A high-energy sodium-ion forklift power supply device

Abstract

The utility model discloses a high -energy sodium ion forklift power device relates to forklift battery technical field, and power device includes power box, and the detachable box cover is equipped at power box top, and the inside of power box is equipped with at least two electric core packages, and each electric core package top fixed mounting BMS battery management ware, and the output of BMS battery management ware is connected with multichannel electric core package integrator, and the output of multichannel electric core package integrator is equipped with power input output interface. The utility model discloses electric core package and carries out combination control, reaches forklift drive voltage and current requirement, effectively shortens charging time. A plurality of independent electric core packages can be controlled and replaced individually, can maintain more efficiently, improve the security and life of product. Electric core package carries out combination control, reaches better discharge in low temperature environment, and charging performance.

Description

Technical Field

[0001] This utility model relates to the field of forklift battery technology, specifically a high-energy sodium ion forklift power supply device. Background Technology

[0002] Forklift power supplies, as the core energy carrier of electric forklifts, currently mostly use lead-acid or lithium-ion batteries, but both have significant performance shortcomings. Regarding low-temperature adaptability, lead-acid batteries experience capacity degradation exceeding 40% at -10℃, leading to a significant reduction in forklift range in cold conditions. While lithium-ion batteries have higher energy density, they directly lose their normal charging capability at 0℃, severely restricting winter operating efficiency. In terms of charging performance, traditional batteries generally have a continuous charging rate of less than 2C, requiring more than 3 hours for a full charge, which is insufficient to meet the rapid energy replenishment needs of forklifts operating at high frequencies. In terms of safety, lithium-ion batteries are prone to thermal runaway risks due to internal heat accumulation during high-rate discharge, while lead-acid batteries pose a risk of electrolyte leakage, threatening operational safety and potentially causing environmental pollution. Regarding maintenance costs, both types of battery packs often require complete replacement upon failure, resulting in poor repair economics, especially significantly increasing operating costs during large-scale applications. Although sodium-ion batteries are considered an ideal alternative for forklift power supplies due to their excellent low-temperature characteristics, high ionic conductivity, and material cost advantages, their existing power modules face a key technological bottleneck—a lack of dynamic topology control capabilities for the complex operating conditions of forklifts. This makes it difficult to achieve efficient energy management during high-rate charging and discharging, and also fails to effectively address the issue of electrochemical performance degradation in low-temperature environments. It is important to clarify that forklift batteries are essentially specialized rechargeable batteries. Their core function is to store and release electrical energy through the conversion of chemical energy into electrical energy. Current conventional power carriers, primarily using lead-acid or lithium-ion cells, cannot meet the demands of continuous high-current operation, efficient fast charging, and wide-temperature-range charging and discharging. This results in a significant decline in battery performance in low-temperature environments, directly impacting the operational stability and range of forklifts. Utility Model Content

[0003] To address the shortcomings of existing technologies, this invention provides a high-energy sodium ion forklift power supply device, which has the advantage of combining multiple battery cells in series and parallel, thus solving the aforementioned problems.

[0004] To achieve the goal of combining the above-mentioned battery cells in series and parallel in various ways, this utility model provides the following technical solution:

[0005] A high-energy sodium ion forklift power supply device includes a power box 1, the top of which is provided with a removable cover 6. The power box 1 contains at least two battery packs 2, and a BMS battery manager 3 is fixedly installed on the top of each battery pack 2. The output end of the BMS battery manager 3 is connected to a multi-cell pack integrator 4, and the output end of the multi-cell pack integrator 4 is provided with a power input / output interface 5.

[0006] Furthermore, the battery pack 2 includes a battery compartment 201, a plurality of sodium-ion batteries 202 disposed in the battery compartment 201, a battery cover 204 covering the battery compartment 201, and a battery protector 203 disposed on the battery cover 204.

[0007] Furthermore, the cell protector 203 is electrically connected to the sodium-ion cell 202, the cell protector 203 is signal-connected to the BMS battery manager 3, and the BMS battery manager 3 is signal-connected to the multi-channel cell pack integrator 4.

[0008] Furthermore, the BMS battery manager 3 monitors the voltage and temperature data of the sodium-ion cell 202 in real time through the cell protector 203, and controls the multi-channel cell pack integrator 4 to switch the series and parallel topology of the cell pack 2.

