A battery internal resistance detection device
By using a modular design and short-wire connection for the battery internal resistance detection device, the problems of inefficient expansion, low accuracy, and high cost in existing battery internal resistance detection devices are solved. This achieves efficient and flexible battery internal resistance detection, extends battery life, and reduces costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DALIANSHILVSHUNDIANLIDIANZISHEBEIYOUXIANGONGSI
- Filing Date
- 2025-04-01
- Publication Date
- 2026-06-26
AI Technical Summary
Existing battery internal resistance detection devices cannot be efficiently expanded to adapt to battery packs of different sizes, have excessively long sampling line distances, complex installation processes, low detection accuracy, high costs, and poor device adaptability.
The battery internal resistance detection device adopts a modular design, including an embedded monitoring host module, a communication module, an information convergence module, and a single-cell internal resistance sampling module. It is directly connected to the battery via a short connection line, uses high-precision chips and topology, integrates alarm and display functions, and supports modular expansion.
It significantly improves detection accuracy, reduces construction costs, enhances system adaptability, extends battery life, and simplifies the installation process.
Smart Images
Figure CN224417007U_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of DC substation technology, specifically relating to a battery internal resistance detection device. Background Technology
[0002] As the core energy storage unit of substation DC systems, communication systems, and UPS systems, the performance of batteries directly affects the reliability of power supply. Although lead-acid maintenance-free batteries offer high cost-effectiveness, their lifespan is limited by a typical 6-10 year lifespan and their pollution characteristics, requiring precise monitoring and maintenance to extend their service life.
[0003] Existing battery internal resistance testing devices mostly employ a centralized sampling host, connecting multiple batteries via long-distance cables. This leads to the following problems: complex wiring and high construction costs, especially noticeable in 104- or 192-cell battery systems; excessively long sampling lines easily introduce impedance errors, reducing internal resistance testing accuracy; and fixed installations lack flexibility and are difficult to maintain. Furthermore, existing battery internal resistance testing devices lack modular design, making them inefficiently expandable to adapt to battery packs of different sizes. Therefore, there is an urgent need for a new testing device that optimizes the modular structure, shortens the sampling line distance, and simplifies the installation process to improve testing accuracy, reduce costs, and enhance system adaptability. Summary of the Invention
[0004] This invention addresses the problems of existing battery internal resistance detection devices, such as inefficient scalability to adapt to battery packs of different sizes, excessively long sampling line distances, complex installation processes, low detection accuracy, high costs, and poor device adaptability. The invention proposes a battery internal resistance detection device comprising: an embedded monitoring host module for receiving and displaying battery internal resistance data, and equipped with alarm and background monitoring communication interfaces; a communication module connected to the embedded monitoring host module; an information convergence module connected to the embedded monitoring host module via the communication module; a single-cell internal resistance sampling module connected to the information convergence module; and a battery module connected to the single-cell internal resistance sampling module. The number of single-cell internal resistance sampling modules is the same as the number of battery modules. Each single-cell internal resistance sampling module is directly connected to its corresponding battery module via a short connection wire and connected in parallel to the information convergence module via a crimped RJ45 connector wire.
[0005] According to the battery internal resistance detection device described above, the embedded monitoring host module has a built-in STM32F302 microcontroller U1 and a TFT touch screen SC. It is connected to the information convergence module through an RS485 communication interface. The RS485 interface uses a MAX3485 chip U2 to realize level conversion and integrates a Modbus protocol parsing module to receive the battery internal resistance data of the battery module collected by the single-cell internal resistance sampling module and display it in real time. It also supports threshold setting and audible and visual alarm functions.
[0006] According to the above-described battery internal resistance detection device, the information convergence module includes a multi-channel RS485 bus controller BC, model ADM2587E. The front of the information convergence module is provided with a 32-port RJ45 slot LGA. Each slot LGA is connected in series with a single-cell internal resistance sampling module through a shielded twisted pair cable TP. The information convergence module interacts with the embedded monitoring host module through an SPI interface.
