately 45 minutes, a 62.5% reduction in maintenance time. Since only one battery module needs to be replaced instead of the entire cluster of spare parts, spare parts and labor costs are reduced by more than 50%. Furthermore, all operations are completed by a single person using conventional screw removal tools, eliminating the need for hoisting equipment and specialized fixtures.

[0033] 4. By setting a multi-layered insulating buffer structure consisting of a first epoxy board, a second epoxy board, a foamed silicone pad, and a heating film inside the second housing, and by setting an explosion-proof valve on the first housing, a pressure relief-buffering-insulation-heating cooperative protection system is formed. The first epoxy board and the second epoxy board respectively isolate the peripheral wall and bottom surface of the battery cell assembly, and their dielectric strength is not less than 20kV / mm, so that the insulation resistance between the battery cell assembly and the second housing is maintained above 100MΩ. Even if the battery cell insulation layer ages and breaks, leakage to the metal housing can still be avoided. The foamed silicone pad is in the compressive stress range of 0.15MPa to 0.30MPa. The internal structure absorbs 2%–3% of the cyclic expansion deformation of the battery cell assembly, preventing misalignment of the cell electrodes and tensile cracking of the series connectors. A heating film, with a power density not exceeding 0.25 W / cm², uniformly heats the bottom surface of the battery cell assembly via a second epoxy plate, raising the temperature from -20°C to a rechargeable temperature range above 5°C within 15 minutes in an environment of -20°C. When the above passive protection is insufficient to prevent the internal pressure from rising, the explosion-proof valve opens and releases pressure in a directional manner when the pressure reaches 25 kPa ± 5 kPa, discharging high-temperature gas in a predetermined direction to prevent the casing from bursting and heat from spreading to adjacent battery modules. These layers complement each other in four dimensions: electrical isolation, deformation buffering, low-temperature heating, and overpressure discharge, ensuring that anomalies in a single battery module do not spread to adjacent modules.

[0034] 5. By configuring a status indicator module and an infrared sensor at the front end of the combiner box, and by turning off the display screen and maintaining only the infrared sensor in low-power mode in standby mode, the on-demand wake-up of the human-machine interface unit is achieved. Actual measurements show that the standby power consumption of the comparison prototype using the constant-on indicator method is 3.5W, with a cumulative power consumption of 84Wh after 24 hours of inactivity; the prototype using the infrared wake-up scheme of this invention has a standby power consumption of 0.8W, with a cumulative power consumption of 19.2Wh after 24 hours of inactivity, representing a reduction of approximately 77% in standby power consumption. Based on 12 hours of no personnel presence per day, each device can save approximately 11.8kWh of electricity per year. Simultaneously, when personnel enter the detection range of 3m in front of the cabinet, the infrared sensor outputs a high-level wake-up signal within 0.5s and illuminates the display screen and battery status indicator, reducing standby power consumption without sacrificing the convenience of maintenance and inspection.

[0035] 6. Through a vertical stacking structure consisting of a top cover, combiner box, battery unit, and base, the boost converter, battery management control board, floating connector, explosion-proof valve, and heating and insulation structure are integrated into each battery module. The system has a high degree of integration and a compact structure, saving more than 40% of the floor space compared to traditional cabinet-type energy storage. It is suitable for residential and small-scale industrial and commercial applications with requirements for floor space, ease of installation, and expansion flexibility. Furthermore, capacity can be expanded on demand simply by adjusting the number of stacked battery modules, without the need to replace common components such as the combiner box. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0037] Figure 1 This is a schematic diagram of the boost-type vertical lithium iron phosphate energy storage battery system of the present invention;

[0038] Figure 2 This is a front view of the boost-type vertical lithium iron phosphate energy storage battery system of the present invention.

[0039] Figure 3 for Figure 2 The left view;

[0040] Figure 4 for Figure 2 The right view;

[0041] Figure 5 This is one of the exploded structural diagrams of the boost-type vertical lithium iron phosphate energy storage battery system in this invention;

[0042] Figure 6 This is the second exploded view of the boost-type vertical lithium iron phosphate energy storage battery system in this invention;

[0043] Figure 7 This is a top view of the battery module in this invention;

[0044] Figure 8 for Figure 7 The left view;

[0045] Figure 9 for Figure 7 The right view;

[0046] Figure 10 This is an exploded view of the battery module in this invention;

[0047] Figure 11 This is a front view of the combiner box in this invention;

[0048] Figure 12 This is a schematic diagram of one side of the combiner box in this invention;

[0049] Figure 13 This is a schematic diagram of the other side of the combiner box in this invention;

[0050] Figure 14 This is an exploded view of the combiner box structure in this invention;

[0051] Figure 15 This is a top view of the base in this invention;

[0052] Figure 16 for Figure 15 The left view;

[0053] Figure 17 for Figure 15 The right view.

[0054] 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.

[0055] Explanation of icon numbers:

[0056] 10. Top cover;

[0057] 20. Combiner box; 21. Box body; 211. MC4 negative terminal interface; 212. MC4 positive terminal interface; 213. Low voltage switch; 214. Circuit breaker; 215. Waterproof cover; 216. Pressure relief valve; 217. Signal receiving antenna; 218. Communication input port; 219. Communication output port; 220. Debugging interface; 221. Inverter communication port; 222. Status indicator module; 2221. Display screen; 2222. Battery status scrolling light; 223. Infrared sensor; 224. Main control board; 23. Box cover; 24. First side cover; 25. Second side cover;

[0058] 30. Battery cell; 31. Battery module; 311. Mounting bracket; 312. Assembly positioning pin; 313. Assembly positioning hole; 3141. Male floating terminal; 3142. Female floating terminal; 315. First housing; 3151. Explosion-proof valve; 3152. First mounting hole; 3153. First locking hole; 3154. Second locking hole; 316. Battery cell; 3161. Second housing; 3162. Cell assembly; 3163. Foamed silicone pad; 3164. First epoxy board; 3165. Second epoxy board; 3166. Heating film; 317. First side panel; 318. Second side panel; 319. Cover; 320. Battery management control board; 321. Boost converter;

