An ultrasonic-based online battery detection device

Abstract

The utility model relates to lithium cell detection technical field, concretely relates to an online battery detection device based on ultrasonic wave, including host computer, ultrasonic generator, acoustic imaging appearance, ultrasonic probe, transducer and sealed test frame, the sealed test frame is provided with battery fixture in, the battery to be measured is fixed and erected in battery fixture, acoustic imaging appearance is arranged to be towards the battery to be measured, ultrasonic probe is connected with transducer and sets up in the battery to be measured just above, the transducer is connected with ultrasonic generator outside sealed test frame, the acoustic wave of ultrasonic generator output acts on the battery to be measured through ultrasonic probe, acoustic imaging appearance is connected on line with host computer outside sealed test frame, and the sound signal that acoustic imaging appearance captured is detected through host computer.

Description

Technical Field

[0001] This utility model relates to the field of lithium battery testing technology, specifically to an online battery testing device based on ultrasound. Background Technology

[0002] In the field of lithium-ion battery technology, metal encapsulation shells are widely used as the mainstream packaging form in various battery structures. The highly sealed structure (achieving IP68 protection level) formed by laser welding or mechanical sealing effectively blocks the intrusion of moisture and oxygen from the air, preventing irreversible side reactions inside the cell. However, this also makes the internal state of the battery a difficult-to-detect "black box system." Potential defects inside the battery, such as microcracks in the electrode coating, abnormal pores in the separator, and lithium dendrite growth, lack intuitive characteristics in their early stages. Their physical dimensions are often in the micrometer or even nanometer range, making them impossible to detect in a timely manner through conventional visual inspection or simple performance testing. Furthermore, macroscopic performance degradation of the battery, such as capacity decay and increased internal resistance, often lags behind the evolution of internal defects. These defects only become significant when safety hazards accumulate to a critical point, greatly increasing the probability of risk events such as thermal runaway.

[0003] With the electric vehicle range exceeding 1,000 kilometers and the commercial deployment of large-scale energy storage power stations, the safety and reliability requirements of lithium battery systems have significantly increased. Existing battery testing technologies face multiple technical bottlenecks: traditional non-destructive testing methods such as industrial CT scanning are limited by spatial resolution (usually greater than 10 micrometers), making it difficult to identify microscopic defects at the particle level of electrode materials. While high-precision synchrotron radiation technology has nanometer-level detection capabilities, its high equipment cost and inefficient testing process (a single test takes more than 12 hours) severely restrict its industrial application. Electrochemical characterization methods such as electrochemical impedance spectroscopy (EIS) require the application of perturbation signals and scanning a wide frequency domain, with testing times as long as 30 minutes, and are extremely sensitive to environmental temperature fluctuations (±2℃ can cause a phase angle error of more than 5°). Mechanical abuse tests such as needle penetration and crush tests can simulate extreme failure scenarios, but their destructive nature means that each test requires multiple battery samples, and it is impossible to quantify and analyze the failure threshold under different operating conditions.

[0004] Insufficient environmental adaptability further exacerbates the limitations of existing technologies. Under extreme temperature conditions (-30℃ to 55℃), the sensitivity of infrared thermal imaging detection decreases by more than 60%, and ultrasonic detection suffers signal distortion exceeding 30% due to environmental noise interference under vibration conditions (amplitude > 0.5g). In terms of online monitoring, conventional battery management systems (BMS) only collect macroscopic parameters such as voltage, current, and temperature, and cannot monitor changes in internal battery pressure (typical rate of change < 0.1 kPa / min) and electrolyte decomposition products (such as HF gas concentration < 5 ppm) in real time, resulting in a lack of early warning capabilities for early safety degradation.

[0005] The aforementioned technical deficiencies pose significant challenges to battery lifecycle management. In the scenario of secondary use of power batteries, the lack of technical means to accurately assess the state of health (SOH) and state of safety (SOS) of batteries results in the cost of screening retired batteries accounting for as much as 25% of the total operating cost. When energy storage systems are deployed on a large scale, existing testing technologies struggle to balance the demands for efficiency, cost, and testing accuracy, increasing systemic safety risks. Utility Model Content

[0006] To overcome the shortcomings of existing technologies, this application provides an online battery testing device based on ultrasound. Through online ultrasonic testing, the physical changes inside the battery can be captured in real time, effectively improving testing efficiency and accuracy, thereby ensuring the safe operation of the battery.