[0007] According to the battery internal resistance detection device described above, the single-cell internal resistance sampling module adopts a four-wire internal resistance measurement circuit. The core chip is the LTC2945 high-precision battery monitoring chip IC. Its positive and negative input terminals are directly soldered to the battery BT terminals of the battery module through 10cm tinned copper wires. The output terminal is connected in parallel with the adjacent single-cell internal resistance sampling module through a pre-pressurized RJ45 crystal head wire to form a daisy-chain topology. Each single-cell internal resistance sampling module has a built-in ADS1220 analog-to-digital converter, which uses the 1kHz AC injection method to measure the battery BT internal resistance of the battery module. The measurement accuracy is ±0.5mΩ.
[0008] According to the battery internal resistance detection device described above, the back of the single-cell internal resistance sampling module is provided with a 3M VHB double-sided adhesive layer, and the shell of the single-cell internal resistance sampling module is made of ABS flame-retardant material with dimensions of 50mm×30mm×10mm.
[0009] According to the battery internal resistance detection device described above, the connection between the tinned copper wire and the battery BT terminal is coated with an antioxidant conductive adhesive, model Loctite ECI 1010, and covered with a heat-shrinkable insulating sleeve.
[0010] According to the battery internal resistance detection device described above, the outer shielding layer of the shielded twisted pair cable is connected to the outer shell of the information convergence module through a grounding screw, and the grounding resistance is less than 1Ω.
[0011] According to the battery internal resistance detection device described above, the audible and visual alarm function of the embedded monitoring host module consists of a buzzer HA with a frequency of 2kHz and an RGB LED indicator, with the LED color switching according to the level of internal resistance exceeding the standard.
[0012] According to the battery internal resistance detection device described above, the single-cell internal resistance sampling module incorporates a DS18B20 temperature sensor, and the measurement data is transmitted via I... 2 The C-bus transmits data to the LTC2945 chip to achieve temperature compensation of the internal resistance value.
[0013] According to the battery internal resistance detection device described above, the RJ45 slot of the information convergence module has a built-in anti-reverse insertion buckle, and each slot corresponds to an independent optocoupler isolation circuit, model TLP281-4, with an isolation voltage of 2500Vrms.
[0014] The beneficial effects of the present invention are as follows:
[0015] 1. The present invention uses a single-cell internal resistance sampling module directly attached to the positive and negative terminals of the battery, and collects battery internal resistance data through a short connection within 10cm, avoiding interference from long line impedance and significantly improving sampling accuracy.
[0016] 2. The information convergence module of the present invention supports at least 200 single-section internal resistance sampling modules connected in parallel, and achieves quick connection through RJ45 crimping, which greatly reduces wiring length and construction cost.
[0017] 3. The embedded monitoring host module of the present invention integrates alarm and display functions, supports RS485 communication, can monitor the changes in battery internal resistance in real time and generate a bar chart comparison, which facilitates maintenance personnel to quickly locate abnormal batteries.
[0018] 4. The modular structure of this invention is flexible and adaptable to battery modules of different sizes, with strong scalability, and is suitable for various industry scenarios such as substations, steel, and petrochemicals.
[0019] This invention improves overall installation efficiency by more than 50%, reduces maintenance costs by 30%, and extends battery life by 15%-20% due to timely replacement of faulty individual batteries. Attached Figure Description
[0020] Figure 1 This is a simplified structural diagram of a battery internal resistance detection device according to the present invention.
[0021] Figure 2 This is a simplified structural diagram of a battery internal resistance detection device based on existing technology.
[0022] Figure 3 This is a simplified circuit diagram of a battery internal resistance detection device according to the present invention.
[0023] Figure 4 This is a simplified circuit diagram of a single-cell internal resistance sampling module of a battery internal resistance detection device according to the present invention.