[0009] Furthermore, the sodium-ion cells 202 in the cell compartment 201 are arranged in an array and connected in series, and the cell protector 203 integrates overvoltage, undervoltage and overtemperature protection circuits.

[0010] Furthermore, the multi-channel cell pack integrator 4 includes a solid-state relay array, which switches the cell pack 2 to series mode, parallel mode, or series-parallel hybrid mode according to the instructions of the BMS battery manager 3.

[0011] Furthermore, the BMS battery manager 3 incorporates an adaptive control algorithm that dynamically adjusts at least one of the following parameters based on forklift load requirements, ambient temperature, and historical charge / discharge data:

[0012] Output power mode of battery pack 2;

[0013] The constant current / constant voltage switching threshold during the charging phase;

[0014] Preheating start-stop strategy for single cell pack 2 under low temperature environment.

[0015] Beneficial effects

[0016] Compared with the prior art, this utility model provides a high-energy sodium ion forklift power supply device, which has the following beneficial effects:

[0017] This high-energy sodium-ion forklift power supply unit consists of cell packs composed of sodium-ion electrochemical cells. A Battery Management System (BMS) effectively controls the series-parallel combination of these cell packs, managing and controlling the overall input and output. The input and output are controlled through a multi-cell pack integrator, connected to the forklift's power input via power input / output interfaces. Multiple cell packs are independently controlled before being integrated into a single unit, rationally configured according to the load requirements of different forklifts. The combined control of the cell packs achieves the forklift's drive voltage and current requirements, reaching a discharge rate of over 5C and a charging rate of 8C, effectively shortening charging time. Multiple independent cell packs can be controlled and replaced individually, enabling more efficient maintenance and improving product safety and lifespan. The combined control of the cell packs also achieves better discharge and charging performance in low-temperature environments. Furthermore, a multi-cell pack integrator enables real-time series and parallel reconfiguration of cell packs, supporting a wide range of adjustable output voltage and continuous discharge current to meet the power requirements of forklifts of different tonnages. Sodium-ion cells maintain a capacity retention rate of ≥85% at -20℃, and with the BMS battery manager (which can be equipped with a low-temperature self-heating strategy), stable operation of the forklift can be ensured in scenarios such as cold storage warehouses. The cell protector can monitor the status of individual cells in real time, and, if the circuit allows, can trigger the BMS battery manager to isolate the faulty pack in case of an anomaly. The modular design reduces the replacement time of a single cell pack to ≤5 minutes, significantly improving maintenance efficiency. Based on the BMS, it can also incorporate artificial intelligence algorithms to learn user charging habits and dynamically optimize cycle life, with an expected lifespan of 3000 cycles. Attached Figure Description

[0018] Figure 1 This is a three-dimensional exploded view of the present invention;

[0019] Figure 2 This is an exploded view of the battery cell pack of this utility model.

[0020] In the diagram: 1. Power supply box; 2. Cell pack; 3. BMS battery manager; 4. Multi-cell pack integrator; 5. Power input / output interface; 6. Box cover; 201. Cell compartment; 202. Sodium-ion cell; 203. Cell protector; 204. Cell cover. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] Please see Figure 1 A high-energy sodium ion forklift power supply device includes a power supply box 1, a box cover 6 snapped onto the top of the power supply box 1, and multiple battery cell packs 2 arranged at equal intervals inside the power supply box 1. A BMS battery manager 3 is fixedly installed on the top of the battery cell packs 2. A multi-channel battery cell pack integrator 4 is fixedly installed at the output end of the BMS battery manager 3. A power input / output interface 5 is fixedly installed at the output end of the multi-channel battery cell pack integrator 4. The BMS battery manager 3 effectively controls the series and parallel combination of battery cells in the battery cell packs 2 and manages and controls the battery cell packs 2. The overall input and output are controlled by the multi-channel battery cell pack integrator 4 and connected to the power input of the forklift through the power input / output interface 5.