[0059] 40. Base; 41. Grounding connection hole; 42. Base foot;

[0060] 50. Mounting bracket; 51. First hanging ear; 52. Second hanging ear; 521. Second mounting hole. Detailed Implementation

[0061] The present invention will now be clearly and completely described in conjunction with the technical solutions in the embodiments thereof. Obviously, the described embodiments are merely a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0062] The boost-type vertical lithium iron phosphate energy storage battery system provided by this invention is mainly used in marine lithium iron phosphate energy storage battery systems, but obviously its application scenarios are not limited to this. It can also be extended to other energy storage or power applications that require multi-level battery management, such as large-scale energy storage power stations, mining trucks, rail transit equipment and special vehicles.

[0063] See Figures 1-17 As shown, this embodiment provides a boost-type vertical lithium iron phosphate energy storage battery system, including a top cover 10, a combiner box 20, battery units 30, and a base 40 stacked sequentially from top to bottom. Each battery unit 30 is composed of N battery modules 31 stacked vertically, where N is at least 2. In practical engineering design, the preferred range of N is 2 to 10, and more preferably, N is 6. The top cover 10 is located at the top of the system, serving as a top enclosure and for aesthetic decoration. The combiner box 20 is located below the top cover 10, acting as the power dispatching and communication management hub for the entire system. The battery units 30 are located between the combiner box 20 and the base 40. The base 40 is located at the bottom of the system, supporting the weight of the top cover 10, combiner box 20, and battery units 30, and providing grounding functionality.

[0064] In this embodiment, each battery module 31 is equipped with a fixing bracket 311 on both sides. Two adjacent battery modules 31 are detachably connected through the fixing bracket 311. A mounting positioning pin 312 is provided on the top of the battery module 31. The mounting positioning pin 312 is used to insert and cooperate with the mounting positioning hole 313 on the bottom of another battery module 31. Two adjacent battery modules 31 are electrically connected through a floating connector. The floating connector includes a male floating terminal 3141 and a female floating terminal 3142. One of the male floating terminal 3141 and the female floating terminal 3142 is disposed on one battery module 31, and the other of the male floating terminal 3141 and the female floating terminal 3142 is disposed on another battery module 31. The male floating terminal 3141 and the female floating terminal 3142 are inserted and cooperated. With this design, each battery module 31 has a fixed bracket 311 installed on both sides, and adjacent battery modules 31 are detachably connected through the fixed bracket 311. At the same time, the electrical path between adjacent battery modules 31 is achieved by the insertion and cooperation of the separable male floating plug terminal 3141 and the female floating plug terminal 3142. When a single battery module 31 experiences performance degradation or failure, the operator only needs to remove the fixed bracket 311 between the battery module 31 and the adjacent battery module 31, and then separate the floating connector in the vertical direction to independently extract the faulty battery module 31 from the stacking system without disassembling the top cover 10, combiner box 20, base 40 or other non-associated battery modules 31. This solves the problem that existing energy storage battery systems require disassembly of the entire unit for fault repair, resulting in high repair difficulty, high maintenance costs and high modification difficulty.

[0065] In this embodiment, each battery module 31 has an independent rectangular box structure, and each battery module 31 has a fixing bracket 311 installed on both sides. Adjacent battery modules 31 are connected by the fixing brackets 311 in a detachable rigid connection. The fixing brackets 311 are made of high-strength steel plate by stamping. During the stacking assembly process, the fastening screws pass through the through holes at the upper end of the fixing brackets 311 to lock onto one battery module 31, and the fastening screws pass through the through holes at the lower end of the fixing brackets 311 to lock onto another battery module 31, thereby locking adjacent battery modules 31 into a single unit through the fixing brackets 311. This process is repeated until all battery modules 31 are stacked and assembled.

[0066] In this embodiment, in addition to mechanical connection, a power transmission channel and a communication signal transmission channel need to be established between two adjacent battery modules 31. To achieve this, the present invention uses a floating connector to realize integrated electrical and communication connection between adjacent battery modules 31. The floating connector includes a male floating terminal 3141 and a female floating terminal 3142, which are inserted and mated in the vertical direction. The male floating terminal 3141 is provided with a power pin and a communication pin extending in the vertical direction, and the female floating terminal 3142 is provided with a power socket and a communication socket extending in the vertical direction respectively. The power pin and the power socket are inserted and mated to form a power current transmission channel, and the communication pin and the communication socket are inserted and mated to form a communication signal transmission channel.

[0067] In one embodiment, the male floating connector 3141 is fixedly mounted to the lower end of the battery module 31, and the female floating connector 3142 is fixedly mounted to the upper end of the battery module 31. When two battery modules 31 are stacked vertically, the male floating connector 3141 at the lower end of the upper battery module 31 and the female floating connector 3142 at the upper end of the lower battery module 31 approach each other vertically and eventually engage. Both the male and female ends of the floating connector have a certain radial floating margin to absorb positional deviations between the battery modules 31 during stacking. With the above structural design, when a single battery module 31 experiences performance degradation or failure, the operator does not need to disassemble the top cover 10, combiner box 20, base 40, or other unrelated battery modules 31. They only need to remove the locking screws on the fixing bracket 311 between the faulty battery module 31 and its adjacent battery modules, and then lift the battery module 31 vertically upwards to separate the male floating terminal 3141 and the female floating terminal 3142 vertically, thus independently removing the battery module 31 from the stacking system. When replacing a new battery module 31, the reverse steps are followed: lower the new battery module 31 vertically to allow the male floating terminal 3141 and the female floating terminal 3142 to engage, and then tighten the fixing bracket 311 between the two adjacent battery modules 31 using the locking screws to complete the replacement. Furthermore, in order to ensure that each battery module 31 can be precisely aligned during the stacking process, each battery module 31 is provided with an assembly positioning pin 312 on the top and an assembly positioning hole 313 at the corresponding position on the bottom.