[0007] The technical problem solved by this invention is addressed by an online battery testing device based on ultrasound, which is improved by including: a host computer, an ultrasonic generator, an acoustic imager, an ultrasonic probe, a transducer, and a sealed test frame.

[0008] The sealed test frame is equipped with a battery clamp, the battery to be tested is fixedly mounted in the battery clamp, and the acoustic imager is arranged to face the battery to be tested.

[0009] The ultrasonic probe is connected to the transducer and positioned directly above the battery under test. The transducer is connected to an ultrasonic generator outside the sealed test frame. The sound waves output by the ultrasonic generator act on the battery under test through the ultrasonic probe.

[0010] The acoustic imager is connected online to a host computer outside the sealed test frame, and the host computer detects the sound signals captured by the acoustic imager.

[0011] The device described in the above technical solution also includes a flashlight installed in the frame, used to illuminate the front of the battery under test, and the brightness can also be adjusted.

[0012] The device described in the above technical solution also includes a tripod set inside a sealed test frame, the tripod being used to adjust the height of the acoustic imager.

[0013] The sealed test frame described in the above technical solution has 7cm thick sound insulation cotton attached to its six sides.

[0014] In the above technical solution, a sealing sleeve is provided at the connection between the transducer and the ultrasonic probe, and the inner wall and end face of the sealing sleeve are coated with sealant.

[0015] The battery clamp described in the above technical solution can be adjusted vertically, and by adjusting the distance up and down, the ultrasonic probe can be pressed into the liquid injection hole of the battery to be tested.

[0016] The battery clamp described in the above technical solution includes:

[0017] A fixed base is installed inside a sealed test fixture;

[0018] An adjustable clamp, located within a fixed base, is used to hold the battery under test.

[0019] The ultrasonic probe described in the above technical solution adopts an array design, which includes multiple ultrasonic transducer units arranged in a matrix. Each transducer unit can independently adjust its transmission power and frequency. The acoustic imager is equipped with a beamforming module for phase calibration and superposition imaging of multi-channel ultrasonic signals.

[0020] The transducer described in the above technical solution is a piezoelectric ceramic transducer.

[0021] The beneficial effects of this utility model are:

[0022] By integrating ultrasonic technology and an acoustic imaging system, real-time online monitoring and non-destructive testing of battery status are achieved. It can efficiently capture internal micro-defects (such as bubbles, cracks, or electrode detachment) and accurately locate abnormal areas. Combined with the environmental stability design of the sealed test frame, it effectively isolates external interference and ensures testing accuracy. The intelligent linkage between its acoustic imager and the host computer supports automated signal analysis, which can provide early warning of safety hazards such as thermal runaway and gas leakage. It is also compatible with the testing of multiple types of batteries. Through long-term data accumulation, it optimizes battery design, significantly improves production efficiency, quality control level, and product safety, and provides an innovative solution for battery life cycle management. Attached Figure Description

[0023] Figure 1 An online battery testing device based on ultrasound is shown in this embodiment of the present invention;

[0024] Figure 2 This is a schematic diagram of the transducer and ultrasonic probe shown in an embodiment of the present invention;

[0025] Figure 3 This is a schematic diagram of the battery under test shown in an embodiment of the present invention;

[0026] Figure 4 This is a schematic diagram of the sealing sleeve shown in an embodiment of the present utility model;

[0027] Figure 5 This is a schematic diagram of a battery clamp according to an embodiment of the present invention. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0029] The following will clearly and completely describe the concept, specific structure, and technical effects of this utility model in conjunction with embodiments and accompanying drawings, so as to fully understand the purpose, features, and effects of this utility model. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are all within the scope of protection of this utility model. Furthermore, all connections / linkages involved in the patent do not simply refer to direct contact between components, but rather to the ability to form a better connection structure by adding or reducing connecting accessories according to specific implementation conditions. The various technical features in this utility model can be combined interactively without contradicting each other.