[0023] Please see Figure 2 The battery pack 2 includes a battery compartment 201, inside which are arranged multiple sodium-ion batteries 202 at equal intervals. The sodium-ion batteries 202 are fixedly connected to the battery compartment 201 via a battery cover 204, on which a battery protector 203 is provided. The multiple sodium-ion batteries 202 are connected in series, and the multiple battery packs 2 are connected in parallel or in series with the multi-channel battery pack integrator 4. Multiple batteries are connected in series and parallel to form an independent battery pack 2. After the multiple sodium-ion batteries 202 are cascaded and placed in the battery compartment 201, fixed by the battery cover 204 and protected by the battery protector 203, they form a single independent battery pack, which is then installed in the power supply box 1.

[0024] Cell protector 203 is electrically connected to sodium-ion cell 202, cell protector 203 is signal connected to BMS battery manager 3, and BMS battery manager 3 is signal connected to multi-channel cell pack integrator 4.

[0025] The BMS battery manager 3 controls the sodium-ion electrochemical type cell pack 2. When it detects that the vehicle needs high power, it selects a high-power mode to supply power. In standby mode, it selects a low-power mode to supply power.

[0026] The BMS Battery Manager 3 has a control module with a central processing unit that serves as the control hub for this module. It collects and processes data and performs deep learning to achieve artificial intelligence-based autonomous management and control.

[0027] The multi-channel battery pack integrator 4 connects the sodium ion electrochemical type battery packs 2 in series and parallel. The series and parallel connection methods can be changed as needed to meet the voltage and current requirements of different forklift operations. It can detect battery pack parameters, perform operations or safety protection, and also serve as an expansion interface for the later combination of multiple forklift power packs.

[0028] The BMS battery manager 3 transmits various parameters and status data of the sodium-ion electrochemical cell pack 2 to the central processing unit of the control module for processing. It performs deep learning on the data and uses artificial intelligence for control and management, such as the user's recent power consumption habits, charging time, and environmental conditions, to effectively manage the battery status.

[0029] The BMS battery manager 3, in conjunction with the multi-cell pack integrator 4, can control various series and parallel connection methods. It can perform different series and parallel connection conversions according to the working needs of the forklift to meet the power demand. It can also perform operations such as executing actions, state transitions, and protection actions on sodium-ion electrochemical cell packs.

[0030] Overall working principle: During use, the forklift power unit consists of a cell pack 2 composed of sodium-ion electrochemical cells. The BMS battery manager 3 effectively controls the series and parallel combination of cells in the cell pack 2 and manages the cell pack 2. The overall input and output are controlled by the multi-channel cell pack integrator 4 and connected to the power input of the forklift through the power input and output interface 5.

[0031] The battery pack 2 is integrated into a whole after multiple independent controls are performed, and is reasonably configured according to the power requirements of different forklifts.

[0032] The battery pack 2 is combined and controlled to meet the forklift drive voltage and current requirements, achieving a discharge rate of over 5C during discharge and an 8C charging rate during charging, effectively shortening the charging time.

[0033] Multiple independent battery packs can be controlled and replaced individually, enabling more efficient maintenance and improving product safety and lifespan.

[0034] The battery pack 2 is combined and controlled to achieve better discharge and charging performance in low-temperature environments.

[0035] This power supply design employs artificial intelligence to manage and control the combined sodium-ion electrochemical cells, achieving a state that adapts to user needs and continuously improving autonomously.

[0036] One embodiment of the present invention: A high-energy sodium ion forklift power supply device includes a power supply box 1, the power supply box 1 having a removable box cover 6 on the top, the power supply box 1 having at least two battery packs 2 inside, a BMS battery manager 3 fixedly installed on the top of each battery pack 2, the output end of the BMS battery manager 3 being connected to a multi-channel battery pack integrator 4, and the output end of the multi-channel battery pack integrator 4 having a power input / output interface 5.

[0037] The working principle of this implementation is as follows: Multiple cell packs 2 form a modular power unit within the power supply box 1. The BMS battery manager 3 collects the voltage and temperature data of each sodium-ion cell 202 in real time through the cell protector 203, and generates control commands based on the forklift load requirements; the multi-cell pack integrator 4 switches the series / parallel topology of the cell packs 2 according to the commands, and finally delivers the appropriate voltage and current to the forklift through the power input / output interface 5. Technical benefits: Dynamic reconfiguration capability: Achieves a wide range of output voltage, compatible with forklifts of different tonnages; Independent maintainability: In case of a single cell pack failure, only the module needs to be replaced, and the maintenance time is ≤5 minutes; Low temperature adaptability: Maintains more than 85% capacity output even at -20℃ (traditional lithium batteries only reach 40%).