[0068] In a preferred embodiment, each of the four corner areas of the top surface of the battery module 31 is provided with an assembly positioning pin 312, and each of the four corner areas of the bottom surface of the battery module 31 is provided with an assembly positioning hole 313. Each assembly positioning pin 312 corresponds one-to-one with each assembly positioning hole 313 in the vertical direction. When two adjacent battery modules 31 are stacked, the four assembly positioning pins 312 of the lower battery module 31 are respectively inserted into the four assembly positioning holes 313 of the upper battery module 31, forming a four-corner positioning constraint.

[0069] In this embodiment, the battery module 31 is the basic energy storage unit constituting the battery cell 30. Each battery module 31 includes a first housing 315, a battery cell 316 housed within the first housing 315, a first side panel 317 and a second side panel 318 mounted on the left and right sides of the first housing 315, and a cover 319 sealing the top of the first housing 315. The first housing 315 is formed from AL6063-T5 aluminum alloy sheet metal through bending, welding, and surface treatment processes. AL6063-T5 aluminum alloy has excellent thermal conductivity, with a thermal conductivity of approximately 200 W / (m•K), and also possesses good structural strength and corrosion resistance. The first housing 315 has an overall flat rectangular parallelepiped shape, with external dimensions of 820 mm (width) × 310 mm (depth) × 321 mm (height). The dimensional tolerances of each dimension are controlled within ±2.5 mm to ensure geometric consistency when the battery modules 31 are stacked.

[0070] The battery cell 316 includes a second housing 3161 and a cell assembly 3162 housed within the second housing 3161. The second housing 3161 is made of high-strength engineering plastic or thin-walled stainless steel and has an internal cavity. The cell assembly 3162 uses lithium iron phosphate cells with a single cell capacity of 314Ah, a nominal voltage of 3.2V, a charging cut-off voltage of 3.65V, and a discharging cut-off voltage of 2.5V. Each battery module 31 contains nine lithium iron phosphate cells connected in series in a 9-series-1-parallel configuration, resulting in a module nominal voltage of 28.8V, a module charging input voltage of 32.85V, and a module output voltage range of 26.1V to 32.85V. The nine lithium iron phosphate cells are arranged horizontally inside the second housing 3161, and adjacent cells are electrically connected in series via series connectors. These connectors are made of pure nickel or nickel-plated copper and are fixed to the positive and negative terminals of the cells by laser welding or resistance welding.

[0071] A battery management control board 320 and a boost converter 321 are installed on the first side panel 317. The battery management control board 320 is electrically connected to the cell group 3162 through a data acquisition harness and is used to acquire the voltage, temperature and charging / discharging current of the cell group 3162. The low-voltage input terminal of the boost converter 321 is directly electrically connected to the positive and negative output terminals of the cell group 3162, and its high-voltage output terminal is electrically connected to a floating connector. It is used to boost the low-voltage DC power output by the cell group 3162 locally and then output high-voltage DC power to the outside through the floating connector. Because the boost converters 321 are distributed and integrated on the first side panel 317 of each battery module 31, rather than being centrally located in a certain position in the whole machine, on the one hand, the boost units of each battery module 31 are independent of each other, and when the boost converter 321 of any module fails, its impact range is limited to the power unit of that module itself; on the other hand, the low-voltage high-current circuit is completely confined inside the battery module 31, the length of the low-voltage current-carrying cable does not exceed 150mm, and the high-voltage bus transmits the same power with a small current, so that the boost and local current combining of a single module level replace the whole-machine level boost under the centralized boost architecture.

[0072] To improve the safety performance of the battery module 31 under extreme operating conditions, an explosion-proof valve 3151 is provided on the side of the first housing 315. The explosion-proof valve 3151 is used to release pressure when the internal pressure of the first housing 315 reaches a preset threshold. When the gas pressure inside the first housing 315 rapidly rises to the opening threshold due to thermal runaway of the battery cell or other abnormal operating conditions, the valve plate of the explosion-proof valve 3151 opens under the action of pressure difference, releasing the internal high-pressure gas and preventing the first housing 315 from bursting. A foamed silicone pad 3163 is provided above the battery cell 316. A first epoxy plate 3164 is provided between the inner side wall of the second housing 3161 and the battery cell assembly 3162. A second epoxy plate 3165 is provided between the inner bottom wall of the second housing 3161 and the battery cell assembly 3162. A heating film 3166 is provided between the second epoxy plate 3165 and the battery cell assembly 3162. The first epoxy plate 3164 electrically isolates the sidewall of the cell assembly 3162 from the inner sidewall of the second housing 3161, and the second epoxy plate 3165 electrically isolates the bottom of the cell assembly 3162 from the inner bottom wall of the second housing 3161. Due to the high dielectric strength of the epoxy plate, even if the insulation layer of the cell assembly 3162 ages and breaks down after long-term operation, the epoxy plate can still prevent leakage current from being conducted to the metal wall of the second housing 3161, preventing electric shock accidents to external personnel due to contact with the housing. The heating film 3166 generates heat when energized in a low-temperature environment. The heat is conducted through the second epoxy plate 3165 to the bottom of the cell assembly 3162, raising the temperature of the cell assembly 3162 to a suitable operating temperature range for charging and discharging. This significantly improves the usable capacity and charging / discharging efficiency of the lithium iron phosphate battery in low-temperature environments and avoids lithium deposition caused by low-temperature charging.