[0024] Figure 5 This is a simplified circuit diagram of the information convergence module of a battery internal resistance detection device according to the present invention.
[0025] In the diagram: 100 - Embedded monitoring host module, 200 - Communication module, 300 - Information convergence module, 400 - Single-cell internal resistance sampling module, 500 - Battery module, B1 to B18 - First battery to eighteenth battery. Detailed Implementation
[0026] Preferred Implementation
[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.
[0028] like Figure 1 As shown: In this embodiment, a battery internal resistance detection device includes: an embedded monitoring host module 100 for receiving and displaying battery internal resistance data, and having an alarm and background monitoring communication interface; the embedded monitoring host module 100 is connected to a communication module 200; the embedded monitoring host module 100 is connected to an information convergence module 300 through the communication module 200; the information convergence module 300 is connected to a single-cell internal resistance sampling module 400; and the single-cell internal resistance sampling module 400 is connected to a battery module 500. The number of single-cell internal resistance sampling modules 400 is the same as the number of battery modules 500. Each single-cell internal resistance sampling module 400 is directly connected to its corresponding battery module 500 via a short connection wire, and is connected in parallel to the information convergence module 300 via a crimped crystal head connection wire.
[0029] like Figure 3 As shown, the embedded monitoring host module 100 has a built-in STM32F302 microcontroller U1 and a TFT touch screen SC. It is connected to the information convergence module 300 through an RS485 communication interface. The RS485 interface uses a MAX3485 chip U2 to realize level conversion and integrates a Modbus protocol parsing module to receive the battery internal resistance data of the battery module 500 collected by the single-cell internal resistance sampling module 400 and display it in real time. It also supports threshold setting and audible and visual alarm functions.
[0030] like Figure 5 As shown, the information convergence module 300 includes a multi-channel RS485 bus controller BC, model ADM2587E. The front of the information convergence module 300 has a 32-port RJ45 slot LGA. Each slot LGA is connected in series with a single-section internal resistance sampling module 400 through a shielded twisted pair cable TP. The information convergence module 300 interacts with the embedded monitoring host module 100 through an SPI interface.
[0031] like Figure 4As shown, the single-cell internal resistance sampling module 400 adopts a four-wire internal resistance measurement circuit. The core chip is the LTC2945 high-precision battery monitoring chip IC. Its positive and negative input terminals are directly soldered to the battery BT terminals of the battery module 500 through 10cm tinned copper wires. The output terminal is connected in parallel with the adjacent single-cell internal resistance sampling module 400 through a pre-pressurized RJ45 crystal head wire to form a daisy-chain topology. Each single-cell internal resistance sampling module 400 has a built-in ADS1220 analog-to-digital converter, which uses the 1kHz AC injection method to measure the battery BT internal resistance of the battery module 500. The measurement accuracy is ±0.5mΩ.
[0032] The single-cell internal resistance sampling module 400 has a 3M VHB double-sided adhesive layer on the back. The shell of the single-cell internal resistance sampling module 400 is made of ABS flame-retardant material and its dimensions are 50mm×30mm×10mm.
[0033] The connection between the tinned copper wire and the battery BT terminal is coated with an antioxidant conductive adhesive, model Loctite ECI 1010, and covered with a heat-shrinkable insulating sleeve.
[0034] The outer shielding layer of the shielded twisted pair cable is connected to the outer shell of the information convergence module 300 via a grounding screw, and the grounding resistance is less than 1Ω.
[0035] The audible and visual alarm function of the embedded monitoring host module 100 consists of a buzzer HA with a frequency of 2kHz and an RGB LED indicator. The LED color changes according to the level of internal resistance exceeding the standard.
[0036] The single-section internal resistance sampling module 400 incorporates a DS18B20 temperature sensor, and the measurement data is transmitted via I... 2 The C-bus transmits data to the LTC2945 chip to achieve temperature compensation of the internal resistance value.
