An automobile and a power battery deformation monitoring and active power-off protection system thereof
By introducing strain gauges, fiber optic strain gauges, or pressure sensors into the battery system and combining them with the control module and active power-off module, the problems of monitoring lag and passivity in battery deformation monitoring systems are solved, enabling early warning and active protection, and improving battery safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHENZHEN POLYTECHNIC
- Filing Date
- 2025-07-17
- Publication Date
- 2026-06-19
AI Technical Summary
Existing battery deformation monitoring systems suffer from monitoring lag and passivity, making them unable to effectively prevent thermal runaway. Furthermore, high-precision sensors are costly to deploy or lack sufficient accuracy.
By combining strain gauges, fiber optic strain gauges, or pressure sensors with control modules and active power-off modules, the battery deformation is monitored in real time and the power is actively cut off, forming an active defense chain.
It enables early detection and active protection against battery deformation, avoids the spread of thermal runaway, reduces costs, and improves safety.
Smart Images
Figure CN224385070U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the automotive field, and in particular relates to a vehicle and its power battery deformation monitoring and active power-off protection system. Background Technology
[0002] Existing battery deformation monitoring systems only have monitoring functions and suffer from the following defects, resulting in delayed thermal runaway protection and passive safety protection, specifically manifested as follows:
[0003] 1. Monitoring Lag: The time gap between deformation signals and thermal runaway is not effectively utilized. Existing technologies rely on temperature or voltage threshold triggers, with most battery deformation monitoring systems only alarming when the battery temperature exceeds 100°C or the voltage drop exceeds 20%. However, experiments show that the gas generated by electrolyte decomposition before thermal runaway in lithium-ion batteries causes deformation of the cell casing, and this deformation signal can be detected 2 hours earlier than the temperature signal. Referring to GB38031, after applying pressure, observation for at least 2 hours is required, and the temperature at all monitoring points should not exceed 60°C; therefore, the deformation signal can be detected 2 hours earlier.
[0004] 2. System passivity: It only has an alarm function and lacks an active power-off mechanism. When a single cell experiences thermal runaway, the existing system can only prevent the spread of heat by issuing audible and visual alarms or reducing the charging / output current response. The modules remain electrically connected, causing high temperatures to spread between the modules.
[0005] 3. Cost vs. Reliability: Deploying high-precision sensors is difficult. While fiber optic sensors can detect micro-strain, their high cost per point and requirement for laser demodulation equipment limit their widespread adoption in mass-produced vehicles. Low-cost solutions, on the other hand, lack sufficient accuracy. Pressure sensors, being relatively thick, can only detect macroscopic bulges and cannot capture early-stage micro-strain. Utility Model Content
[0006] The purpose of this invention is to provide a vehicle and its power battery deformation monitoring and active power-off protection system, which aims to solve the problem that the existing battery deformation monitoring system only has a monitoring function, resulting in lagging thermal runaway protection and passive safety protection.
[0007] In a first aspect, this utility model provides a power battery deformation monitoring and active power-off protection system for automobiles, including a control module, a transmitter electrically connected to the control module, and an active power-off module. The system also includes a strain gauge electrically connected to the transmitter.
[0008] Strain gauges are used to contact the cells of a car's power battery to convert the mechanical deformation of the cells into measurable raw deformation electrical signals.
[0009] The transmitter is used to receive the raw deformation electrical signal output by the strain gauge, and after processing, it is converted into a general standard deformation electrical signal;
[0010] The control module is used to receive the standard deformation electrical signal output by the transmitter and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
[0011] Secondly, this utility model provides a power battery deformation monitoring and active power-off protection system for automobiles, including a control module and an analyzer and an active power-off module respectively electrically connected to the control module. The system also includes an optical fiber strain gauge electrically connected to the analyzer.
[0012] Fiber optic strain gauges are used to contact the cells of automotive power batteries, converting the mechanical deformation of the cells into measurable raw deformation electrical signals.
[0013] The analyzer is used to receive the raw deformation electrical signal output by the fiber optic strain gauge and resolve it into a common standard deformation electrical signal;
[0014] The control module is used to receive the standard deformation electrical signal output by the analyzer and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
[0015] Thirdly, this utility model provides a power battery deformation monitoring and active power-off protection system for automobiles, including a control module, a transmitter electrically connected to the control module, and an active power-off module. The system also includes a pressure sensor electrically connected to the transmitter.
[0016] Pressure sensors are used to contact the cells of a car's power battery and convert the deformation pressure value of the cell into a measurable raw deformation electrical signal.