[0073] Based on the above structure in this embodiment, the foamed silicone pad 3163, the first epoxy board 3164, the second epoxy board 3165, the heating film 3166, and the explosion-proof valve 3151 are not isolated structures, but rather perform protective functions in four dimensions: electrical isolation, deformation buffering, low-temperature heating, and overpressure relief, and complement each other to form a multi-level safety protection system acting on the same battery cell assembly 3162. In the electrical dimension, the first epoxy board 3164 and the second epoxy board 3165 provide protection from the sides and... The bottom two directions completely enclose the cell assembly 3162, forming a continuous insulating barrier between the cell assembly 3162 and the second housing 3161. Even if the insulating film on the outer surface of the cell assembly 3162 experiences partial damage after long-term cycling, leakage current is still blocked outside the second housing 3161, preventing the housing from becoming charged. In terms of deformation, the foamed silicone pad 3163 is pressed between the cover 319 and the battery cell 316, applying a stable vertical clamping force to the cell assembly 3162 to suppress cell deformation during charging and discharging. The displacement along the stacking direction, on the other hand, absorbs the thickness expansion of the battery cell assembly 3162 accumulated with the increase of the number of cycles through its own compression and rebound, avoiding cracking due to tensile fatigue of the series connecting pieces; in the temperature dimension, the heating film 3166 is sandwiched between the second epoxy plate 3165 and the bottom surface of the battery cell assembly 3162, which not only provides uniform heat along the entire bottom surface, but also relies on the second epoxy plate 3165 to achieve coupling of heat conduction and electrical isolation, so that heat can be transferred to the battery cell assembly 3162 without making the second shell 3161 electrified or locally charged. Overheating; In terms of pressure, when the above three layers of passive protection are insufficient to suppress the thermal runaway trend of the cell assembly 3162, causing the internal pressure of the first housing 315 to rise to the opening threshold of the explosion-proof valve 3151, the explosion-proof valve 3151 opens first to release pressure and direct the high-temperature gas outward. This allows the foamed silicone pad 3163, the first epoxy board 3164, and the second epoxy board 3165 to continue to maintain structural integrity and electrical isolation while completing the pressure release, thus preventing heat from spreading to the adjacent battery module 31.

[0074] The first housing 315 has a first mounting hole 3152, a first locking hole 3153, and a second locking hole 3154. The first mounting hole 3152 is used to install an explosion-proof valve 3151, which is embedded in the side wall of the first housing 315 through the first mounting hole 3152. The first locking hole 3153 is used for a locking screw to pass through, so as to fix the fixing bracket 311 to the first housing 315. The second locking hole 3154 is used for a locking screw for a lifting handle to pass through, so as to fix the lifting handle to the first housing 315. The lifting handle provides the operator with a point of leverage to lift the battery module 31 during installation and disassembly. When the operator needs to pull out the faulty battery module 31, he can apply a vertical upward pulling force by holding the lifting handle to overcome the locking force of the floating connector and lift the battery module 31.

[0075] The combiner box 20 includes a box body 21, a cover 23, a first side cover 24, and a second side cover 25. A male floating terminal 3141 is provided at the lower end of the box body 21 for insertion and mating with a female floating terminal 3142 on the battery module 31, enabling power transmission and communication signal transmission between the combiner box 20 and the battery module 31. The cover 23 is installed on the upper end of the box body 21 and is detachably connected to the box body 21 by screws. When it is necessary to inspect the internal components of the combiner box 20, the internal space can be exposed by removing the cover 23 without disassembling the entire combiner box 20. The first side cover 24 is installed on one side of the box body 21, and the second side cover 25 is installed on the other side of the box body 21, both detachably connected to the box body 21. The enclosure 21 and the battery module 31 are detachably connected via a fixing bracket 311. The upper end of the fixing bracket 311 is fixed to the side wall of the enclosure 21 with a locking screw, and the lower end of the fixing bracket 311 is fixed to the side wall of the battery module 31 with a locking screw. The bottom of the enclosure 21 is provided with an assembly positioning hole 313 for insertion and engagement with the assembly positioning pin 312 on the battery module 31, achieving precise alignment between the combiner box 20 and the battery module 31. One side wall of the enclosure 21 is equipped with an MC4 negative interface 211, an MC4 positive interface 212, a low-voltage switch 213, a circuit breaker 214, and a waterproof cover 215 that covers the circuit breaker 214. One end of both the MC4 negative interface 211 and the MC4 positive interface 212 protrudes from the outer surface of the enclosure 21 for connection to the DC power cable of external equipment, while the other end passes inside the enclosure 21 for electrical connection to the system's main circuit. The MC4 interface adopts a standard quick-connect terminal structure, which provides clear tactile and audible feedback when plugged in, ensuring that operators can confirm that the plug is in place.

[0076] The operating terminals of the low-voltage switch 213 are exposed on the outer surface of the enclosure 21. Operators can switch the system between standby and running states by toggling the switch. When the switch is in the standby position, the main circuit remains open, with only the battery management control board 320 and communication interface receiving power to receive external commands. When the switch is in the running position, the main circuit is closed, and the system has charging and discharging capabilities. A circuit breaker 214 is connected in series in the main circuit. When the main circuit current exceeds the rated current of the circuit breaker 214, it automatically trips to cut off the main circuit power, providing overload and short-circuit protection. A waterproof cover 215 is hinged to the side wall of the enclosure 21 and covers the circuit breaker 214. With the cover closed, water spray cannot directly impact the circuit breaker 214, ensuring its safety in humid environments or outdoor applications.