[0030] like Figure 1-4 As shown, this application provides an online battery testing device based on ultrasound, including: a host computer 1, an ultrasonic generator 2, an acoustic imager 3, an ultrasonic probe 4, a transducer 5, and a sealed test frame 6.

[0031] The sealed test frame 6 is equipped with a battery clamp 7, and the battery A to be tested is fixedly mounted in the battery clamp 7. The acoustic imager 3 is arranged to face the battery to be tested.

[0032] The ultrasonic probe 4 is connected to the transducer 5 and is positioned directly above the battery A under test. The transducer 5 is connected to the ultrasonic generator 2 outside the sealed test frame 6. The sound waves output by the ultrasonic generator 2 act on the battery A under test through the ultrasonic probe 4.

[0033] The acoustic imager 3 is connected online to the host computer 1 outside the sealed test frame 6, and the host computer 1 detects the sound signals captured by the acoustic imager 3.

[0034] The ultrasonic generator 2 converts mains power into a high-frequency electrical signal that matches the transducer 5 to generate ultrasonic energy. The ultrasonic generator 2 has a power of 15W and a frequency of 52KHz. The transducer 5 utilizes the piezoelectric effect of certain single-crystal materials and the electrostriction effect of certain polycrystalline materials to achieve mutual conversion between different forms of energy.

[0035] In an exemplary embodiment, the transducer 5 of this application employs a piezoelectric ceramic transducer; the ultrasonic probe 4 acts directly on the inside of the battery under test to emit sound waves. The piezoelectric ceramic transducer has high precision and sensitivity, and can accurately sense minute changes in ultrasonic waves propagating inside the battery, thereby detecting subtle structural differences, defects, or abnormalities inside the battery.

[0036] In one possible implementation, the device further includes a flashlight 8 disposed within the frame for illuminating the front of the battery A under test, and the brightness can be adjusted.

[0037] The light source provided by the flashlight can illuminate the front of the battery under test, allowing the operator to observe the condition of the battery surface more clearly, such as whether there are scratches, wear, leakage, bulging and other appearance problems. This helps to perform visual inspection at the same time as ultrasonic testing, improving the comprehensiveness of the test.

[0038] In one possible implementation, the device further includes a tripod 9 disposed within a sealed test frame, the tripod 9 being used to adjust the height of the acoustic imager 3.

[0039] Adjusting the height of the acoustic imager using a tripod allows for better alignment with the battery under test, finding the most suitable imaging angle, and thus clearly capturing the internal structural information of the battery, improving the accuracy of the test.

[0040] In one possible implementation, 7cm thick sound-absorbing cotton is attached to the six surfaces inside the sealed test fixture 6.

[0041] The sound insulation cotton effectively blocks various noises from the external environment from entering the test frame, preventing noise from interfering with the ultrasonic detection signal, ensuring that the sound signal captured by the acoustic imager is purer, and improving the accuracy of the test results. At the same time, it can also prevent the noise generated by the ultrasonic generator inside the test frame from propagating outward, reducing noise pollution to the surrounding working environment, creating a relatively quiet working environment for operators, and also helping to avoid interference with other nearby equipment or testing work.

[0042] In one possible implementation, a sealing sleeve 10 is provided at the connection between the transducer 5 and the ultrasonic probe 4, and the inner wall and end face of the sealing sleeve 10 are coated with sealant.

[0043] By filling the tiny gaps at the connection points with sealing sleeves and sealant, the connection between the transducer and the ultrasonic probe is made tighter, reducing relative displacement and thus enhancing the stability of the connection. This ensures that the acoustic matching and signal transmission performance between the two remain good during long-term use.

[0044] In one possible implementation, the battery clamp 7 is vertically adjustable, and by adjusting the distance up and down, the ultrasonic probe 4 can be pressed into the liquid injection hole of the battery A to be tested.