[0037] The RJ45 slot of the information convergence module 300 has a built-in anti-reverse insertion clip, and each slot corresponds to an independent optocoupler isolation circuit, model TLP281-4, with an isolation voltage of 2500Vrms.
[0038] The specific embodiments of this utility model are described below in conjunction with the accompanying drawings:
[0039] Embedded Monitoring Host Module 100: Utilizing an industrial-grade embedded host, this module features a touchscreen display and a built-in RS485 communication interface. The host connects to the information convergence module via a standard CAT5e communication cable, receiving and displaying the internal resistance data of each individual battery cell in real time. The host interface supports a bar chart comparison function. Abnormal data, such as internal resistance exceeding a set threshold, triggers an audible and visual alarm and uploads the internal resistance data of each battery cell to the backend monitoring center via Ethernet or a wireless module.
[0040] The information convergence module 300 has an IP65 protection rating housing and integrates a multi-channel RS485 bus controller. The front of the information convergence module 300 has a set of RJ45 connector slots for connecting parallel lines to the single-cell internal resistance sampling module 400. Each slot corresponds to a battery number, which the single-cell internal resistance sampling module 400 automatically identifies and assigns an address to. The communication cable between the information convergence module 300 and the embedded monitoring host module 100 uses shielded twisted-pair cable with a length not exceeding 50 meters to reduce signal attenuation.
[0041] Each single-cell internal resistance sampling module 400 measures 50mm × 30mm × 10mm and has 3M double-sided adhesive on the back for direct attachment to the battery casing. Two 10cm tinned copper wires extend from the positive and negative terminals of each module 400, connecting to the battery terminals via crimp terminals. Internally, each module 400 integrates a four-wire internal resistance measurement circuit, employing a 1kHz AC injection method to measure internal resistance with an accuracy of ±1%. Adjacent modules 400 are connected in series via pre-crimped 20cm RJ45 connector wires. The module 400 is also connected to the information convergence module 300.
[0042] Installation process
[0043] The single-cell battery internal resistance sampling module 400 is attached to the surface of each battery cell in sequence, and a short connection is made to the battery terminal.
[0044] Connect adjacent single-cell internal resistance sampling modules 400 in series using crystal head wires to form a daisy chain topology, connecting the single-cell internal resistance sampling modules 400 and the information convergence module 300.
[0045] Connect the information convergence module 300 to the embedded monitoring host module 100 and power it on for initialization;
[0046] Configure the device by setting the number of batteries, internal resistance threshold, and alarm parameters in the embedded monitoring host module 100.
[0047] The single-cell internal resistance sampling module 400 collects battery internal resistance data at a 1-second interval and transmits it to the information convergence module 300 via a parallel link. The information convergence module 300 verifies and formats the data before uploading it to the embedded monitoring host module 100 via RS485. The embedded monitoring host module 100 displays the internal resistance values of each battery and a histogram comparison in real time. When the internal resistance of a battery exceeds a threshold, an alarm is triggered and an event log is recorded. The background monitoring system can read the data via the Modbus protocol to achieve remote centralized management.
[0048] The embedded monitoring host module 100 connects to the TCP / IP network via the W5500 Ethernet chip and supports uploading data to the cloud platform via the SNMP protocol.
[0049] The single-cell internal resistance sampling module 400 is powered by the battery itself of the battery module 500 through an LDO voltage regulator circuit, model TPS7A4700, with an input voltage range of 2.7V to 28V and an output voltage stable at 3.3V±1%.
[0050] The short connection structure of this invention reduces the sampling error to below 0.5mΩ; the crystal head plug-in and modular serial connection reduce the amount of on-site wiring work by 80%; this invention supports hot-swapping, and the failure of a single module does not affect the overall operation.
[0051] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.