[0077] On the other side wall of the enclosure 21 are installed a pressure relief valve 216, a signal receiving antenna 217, a communication input port 218, a communication output port 219, a debugging interface 220, and an inverter communication port 221. The pressure relief valve 216 opens to release internal pressure when the internal air pressure of the enclosure 21 reaches the opening threshold. The signal receiving antenna 217 includes both Bluetooth and Wi-Fi antennas. The Bluetooth antenna supports the Bluetooth communication protocol, and the Wi-Fi antenna supports the Wi-Fi communication protocol. Through these two wireless communication methods, the system can establish a short-range direct communication connection with a mobile terminal for on-site debugging and status monitoring. Simultaneously, it can access a local area network or the internet via Wi-Fi for remote monitoring and data uploading. The communication input port 218 receives parallel communication signals from adjacent battery clusters, and the communication output port 219 outputs parallel communication signals to adjacent battery clusters. Multiple energy storage battery systems are cascaded in a daisy-chain configuration via the communication input port 218 and the communication output port 219, enabling data interaction and master-slave coordination during parallel operation of multiple systems. The debugging interface 220 is used for connecting external debugging equipment to read data and configure parameters of the battery management system. Engineers can use the debugging interface 220 to read fault logs, update protection threshold parameters of the battery management system, and upgrade firmware. The inverter communication port 221 is a composite communication interface that supports both CAN bus and RS485 dual-protocol communication, used to connect the communication cable of an external inverter. This composite communication interface has an internal protocol identification circuit that can detect the communication protocol type used by the connected inverter and switch to the corresponding communication mode, enabling the energy storage battery system to achieve plug-and-play communication with inverters of different brands and models without the need for hardware replacement or wiring modifications.

[0078] The front end of the enclosure 21 is equipped with a status indicator module 222, an infrared sensor 223, and a main control board 224. The status indicator module 222 includes a display screen 2221 and a battery status scrolling light 2222. The display screen 2221 and the battery status scrolling light 2222 are electrically connected to the main control board 224. The display screen 2221 displays the operating parameters of the battery management system, including key information such as system voltage, system current, battery state of charge, battery health status, charge / discharge power, and fault codes, providing a visual interface for maintenance personnel to perform system diagnosis and parameter configuration. The battery status scrolling light 2222 includes multiple LED beads, and the main control board 224 drives each LED bead to light up and turn off sequentially along the arrangement direction to create a flowing dynamic effect. The infrared sensor 223 is electrically connected to the main control board 224, and outputs a high-level wake-up signal when personnel activity is detected to wake up the status indicator module 222. When the system is in standby mode, the main control board 224 controls the display screen 2221 to turn off to reduce power consumption, leaving only the infrared sensor 223 operating in low-power mode. When a person enters the detection range of the infrared sensor 223, the infrared sensor 223 outputs a wake-up signal, and the main control board 224 responds to the wake-up signal by lighting up the display screen 2221 and activating the dynamic display of the battery status scrolling light 2222.

[0079] In a specific application example, standby power consumption tests were conducted on a comparative prototype using the always-on status indicator module 222 and a prototype using the infrared wake-up scheme of this invention under the same environmental conditions for 24 hours. The comparative prototype, with its display screen 2221 and battery status indicator 2222 continuously lit, had a stable operating power of 3.5W and a cumulative power consumption of 84Wh over 24 hours. The prototype of this invention, in standby mode when no one is present, with the main control board 224 only supplying power to the infrared sensor 223 in a low-power acquisition mode, and both the display screen 2221 and battery status indicator 2222 being off, had a stable operating power of 0.8W and a cumulative power consumption of 19.2Wh over 24 hours. The standby power consumption is approximately 77% lower than that of the comparative prototype. Based on an application scenario of 12 hours of no personnel presence per day, this translates to a reduction of approximately 11.8kWh of power consumption per unit per year. Meanwhile, in terms of response speed, the infrared sensor 223 has a detection distance of 3m and a detection angle of 120°. When a person enters its detection range, the output pin of the infrared sensor 223 changes from low to high level within 0.5s. The main control board 224 then lights up the display screen 2221 and activates the flowing dynamic effect of the battery status marquee 2222 according to a preset rhythm. After a 30s delay after the person leaves, the main control board 224 sets the status indicator module 222 back to the off state. Thus, this invention, without increasing hardware costs, meets the requirements for silent operation and low standby power consumption in user scenarios, while avoiding the inconvenience of manual button operation or frequent lighting.

[0080] The base 40 is located at the bottom of the system. A mounting positioning pin 312 is provided on the top of the base 40, which is inserted into the mounting positioning hole 313 at the bottom of the battery module 31 to achieve precise alignment between the base 40 and the battery module 31. A female floating terminal 3142 is also provided on the top of the base 40, which is used to connect with the male floating terminal 3141 at the bottom of the battery module 31 above the base 40, establishing an electrical connection between the base 40 and the battery module 31. A first locking hole 3153 is provided on the side wall of the base 40 for a locking screw to pass through and fix the lower end of the fixing bracket 311 to the base 40. The upper end of the fixing bracket 311 is fixedly connected to the battery module 31 located above the base 40. A grounding connection hole 41 is provided on the base 40 for connecting a grounding cable. The other end of the grounding cable is connected to the building grounding grid, connecting the system's metal casing and electrical reference ground to the building earth. When a leakage fault occurs inside the system, the leakage current is conducted to the earth through the grounding cable, preventing electric shock to personnel. The base 40 has a base foot 42 at its bottom, which raises the base 40 above the mounting surface, creating a gap between the bottom of the base 40 and the mounting surface. This allows for air circulation to dissipate heat from the bottom of the base 40 and facilitates floor cleaning.

[0081] In this embodiment, the boost-type vertical lithium iron phosphate energy storage battery system further includes a mounting bracket 50. The mounting bracket 50 includes a first hook 51 and a second hook 52, which are connected to form an L-shaped structure. The first hook 51 is connected to the battery cell 30 or the combiner box 20. The second hook 52 has a second mounting hole 521 for expansion bolts to pass through, anchoring the second hook 52 to the building wall. Through the mounting bracket 50, the boost-type vertical lithium iron phosphate energy storage battery system gains additional constraint from the wall in addition to its own weight and ground support. When the system is subjected to an accidental impact, the mounting bracket 50 can transfer the force to the building wall, thereby preventing the boost-type vertical lithium iron phosphate energy storage battery system from tipping over.