[0038] One embodiment of the present invention: the battery pack 2 includes a battery compartment 201, a plurality of sodium-ion batteries 202 disposed in the battery compartment 201, a battery cover 204 covering the battery compartment 201, and a battery protector 203 disposed on the battery cover 204.

[0039] The working principle of this embodiment: Sodium-ion cells 202 are connected in series within the cell compartment 201. The cell cover 204 secures the cell group with mechanical clips. The cell protector 203 is embedded in the cell cover 204 and directly connected to the cell electrodes, monitoring the status of each cell in real time. Technical benefits: Dual protection mechanism: Mechanical fixation prevents vibration and loosening, while the electronic protector prevents overvoltage / overtemperature; Optimized thermal management: The metal material of the cell cover 204 accelerates heat conduction, resulting in a lower temperature compared to a coverless design; Space utilization: The array arrangement improves energy density, far exceeding that of lead-acid batteries.

[0040] In one embodiment of the present invention: the cell protector 203 is electrically connected to the sodium-ion cell 202, the cell protector 203 is signal-connected to the BMS battery manager 3, and the BMS battery manager 3 is signal-connected to the multi-channel cell pack integrator 4.

[0041] The working principle of this implementation is as follows: The cell protector 203 uploads the cell data to the BMS battery manager 3. After analysis, the BMS sends a series-parallel connection command to the integrator 4. Simultaneously, the BMS can issue a preheating / shutdown command to the cell protector 203. Technical benefits: Safety response speed: Short detection and isolation time during short-circuit faults; Energy efficiency optimization: Automatically shuts down idle cell packs in standby mode, reducing standby power consumption.

[0042] In one embodiment of the present invention: the BMS battery manager 3 monitors the voltage and temperature data of the sodium-ion cell 202 in real time through the cell protector 203, and controls the multi-channel cell pack integrator 4 to switch the series and parallel topology of the cell pack 2.

[0043] The working principle of this implementation is as follows: The BMS calculates the optimal topology mode based on load current, SOC (power consumption), and temperature data. For example: under no-load conditions: it switches to parallel mode (low current); under heavy load conditions: it switches to series mode (high current). Technical benefits: Power is allocated on demand: torque is increased under heavy load conditions, and energy consumption is reduced under no-load conditions; lifespan is extended: it avoids high-current discharge under small loads, thus improving cycle life.

[0044] In one embodiment of the present invention: the sodium-ion cells 202 in the cell compartment 201 are arranged in an array and connected in series, and the cell protector 203 integrates overvoltage, undervoltage and overtemperature protection circuits.

[0045] The working principle of this embodiment is as follows: all sodium-ion cells 202 within a single cell pack are connected in series to increase the voltage. The cell protector 203 has a built-in comparator circuit. When any cell abnormality is detected (e.g., voltage > 3.8V or < 2.5V), the circuit is triggered to disconnect. Technical benefits: Voltage consistency management: Active balancing of cell voltage differences avoids the "weakest link" effect; Safety threshold control: High accuracy of overvoltage shutdown response.

[0046] In one embodiment of the present invention, the multi-channel cell pack integrator 4 includes a solid-state relay array, which switches the cell pack 2 to series mode, parallel mode, or series-parallel hybrid mode according to the instructions of the BMS battery manager 3.

[0047] The working principle of this implementation is as follows: The solid-state relay array of integrator 4 receives the PWM signal from the BMS and switches the current path through MOSFETs (e.g., series connection: closing S1-S3; parallel connection: closing P1-P3, etc., adjusted according to the actual situation of the device). Technical effects: Zero arc switching: solid-state devices achieve spark-free topology switching, suitable for flammable environments; microsecond-level response: short mode switching time, ensuring the continuity of forklift power.

[0048] One embodiment of the present invention: The BMS battery manager 3 has a built-in adaptive control algorithm that dynamically adjusts at least one of the following parameters based on forklift load requirements, ambient temperature, and historical charge / discharge data:

[0049] Output power mode of battery pack 2;

[0050] The constant current / constant voltage switching threshold during the charging phase;

[0051] Preheating start-stop strategy for single cell pack 2 under low temperature environment.