[0017] The transmitter is used to receive the raw deformation electrical signal output by the strain gauge, and after processing, it is converted into a general standard deformation electrical signal;
[0018] The control module is used to receive the standard deformation electrical signal output by the transmitter and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
[0019] Fourthly, this utility model provides a car, which includes the aforementioned car power battery deformation monitoring and active power-off protection system.
[0020] In this invention, an active power-off module and strain gauges are included. The strain gauges are used to contact the battery cells of the vehicle's power battery, converting the mechanical deformation of the cells into measurable raw deformation electrical signals. The control module receives the standard deformation electrical signal output by the transmitter and determines whether power disconnection is needed based on the standard deformation electrical signal. If power disconnection is required, the active power-off module is triggered to disconnect the connection between the battery modules. Therefore, an active defense chain is achieved, overcoming the challenges of monitoring lag and passive protection. Attached Figure Description
[0021] Figure 1 This is a functional block diagram of the power battery deformation monitoring and active power-off protection system for automobiles provided in Embodiment 1 of this utility model.
[0022] Figure 2 This is a schematic diagram showing the arrangement of one set of strain gauges attached to the center of each battery cell in the power battery deformation monitoring and active power-off protection system for automobiles provided in Embodiment 1 of this utility model.
[0023] Figure 3 This is a schematic diagram of the arrangement of a set of strain gauges covering the boundary area between two adjacent battery cells in the power battery deformation monitoring and active power-off protection system for automobiles provided in Embodiment 1 of this utility model.
[0024] Figure 4 This is a schematic diagram of the arrangement of strain gauges on cells of each battery module in the power battery deformation monitoring and active power-off protection system for automobiles provided in Embodiment 1 of this utility model.
[0025] Figure 5 This is a functional block diagram of the power battery deformation monitoring and active power-off protection system for automobiles provided in Embodiment 2 of this utility model.
[0026] Figure 6 This is a functional block diagram of the power battery deformation monitoring and active power-off protection system for automobiles provided in Embodiment 3 of this utility model. Detailed Implementation
[0027] To make the objectives, technical solutions, and beneficial effects of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.
[0028] To illustrate the technical solution described in this utility model, specific embodiments are described below.
[0029] Please see Figure 1The first embodiment of this utility model provides a power battery deformation monitoring and active power-off protection system for automobiles, which includes a control module 11, a transmitter 12 and an active power-off module 13 that are electrically connected to the control module 11 respectively. The system also includes a strain gauge 14 that is electrically connected to the transmitter 12.
[0030] The strain gauge 14 is used to contact the battery cell of the car's power battery to convert the mechanical deformation of the battery cell into a measurable raw deformation electrical signal.
[0031] Transmitter 12 is used to receive the original deformation electrical signal output by the strain gauge, and after processing, it is converted into a general standard deformation electrical signal.
[0032] The control module 11 is used to receive the standard deformation electrical signal output by the transmitter, and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
[0033] In the first embodiment of this utility model, the control module can specifically be used to receive the standard deformation electrical signal output by the transmitter, and trigger different levels of cell deformation alarms according to the standard deformation electrical signal and the preset alarm deformation value. When the preset power-off threshold is exceeded, it is determined that power needs to be cut off, and the active power-off module is triggered to disconnect the connection between the battery modules.
[0034] In the first embodiment of this utility model, the preset alarm deformation value may include a first threshold, a second threshold, and a third threshold, wherein the first threshold is less than the second threshold, and the second threshold is less than the third threshold; for example, the first threshold is set to 15% of the third threshold, and the second threshold is set to 50% of the third threshold.
[0035] The steps of triggering different levels of cell deformation alarms based on the standard deformation electrical signal and the preset alarm deformation value, and determining that a power outage is required when the preset power-off threshold is exceeded, and triggering the active power-off module to disconnect the connection between the battery modules, specifically include:
[0036] When the standard deformation electrical signal exceeds the first threshold, an audible and visual alarm is triggered, and the current limit is set to 50%, thereby suppressing the gas production rate and gaining maintenance time.
[0037] When the standard deformation electrical signal exceeds the second threshold, a cockpit pop-up warning is triggered, and the liquid cooling system is activated, thereby delaying the thermal runaway process.
[0038] When the standard deformation electrical signal exceeds the third threshold, the active power-off module is triggered to disconnect the connection between the battery modules and report to the cloud, thereby preventing heat spread and avoiding a chain reaction.