[0082] In summary, the boost-type vertical lithium iron phosphate energy storage battery system proposed in this invention includes a top cover 10, a combiner box 20, battery units 30, and a base 40 stacked sequentially from top to bottom. Each battery unit 30 includes N battery modules 31, which are stacked vertically, where N ≥ 2. Each battery module 31 has a fixing bracket 311 installed on both sides, and adjacent battery modules 31 are detachably connected via the fixing bracket 311. The top of each battery module 31 is provided with an assembly positioning pin 312, which is used for... It is inserted into the mounting positioning hole 313 at the bottom of another battery module 31; two adjacent battery modules 31 are electrically connected by a floating connector; wherein, the floating connector includes a male floating terminal 3141 and a female floating terminal 3142, one of the male floating terminal 3141 and the female floating terminal 3142 is disposed on one battery module 31, and the other of the male floating terminal 3141 and the female floating terminal 3142 is disposed on another battery module 31, and the male floating terminal 3141 and the female floating terminal 3142 are inserted into each other. With this design, each battery module 31 has a fixed bracket 311 installed on both sides, and adjacent battery modules 31 are detachably connected through the fixed bracket 311. At the same time, the electrical path between adjacent battery modules 31 is achieved by the insertion and cooperation of the separable male floating plug terminal 3141 and the female floating plug terminal 3142. When a single battery module 31 experiences performance degradation or failure, the operator only needs to remove the fixed bracket 311 between the battery module 31 and the adjacent battery module 31, and then separate the floating connector in the vertical direction to independently extract the faulty battery module 31 from the stacking system without disassembling the top cover 10, combiner box 20, base 40 or other non-associated battery modules 31. This solves the problem that existing energy storage battery systems require disassembly of the entire unit for fault repair, resulting in high repair difficulty, high maintenance costs and high modification difficulty.

[0083] Furthermore, this application also provides an independent maintenance method based on the above-mentioned boost-type vertical lithium iron phosphate energy storage battery system. Since each battery module 31 in this system has its own boost converter 321, and the high-voltage output terminal of the boost converter 321 is connected to the high-voltage bus via a floating connector, when a single battery module 31 experiences performance degradation or failure, the target battery module can be partially replaced without disassembling the entire system. The method includes the following steps:

[0084] Step S1: The operating status of each battery module 31 in the battery unit 30 is detected module by module through the battery management control board 320 configured one-to-one with each battery module 31.

[0085] Step S2: When the performance degradation or failure of the target battery module is detected, the maintenance work is carried out only around the target battery module. The fixed brackets 311 connected to both sides of the target battery module are disassembled to release the mechanical constraints between the target battery module and its upper and lower adjacent objects, without disassembling the top cover 10, junction box 20, base 40 and other non-associated battery modules.

[0086] Step S3: Lift the target battery module vertically to simultaneously separate the floating connector between the upper end of the target battery module and the adjacent upper battery module, and the floating connector between the lower end of the target battery module and the adjacent lower battery module or the base 40, so that the high voltage output terminal of the target battery module is disconnected from the high voltage bus.

[0087] Step S4: The target battery module is independently extracted from the stacking system in a horizontal direction. During the extraction process, the mechanical and electrical connections of the top cover 10, junction box 20, base 40 and other non-associated battery modules remain unchanged.

[0088] Step S5: Place the backup battery module in the original position of the target battery module, and insert the assembly positioning pin 312 located below it into the assembly positioning hole 313 on the bottom surface of the backup battery module to complete the alignment and guidance. Then, the backup battery module can be detached by reinstalling the fixing bracket 311.

[0089] Step S6: Insert the floating connectors at the upper and lower ends of the backup battery module into place, so that the high voltage output terminal of the boost converter 321 built into the backup battery module is connected to the high voltage bus, and the online replacement of the backup battery module is completed. The work objects of the above steps S1 to S6 are limited to the target battery module and its two adjacent floating connector interfaces. The tools used in the operation are only the screw fastening tools.

[0090] Step S6 and beyond also includes: the backup battery module completes identification through its built-in battery management control board 320, and connects to the system after completing high-voltage bus voltage matching through its built-in boost converter 321, without replacing any power devices inside the machine, and without reconfiguring or re-tuning the parameters of the battery unit 30 as a whole.

[0091] To further verify the linkage effect between the structural features and the independent maintenance method described in this invention, two specific application examples are given below.

[0092] Application Example 1: Partial Replacement Process When a Single Battery Module Fails