[0052] The working principle of this implementation: The BMS built-in algorithm trains an LSTM neural network based on historical data to dynamically optimize parameters: Output power mode: power supply strategy matched to the forklift motor power curve; Constant current / constant voltage switching: CC-CV conversion point adjusted according to cell temperature (low-temperature delayed switching); Preheating strategy: Based on the device's built-in circuitry, pulse heating can be initiated below -10℃ to avoid the risk of lithium plating. Technical benefits: High charging efficiency, good low-temperature performance, and depending on the device's integrated circuitry, different intelligent learning or control can be achieved, predicting load demand based on user habits, resulting in small range error.

[0053] Additional notes:

[0054] All control functions described in this invention (including status monitoring, topology switching, charge / discharge management, etc.) are automatically implemented through the built-in standardized circuitry of the selected device, eliminating the need for additional innovative control modules. Specifically:

[0055] The 203 cell protector uses a mass-produced battery monitoring chip (such as TI BQ76952), whose overvoltage / undervoltage / overtemperature protection functions are automatically triggered by the internal comparator circuit of the chip, which is a common design in the industry.

[0056] The series-parallel switching of the multi-cell pack integrator 4 is achieved through a solid-state relay array (such as Panasonic AQZ207). This device can be turned on / off by receiving a TTL level signal, and the switching logic is automatically completed by the relay drive circuit.

[0057] The adaptive control of BMS Battery Manager 3 is based on the preset firmware of commercial BMS chips (such as NXP MC33771). Its data acquisition, equalization control and communication protocol are all native functions of the chip. Developers only need to configure parameter thresholds (such as setting the CC-CV switching point to 3.65V).

[0058] The coordinated control between the aforementioned devices relies entirely on existing interface protocols and circuit logic:

[0059] Cell protector 203 via I 2 The C bus transmits data to the BMS in accordance with the J1939 protocol standard.

[0060] The switching command sent by the BMS to the integrator 4 is a 12V PWM pulse signal, and the response time of the drive circuit is <10ms, which is the industry benchmark level.

[0061] The low-temperature preheating strategy is automatically executed by the constant current source circuit built into the battery cell protector 203. When the temperature sensor reading is <-10℃, the chip automatically starts a 1A heating current.

[0062] The innovative design of this utility model is reflected only in the hardware combination method (such as the physical architecture of sodium-ion battery pack + integrator + forklift interface), rather than the control method itself. All dynamic management behaviors are inherent capabilities of the selected commercial devices, and the technical effects can be achieved without software algorithm development or external intervention.

[0063] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-energy sodium ion forklift power supply device, comprising a power supply box (1), wherein the top of the power supply box (1) is provided with a removable box cover (6), characterized in that: The power supply box (1) is equipped with at least two battery packs (2), and a BMS battery manager (3) is fixedly installed on the top of each battery pack (2). The output end of the BMS battery manager (3) is connected to a multi-cell pack integrator (4), and the output end of the multi-cell pack integrator (4) is equipped with a power input / output interface (5).

2. The high-energy sodium ion forklift power supply device according to claim 1, characterized in that: The battery pack (2) includes a battery compartment (201), a plurality of sodium-ion batteries (202) disposed in the battery compartment (201), a battery cover (204) covering the battery compartment (201), and a battery protector (203) disposed on the battery cover (204).

3. The high-energy sodium ion forklift power supply device according to claim 1 or 2, characterized in that: The cell protector (203) is electrically connected to the sodium-ion cell (202), the cell protector (203) is signal-connected to the BMS battery manager (3), and the BMS battery manager (3) is signal-connected to the multi-channel cell pack integrator (4).

4. The high-energy sodium ion forklift power supply device according to claim 1, characterized in that: The sodium-ion cells (202) in the cell compartment (201) are arranged in an array and connected in series. The cell protector (203) integrates overvoltage, undervoltage and overtemperature protection circuits.

5. The high-energy sodium ion forklift power supply device according to claim 1, characterized in that: The multi-cell pack integrator (4) includes a solid-state relay array.

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