[0045] In one exemplary embodiment, such as Figure 5 As shown, the battery clamp 7 includes:

[0046] The fixed base 71 is located inside the sealed test fixture;

[0047] An adjustable clamp 72 is located inside the fixed base and is used to clamp the battery to be tested.

[0048] By adjusting the spacing between the clamps, batteries of different sizes (such as length and width) can be accommodated without the need to customize clamps for each battery model, significantly reducing equipment costs. When switching between different battery specifications on the production line, only the position of the clamps needs to be adjusted, without replacing the entire clamp, greatly shortening downtime and improving production efficiency.

[0049] In one possible implementation, the ultrasonic probe 4 adopts an array design, containing multiple ultrasonic transducer units arranged in a matrix. Each transducer unit can independently adjust its transmission power and frequency. The acoustic imager is equipped with a beamforming module for phase calibration and superposition imaging of multi-channel ultrasonic signals.

[0050] Multiple ultrasonic transducers arranged in a matrix can emit ultrasonic waves from different angles and positions, forming a denser sound wave coverage. This allows for more precise capture of detailed information inside the battery, improving detection resolution and helping to detect smaller defects or anomalies. Each transducer can independently adjust its emission power and frequency, enabling flexible adjustment of ultrasonic emission parameters according to different battery types, specifications, and detection needs. For example, for thicker batteries or batteries with complex internal structures, the emission power can be increased or the frequency adjusted for better penetration and imaging; for batteries made of different materials, parameters can also be adjusted to optimize the detection effect.

[0051] The above is a detailed description of the preferred embodiments of the present utility model. However, the present utility model is not limited to the described embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present utility model. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.

Claims

1. An online battery testing device based on ultrasound, characterized in that, include: The system includes a host computer, an ultrasonic generator, an acoustic imager, an ultrasonic probe, a transducer, and a sealed test fixture. The sealed test frame is equipped with a battery clamp, the battery to be tested is fixedly mounted in the battery clamp, and the acoustic imager is arranged to face the battery to be tested. The ultrasonic probe is connected to the transducer and positioned directly above the battery under test. The transducer is connected to an ultrasonic generator outside the sealed test frame. The sound waves output by the ultrasonic generator act on the battery under test through the ultrasonic probe. The acoustic imager is connected online to a host computer outside the sealed test frame, and the host computer detects the sound signals captured by the acoustic imager.

2. The ultrasonic-based online battery testing device according to claim 1, characterized in that, The device also includes a flashlight installed in the frame, used to illuminate the front of the battery under test, and the brightness can be adjusted.

3. The ultrasonic-based online battery testing device according to claim 1, characterized in that, The device also includes a tripod set inside a sealed test frame, the tripod being used to adjust the height of the acoustic imager.

4. The online battery testing device based on ultrasound according to claim 1, characterized in that, The six sides inside the sealed test frame are lined with 7cm thick sound insulation cotton.

5. The online battery testing device based on ultrasound according to claim 1, characterized in that, A sealing sleeve is provided at the connection between the transducer and the ultrasonic probe, and sealant is applied to the inner wall and end face of the sealing sleeve.

6. The ultrasonic-based online battery testing device according to claim 1, characterized in that, The battery clamp can be adjusted vertically, and by adjusting the distance up and down, the ultrasonic probe can be pressed into the liquid injection hole of the battery to be tested.

7. The ultrasonic-based online battery testing device according to claim 6, characterized in that, The battery clamp includes: A fixed base is installed inside a sealed test fixture; An adjustable clamp, located within a fixed base, is used to hold the battery under test.

8. The online battery testing device based on ultrasound according to claim 1, characterized in that, The ultrasonic probe adopts an array design, containing multiple ultrasonic transducer units arranged in a matrix. Each transducer unit can independently adjust its transmission power and frequency. The acoustic imager is equipped with a beamforming module for phase calibration and superposition imaging of multi-channel ultrasonic signals.

9. The online battery testing device based on ultrasound according to claim 1, characterized in that, The transducer is a piezoelectric ceramic transducer.

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