[0093] This application example uses a boost-type vertical lithium iron phosphate energy storage battery system consisting of six vertically stacked battery modules 31. Each battery module 31 contains a cell group 3162 composed of nine 314Ah lithium iron phosphate cells connected in series. The nominal voltage of the module is 28.8V. The boost converter 321 of each module boosts the 28.8V DC to approximately 66.7V, and then connects to the combiner box 20 through the floating connectors between adjacent battery modules 31. The system bus voltage is approximately 400V. After the prototype has been running continuously for 18 months, the main control board 224, through the battery management control board 320 configured one-to-one with each battery module 31, collected data showing that the internal resistance of the fourth battery module 31 from the top increased by approximately 42%, and the voltage difference at the end of charging and discharging exceeded 150mV. Based on this, it was determined that the module had experienced performance degradation. If handled using a traditional centralized booster architecture, this would require disconnecting the entire DC bus, removing the top cover 10 and combiner box 20, and hoisting the entire battery module cluster out for step-by-step inspection. This requires hoisting equipment and at least two operators, and the entire system must be taken offline for an extended period during the inspection. However, with this invention, the actual operations are as follows: First, the operator switches the system to maintenance mode by turning on the low-voltage switch 213 on the side wall of combiner box 20, de-energizing the high-voltage bus. During this process, the top cover 10, combiner box 20, and base 40 remain in their original positions. Second, using a conventional screwdriver, the four locking screws on the two fixing brackets 311 connecting the fourth battery module 31 to its upper third battery module 31 and lower fifth battery module 31 are removed. This process takes only about 8 minutes to release the mechanical constraints of the module without touching the first, second, fifth, and fourth battery modules. The third step involves the operator holding the lifting handle of the module and pulling it vertically upwards by about 30mm, so that the male floating terminal 3141 at the bottom of the module and the female floating terminal 3142 at the top of the fifth battery module 31, and the female floating terminal 3142 at the top of the module and the male floating terminal 3141 at the bottom of the third battery module 31 are simultaneously separated, while the other four adjacent plug-in interfaces remain completely undisturbed; the fourth step involves pulling the fourth battery module 31 out horizontally from the stacking gap as a whole, a process that takes about 12 minutes. When installing the spare module, proceed in the reverse order: After the spare module is pushed into its original position horizontally, its four mounting positioning holes 313 on the bottom surface are first fitted onto the four mounting positioning pins 312 on the top surface of the fifth battery module 31 to complete automatic centering. During the process of the spare module falling into place under its own weight, the floating connectors at its upper and lower ends automatically compensate for the stacking deviation and insert into place by relying on the radial floating margin. Finally, reinstall the two fixed brackets 311 and tighten the four locking screws. The main control board 224 reads the identity code of the spare module, and the boost converter 321 built into the spare module completes the bus voltage matching and completes the SOC calibration. The battery management system parameters and address configuration of the whole machine do not need to be changed.Actual measurements show that the total operation time for this single module replacement was 45 minutes, completed by a single person using a regular screwdriver, without the use of any hoisting equipment or special tooling. In contrast, replacing the same module in the same location on the same prototype using the whole machine disassembly method took about 120 minutes and required two people to hoist it. That is, the present invention reduces the repair time of a single faulty module by about 62.5%. At the same time, since only one battery module needs to be replaced instead of the entire cluster of spare parts, the spare parts cost for a single maintenance is reduced by about 58%.

[0094] Application Example 2: Low-power standby effect of infrared sensor wake-up status indicator module

[0095] This application example, based on the simultaneous installation of a display screen 2221, a battery status indicator 2222, and an infrared sensor 223 at the front end of the combiner box 20, verifies the improvement effect of the infrared wake-up strategy on standby power consumption. Two test scenarios were set up: Scenario A was a constant-on scenario, where the display screen 2221 and the battery status indicator 2222 remained lit after the device was powered on; Scenario B was the infrared wake-up scheme of this invention, where the main control board 224 controlled the display screen 2221 and the battery status indicator 2222 to turn off when no personnel were near, supplying power only to the infrared sensor 223. Both prototypes were left idle for 24 hours under the same environmental conditions. The stable power consumption of Scenario A was measured to be 3.5W, with a cumulative power consumption of 84Wh over 24 hours; the stable power consumption of Scenario B was 0.8W, with a cumulative power consumption of 19.2Wh over 24 hours. Scenario B reduced standby power consumption by approximately 77% compared to Scenario A. In terms of response performance, the infrared sensor 223 has a detection distance of 3m and a detection angle of 120°. When maintenance personnel approach from the front to a distance of approximately 2.5m from the cabinet, the output of the infrared sensor 223 changes from low to high level within 0.5s. The main control board 224 then illuminates the display screen 2221 to show the system voltage, current, SOC, SOH, and fault codes, and sequentially illuminates each LED bead according to a preset rhythm to create a flowing dynamic effect of the battery status running light 2222. After the personnel leave, the status indicator module 222 automatically turns off after a 30s delay and returns to a low-power standby state. As can be seen from this application example, this invention enables energy storage devices that are unattended for long periods in residential and small-scale industrial and commercial scenarios to meet both low standby power consumption requirements and the timeliness of maintenance inquiries without significantly increasing hardware costs.

Claims

1. A boost-type vertical lithium iron phosphate energy storage battery system, characterized in that, It includes a top cover, junction box, battery unit and base stacked from top to bottom; The battery unit includes N battery modules stacked vertically, where N≥2. Adjacent battery modules are detachably connected and connected via a floating connector. The floating connector includes a male floating terminal and a female floating terminal. One of the male and female floating terminals is located on one battery module, and the other is located on another battery module. The male and female floating terminals are vertically connected and interlocked. Each battery module includes a first housing, a battery cell assembly disposed within the first housing, and a first side panel mounted on one side of the first housing. A boost converter is fixedly mounted on the first side panel of each battery module. The low-voltage input terminal of the boost converter is directly electrically connected to the positive and negative output terminals of the battery cell assembly, and the high-voltage output terminal of the boost converter is electrically connected to the floating connector. This is used to boost the low-voltage DC power output by the battery cell assembly and then output high-voltage DC power through the floating connector.

2. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 1, characterized in that, The male floating connector is fixedly installed at the lower end of the battery module, and the female floating connector is fixedly installed at the upper end of the battery module. The male floating connector has a power pin and a communication pin extending vertically, and the female floating connector has a power socket and a communication socket extending vertically. The power pin and the power socket are plugged in for electrical connection, and the communication pin and the communication socket are plugged in for communication connection. The floating connector has a radial floating margin to absorb radial position deviation when two adjacent battery modules are stacked.

3. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 1, characterized in that, An explosion-proof valve is provided on the side of the first housing, which is used to open and release pressure when the internal pressure of the first housing reaches a preset threshold; a battery cell is provided inside the first housing, the battery cell includes a second housing, and the battery cell assembly is housed in the second housing.

4. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 3, characterized in that, A foamed silicone pad is disposed above the battery cell. A first epoxy plate is disposed between the inner sidewall of the second housing and the battery cell assembly. A second epoxy plate is disposed between the inner bottom wall of the second housing and the battery cell assembly. A heating film is disposed between the second epoxy plate and the battery cell assembly. The foamed silicone pad is pressed between the cover and the battery cell to apply vertical pressure to the battery cell assembly and absorb the cyclic expansion deformation of the battery cell assembly. The first epoxy plate and the second epoxy plate together cover the periphery and bottom surface of the battery cell assembly to form an electrical isolation layer. The heating film is used to conduct heat to the battery cell assembly through the second epoxy plate in a low-temperature environment.

5. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 1, characterized in that, Each of the four corner areas on the top surface of the battery module is provided with an assembly positioning pin, and each of the four corner areas on the bottom surface of the battery module is provided with an assembly positioning hole. Each assembly positioning pin and each assembly positioning hole are arranged in a one-to-one correspondence in the vertical direction. When two adjacent battery modules are stacked, the four assembly positioning pins of the lower battery module are respectively inserted into the four assembly positioning holes of the upper battery module to form a four-corner positioning constraint.

6. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 1, characterized in that, The first housing has a first mounting hole, a first locking hole, and a second locking hole; the first mounting hole is used to install the explosion-proof valve, and the first locking hole is used for a locking screw to pass through to fix the fixing bracket to the first housing; the second locking hole is used for a locking screw of a lifting handle to pass through to fix the lifting handle to the first housing, and the lifting handle is used to provide a vertically upward lifting force point when the battery module is pulled out.

7. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 1, characterized in that, The combiner box constitutes a primary structural level independent of the battery unit. The combiner box includes a box body, a box cover, a first side cover plate, and a second side cover plate. The lower end of the box body is provided with the male floating plug terminal, which is used to connect and cooperate with the female floating plug terminal located on the upper end of the battery module below the combiner box to establish a power channel and a communication channel between the combiner box and the battery unit. The box cover is installed on the upper end of the box body and is detachably connected to the box body. The first side cover is installed on one side of the housing and is detachably connected to the housing; the second side cover is installed on the other side of the housing and is detachably connected to the housing; the housing and the battery module are detachably connected through the fixing bracket, and the bottom of the housing is provided with an assembly positioning hole for engaging with the assembly positioning pin on the battery module.

8. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 7, characterized in that, The enclosure has an MC4 negative terminal, an MC4 positive terminal, a low-voltage switch, a circuit breaker, and a waterproof cover installed on the circuit breaker on one side wall. One end of the MC4 negative terminal and the MC4 positive terminal are exposed on the outer surface of the enclosure for connection to the DC power cable of external equipment. The other end of the MC4 negative terminal and the MC4 positive terminal are inserted into the interior of the enclosure and electrically connected to the main circuit of the system. The operating terminal of the low-voltage switch is exposed on the outer surface of the enclosure. The other side wall of the enclosure is equipped with a pressure relief valve, a signal receiving antenna, a communication input port, a communication output port, a debugging interface, and an inverter communication port. The pressure relief valve is used to open when the internal air pressure of the enclosure reaches the opening threshold. The signal receiving antenna is used to receive wireless signals. The communication input port is used to receive parallel communication signals output by adjacent battery clusters, and the communication output port is used to output parallel communication signals to adjacent battery clusters. The debugging interface is used for connecting external debugging equipment to read BMS data and configure parameters. The inverter communication port is a composite communication interface that supports CAN bus and RS485 dual protocol communication and is used to connect the communication cable of the external inverter.

9. The boost-type vertical lithium iron phosphate energy storage battery system according to claim 7, characterized in that, The front end of the enclosure is equipped with a status indicator module, an infrared sensor, and a main control board. The status indicator module includes a display screen and a battery status LED display, which are electrically connected to the main control board. The battery status LED display includes multiple LED beads, and the main control board is used to drive each LED bead to light up and turn off sequentially along the arrangement direction to form a flowing dynamic effect. The infrared sensor is electrically connected to the main control board. The main control board controls the status indicator module to turn off in standby mode when no one is approaching, and keeps the infrared sensor operating in low-power mode. The infrared sensor outputs a high-level wake-up signal when it detects human activity. The main control board responds to the wake-up signal by lighting up the display screen and activating the battery status indicator light, so that the status indicator module is lit only when a person is approaching.

10. An independent maintenance method for a boost-type vertical lithium iron phosphate energy storage battery system according to any one of claims 1 to 9, wherein each battery module in the boost-type vertical lithium iron phosphate energy storage battery system is equipped with a boost converter, and the high-voltage output terminal of the boost converter is connected to the high-voltage bus via the floating connector, the method comprising the following steps: Step S1: The operating status of each battery module in the battery cell is detected module by module through the battery management control board configured one-to-one with each of the battery modules; Step S2: When the performance degradation or failure of the target battery module is detected, the maintenance work is carried out only around the target battery module, and the fixed brackets connected to both sides of the target battery module are disassembled to release the mechanical constraints between the target battery module and its upper and lower adjacent objects. Step S3: Pull the target battery module vertically to simultaneously separate the floating connector between the upper end of the target battery module and the adjacent upper battery module, and the floating connector between the lower end of the target battery module and the adjacent lower battery module or the base, so that the high voltage output terminal of the target battery module is disconnected from the high voltage bus. Step S4: The target battery module is independently extracted from the stacked system in a horizontal direction. During the extraction process, the mechanical and electrical connections of the top cover, the junction box, the base, and other non-associated battery modules remain unchanged. Step S5: Place the backup battery module in the original position of the target battery module, and insert the assembly positioning pin located below it into the assembly positioning hole on the bottom surface of the backup battery module to complete the alignment and guidance. Then, reinstall the fixing bracket to achieve the detachable connection of the backup battery module. Step S6: Insert the floating connectors at the upper and lower ends of the backup battery module into place, so that the high voltage output terminal of the boost converter built into the backup battery module is connected to the high voltage bus, thus completing the online replacement of the backup battery module.

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