[0039] In Embodiment 1 of this utility model, the third threshold can be determined based on a combination of the battery's charge level and its temperature. For example, when the battery's charge level is 0% to 30% and its temperature is <0°C, the third threshold is set to 300 με; when the battery's temperature is 0-45°C, the third threshold is set to 500 με; when the battery's temperature is >45°C, the third threshold is set to 500 με. When the battery's charge level is 30% to 80% and its temperature is <0°C, the third threshold is set to 700 με; when the battery's temperature is 0-45°C, the third threshold is set to 1000 με; when the battery's temperature is >45°C, the third threshold is set to 800 με. When the battery's charge level is 80% to 100% and its temperature is <0°C, the third threshold is set to 1500 με; when the battery's temperature is 0-45°C, the third threshold is set to 2000 με; when the battery's temperature is >45°C, the third threshold is set to 1800 με.
[0040] In the first embodiment of this utility model, the control module can be a battery management system (BMS) or a separately configured controller.
[0041] Active power-off modules can be devices that use high-pressure gas to disconnect copper busbars, which are quite common in the market. They can also be implemented using contactors, software-based power-off methods, etc.
[0042] Strain gauges can include resistance strain gauges, fiber Bragg grating strain gauges, piezoelectric thin film strain gauges, etc.
[0043] Strain gauges can be arranged such that one set of strain gauges 22 is attached to the center of each cell 21 to monitor one cell (e.g., Figure 2 As shown), a set of strain gauges 32 is attached between each pair of adjacent cells 31 to cover the boundary area between the two adjacent cells in order to monitor the two adjacent cells (e.g. Figure 3 (as shown), or for each battery module, a preset proportion of cells 41 are fitted with strain gauges 42 to monitor a preset number of cells (such as...). Figure 4 (As shown). Each group of strain gauges may include one or two strain gauges.
[0044] The arrangement of attaching one set of strain gauges to the center of each battery cell is suitable for high-value automotive and high-energy-density battery cells; it also provides high detection redundancy.
[0045] The arrangement of attaching one set of strain gauges between each pair of adjacent cells to cover the boundary area between the two adjacent cells is suitable for square hard-shell batteries; the detection redundancy is moderate.
[0046] The arrangement of strain gauges on cells in each battery module with a preset ratio is suitable for cost-sensitive vehicle models; the detection redundancy is low.
[0047] The strain gauge can be parallel or perpendicular to the direction of cell expansion. A reference strain gauge can be attached to the battery bracket to compensate for temperature drift, thereby achieving anti-interference.
[0048] In the first embodiment of this utility model, the controller can be the following model: Huichuan Easy320 (PLC); the transmitter can be the following model: RunesKee CMCU-06; and the strain gauge can be the following model: RunesKee BF350-100AA.
[0049] In Embodiment 1 of this utility model, an active power-off module and strain gauges are included. The strain gauges are used to contact the battery cells of the vehicle's power battery, converting the mechanical deformation of the cells into measurable raw deformation electrical signals. The control module receives the standard deformation electrical signal output by the transmitter and determines whether power disconnection is needed based on the standard deformation electrical signal. If power disconnection is needed, the active power-off module is triggered to disconnect the connection between the battery modules. Therefore, an active defense chain is achieved, overcoming the challenges of monitoring lag and passive protection.
[0050] Please see Figure 5 The second embodiment of this utility model provides a power battery deformation monitoring and active power-off protection system for automobiles, which includes a control module 51, an analyzer 52 and an active power-off module 53 that are electrically connected to the control module 51, and the system also includes an optical fiber strain gauge 54 that is electrically connected to the analyzer 52.
[0051] The fiber optic strain gauge 54 is used to contact the battery cells of a car's power battery to convert the mechanical deformation of the battery cells into a measurable raw deformation electrical signal.
[0052] The analyzer 52 is used to receive the raw deformation electrical signal output by the fiber optic strain gauge and analyze it into a general standard deformation electrical signal.
[0053] The control module 51 is used to receive the standard deformation electrical signal output by the analyzer and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
[0054] The second embodiment of this utility model provides a high-precision, high-cost automotive power battery deformation monitoring and active power-off protection system, which is suitable for high-precision scenarios.
[0055] In the second embodiment of this utility model, the controller can be the following model: Huichuan Easy320 (PLC); the fiber optic strain gauge can be the following model: Zhixing Technology ZX-FBG-S01D / F.
[0056] The second embodiment of this utility model is identical to the first embodiment of this utility model except for the differences mentioned above.
[0057] In the second embodiment of this utility model, an active power-off module and a fiber optic strain gauge are included. The fiber optic strain gauge is used to contact the battery cells of the vehicle's power battery, converting the mechanical deformation of the battery cells into a measurable raw deformation electrical signal. The control module is used to receive the standard deformation electrical signal output by the analyzer and determine whether power-off is required based on the standard deformation electrical signal. If power-off is required, the active power-off module is triggered to disconnect the connection between the battery modules. Therefore, an active defense chain is realized, overcoming the problems of monitoring lag and passive protection.