Claims
1. A battery internal resistance detection device, characterized in that, include: An embedded monitoring host module (100) is used to receive and display battery internal resistance data and has an alarm and background monitoring communication interface. The embedded monitoring host module (100) is connected to a communication module (200). The embedded monitoring host module (100) is connected to an information convergence module (300) through the communication module (200). The information convergence module (300) is connected to a single cell internal resistance sampling module (400). The single cell internal resistance sampling module (400) is connected to a battery module (500). The number of single cell internal resistance sampling modules (400) is the same as the number of battery modules (500). Each single cell internal resistance sampling module (400) is directly connected to the corresponding battery module (500) through a short connection wire and is connected in parallel to the information convergence module (300) through a crimped crystal head connection wire.
2. The battery internal resistance detection device according to claim 1, characterized in that, The embedded monitoring host module (100) has a built-in STM32F302 microcontroller U1 and a TFT touch screen SC. It is connected to the information convergence module (300) through an RS485 communication interface. The RS485 interface uses a MAX3485 chip U2 to realize level conversion and integrates a Modbus protocol parsing module to receive the battery internal resistance data of the battery module (500) collected by the single-cell internal resistance sampling module (400) and display it in real time. It also supports threshold setting and audible and visual alarm functions.
3. The battery internal resistance detection device according to claim 2, characterized in that, The information convergence module (300) includes a multi-channel RS485 bus controller BC, model ADM2587E. The information convergence module (300) has a 32-port RJ45 slot LGA on the front. Each slot LGA is connected in series with a single-section internal resistance sampling module (400) via a shielded twisted pair cable TP. The information convergence module (300) interacts with the embedded monitoring host module (100) through the SPI interface.
4. The battery internal resistance detection device according to claim 3, characterized in that, The single-cell internal resistance sampling module (400) adopts a four-wire internal resistance measurement circuit. The core chip is the LTC2945 high-precision battery monitoring chip IC. Its positive and negative input terminals are directly soldered to the battery BT terminals of the battery module (500) through 10cm tinned copper wire. The output terminal is connected in parallel with the adjacent single-cell internal resistance sampling module (400) through a pre-pressurized RJ45 crystal head wire to form a daisy-chain topology. Each single-cell internal resistance sampling module (400) has a built-in ADS1220 analog-to-digital converter. It uses the 1kHz AC injection method to measure the battery BT internal resistance of the battery module (500) with a measurement accuracy of ±0.5mΩ.
5. The battery internal resistance detection device according to claim 4, characterized in that, The single-section internal resistance sampling module (400) has a 3M VHB double-sided adhesive layer on the back and the shell of the single-section internal resistance sampling module (400) is made of ABS flame retardant material with dimensions of 50mm×30mm×10mm.
6. The battery internal resistance detection device according to claim 5, characterized in that: The connection between the tinned copper wire and the battery BT terminal is coated with an antioxidant conductive adhesive, model Loctite ECI 1010, and covered with a heat-shrinkable insulating sleeve.
7. The battery internal resistance detection device according to claim 6, characterized in that: The outer shielding layer of the shielded twisted pair cable is connected to the outer shell of the information convergence module (300) via a grounding screw, and the grounding resistance is less than 1Ω.
8. The battery internal resistance detection device according to claim 7, characterized in that: The audible and visual alarm function of the embedded monitoring host module (100) consists of a buzzer HA with a frequency of 2kHz and an RGB LED indicator. The LED color switches according to the level of internal resistance exceeding the standard.
9. A battery internal resistance detection device according to claim 8, characterized in that: The single-section internal resistance sampling module (400) is built-in with a DS18B20 temperature sensor, and the measurement data is transmitted to the LTC2945 chip through an I 2 C bus to realize temperature compensation of the internal resistance value.
10. A battery internal resistance detection device according to claim 9, characterized in that: The information convergence module (300) has a built-in anti-reverse insertion buckle in its RJ45 slot, and each slot corresponds to an independent optocoupler isolation circuit, model TLP281-4, with an isolation voltage of 2500Vrms.