[0058] Please see Figure 6 The third embodiment of this utility model provides a power battery deformation monitoring and active power-off protection system for automobiles, which includes a control module 61, a transmitter 62 and an active power-off module 63 that are electrically connected to the control module 61 respectively. The system also includes a pressure sensor 64 that is electrically connected to the transmitter 62.
[0059] Pressure sensor 64 is used to contact the cells of the vehicle's power battery and convert the deformation pressure value of the cells into a measurable raw deformation electrical signal.
[0060] Transmitter 62 is used to receive the raw deformation electrical signal output by the strain gauge, and after processing, convert it into a general standard deformation electrical signal;
[0061] The control module 61 is used to receive the standard deformation electrical signal output by the transmitter, and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
[0062] The third embodiment of this utility model provides a low-cost power battery deformation monitoring and active power-off protection system for automobiles.
[0063] In the third embodiment of this utility model, the controller can be the following model: Huichuan Easy320 (PLC); the transmitter can be the following model: RunesKee CMCU-05; and the pressure sensor can be the following model: RunesKee RP-L-110.
[0064] Except for the differences described above, the third embodiment of this utility model is the same as the first embodiment of this utility model.
[0065] In this third embodiment of the invention, an active power-off module and a pressure sensor are included. The pressure sensor is used to contact the battery cells of the vehicle's power battery, converting the deformation pressure value of the battery cells into a measurable raw deformation electrical signal. The control module is used to receive the standard deformation electrical signal output by the transmitter and determine whether power-off is required based on the standard deformation electrical signal. If power-off is required, the active power-off module is triggered to disconnect the connection between the battery modules. Therefore, an active defense chain is realized, overcoming the problems of monitoring lag and passive protection.
[0066] This utility model embodiment also provides a car, the car including the power battery deformation monitoring and active power-off protection system provided in embodiment one, two or three of this utility model.
[0067] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. A power battery deformation monitoring and active power-off protection system for automobiles, characterized in that, The system includes a control module, a transmitter electrically connected to the control module, and an active power-off module. The system also includes a strain gauge electrically connected to the transmitter. Strain gauges are used to contact the cells of a car's power battery to convert the mechanical deformation of the cells into measurable raw deformation electrical signals. The transmitter is used to receive the raw deformation electrical signal output by the strain gauge, and after processing, it is converted into a general standard deformation electrical signal; The control module is used to receive the standard deformation electrical signal output by the transmitter and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
2. The system as described in claim 1, characterized in that, The active power-off module is achieved through a device, contactor, or software-based power-off method that uses high-pressure gas to disconnect the copper busbar.
3. The system as described in claim 1, characterized in that, The strain gauge includes a resistance strain gauge, a fiber optic strain gauge, or a piezoelectric thin film strain gauge.
4. The system as described in claim 1, characterized in that, The strain gauges are arranged such that one set of strain gauges is attached to the center of each cell to monitor one cell, one set of strain gauges is attached between each two adjacent cells to cover the boundary area between the two adjacent cells to monitor two adjacent cells, or strain gauges are attached to a preset proportion of cells in each battery module to monitor a preset number of cells.
5. The system as described in claim 4, characterized in that, The strain gauge is parallel or perpendicular to the cell expansion direction, and a reference strain gauge is attached to the battery bracket to compensate for temperature drift.
6. A power battery deformation monitoring and active power-off protection system for automobiles, characterized in that, The system includes a control module, an analyzer electrically connected to the control module, and an active power-off module. The system also includes an optical fiber strain gauge electrically connected to the analyzer. Fiber optic strain gauges are used to contact the cells of automotive power batteries, converting the mechanical deformation of the cells into measurable raw deformation electrical signals. The analyzer is used to receive the raw deformation electrical signal output by the fiber optic strain gauge and resolve it into a common standard deformation electrical signal; The control module is used to receive the standard deformation electrical signal output by the analyzer and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
7. A power battery deformation monitoring and active power-off protection system for automobiles, characterized in that, The system includes a control module, a transmitter electrically connected to the control module, and an active power-off module. The system also includes a pressure sensor electrically connected to the transmitter. Pressure sensors are used to contact the cells of a car's power battery and convert the deformation pressure value of the cell into a measurable raw deformation electrical signal. The transmitter is used to receive the raw deformation electrical signal output by the strain gauge, and after processing, it is converted into a general standard deformation electrical signal; The control module is used to receive the standard deformation electrical signal output by the transmitter and determine whether power needs to be cut off based on the standard deformation electrical signal. If power needs to be cut off, the active power-off module is triggered to disconnect the connection between the battery modules.
8. A car, characterized in that, The vehicle includes a power battery deformation monitoring and active power-off protection system as described in any one of claims 1 to 7.