A detection module applied to the field of energy storage security and protection

Abstract

The utility model provides a kind of detection module applied to energy storage security field, to solve the technical problems that existing scheme has too large volume, detection parameter is single, performance is insufficient and poor anti-interference ability. The utility model includes shell, integrated sensor unit is arranged in shell, signal processing circuit and main control chip, and the integrated sensor unit is connected with main control chip by signal processing circuit. The utility model reduces module volume, is convenient for integrated installation, adapts different application environment space;Different types of sensors are set, and safety parameters are comprehensively detected under the condition of thermal runaway and battery leakage;Adopt integrated design, can realize efficient operation and maintenance, reduce installation complexity, especially suitable for distributed energy storage scene.

Description

Technical Field

[0001] This utility model relates to the technical field of energy storage security, and in particular to a detection module for energy storage security. Background Technology

[0002] With the large-scale application of renewable energy and the rapid development of the electric vehicle industry, energy storage systems have become a core component of the energy system. However, the safety hazards faced by energy storage devices during operation are becoming increasingly prominent, especially thermal runaway, which can lead to serious accidents such as fires and explosions, causing casualties and significant property damage. Statistics show that globally, over 60% of safety accidents each year are caused by thermal runaway of energy storage systems, with most of these accidents stemming from early detection failures of abnormal conditions. Therefore, developing efficient and reliable detection modules has become a key issue in the field of energy storage security.

[0003] Currently, the main problems with energy storage safety testing equipment on the market are as follows: ① Insufficient equipment size and integration. Traditional testing modules are bulky and difficult to adapt to the installation requirements of small-space scenarios. The size limitation of the testing modules directly affects the deployment density and coverage, making it impossible to achieve "refined" safety monitoring.

[0004] ② Single detection parameter. Existing solutions mostly focus on a single-dimensional parameter, lacking the ability to coordinate monitoring and timely feedback of abnormal information. The evolution of thermal runaway involves multi-physical field coupling phenomena such as sudden temperature rise, gas evolution (such as CO, H2), pressure change, and smoke generation. Single parameter detection is prone to misjudgment or missed detection. For example, relying solely on temperature thresholds to trigger early warnings may miss early gas leak signals, delaying the best response time.

[0005] ③ Insufficient environmental adaptability and anti-interference capability. Energy storage scenarios commonly involve complex operating conditions such as strong electromagnetic interference and drastic fluctuations in temperature and humidity, which place stringent demands on the stability of sensors and signal processing algorithms. Current detection modules experience data deviation and communication interference under harsh operating temperature, humidity, and strong electromagnetic interference environments, leading to false alarms.

[0006] In summary, developing a miniaturized, multi-parameter fusion, and highly environmentally robust detection module has become an urgent need to overcome the technological bottlenecks in energy storage safety protection.

[0007] A utility model patent with application number 202221509204.4 discloses an intelligent security device for an energy storage system. The device includes a gas detection sensing unit, a current sensor, a temperature sensor, and a main control MCU unit. The main control MCU uses harmful gas fault signals fed back by the gas detection sensing unit, current signals collected by the current sensor, and temperature signals collected by the temperature sensor to effectively monitor lithium battery failures in centralized energy storage systems and to monitor arc faults in energy storage circuits and the reliability of electrical connection points in real time. It feeds fault information back to the energy management system, promptly stopping the charging and discharging of faulty battery clusters to avoid safety accidents caused by charging and discharging in the event of battery failure, thus improving the overall safety performance of the system. However, the aforementioned patent has drawbacks, including a single gas detection parameter, large size, poor anti-interference capability, and unsuitability for thermal runaway scenarios. Utility Model Content

[0008] To address the technical problems of existing solutions in the special environmental applications of energy storage security, such as excessive size, limited detection parameters, insufficient performance, and poor anti-interference capabilities, this utility model proposes a detection module for energy storage security applications. Addressing the multi-parameter detection needs of this application scenario, it integrates detection functions for five key parameters: VOC (volatile organic compounds), CO (carbon monoxide), H2 (hydrogen), temperature, and smoke. It employs sensors based on different principles, and matches optimal signal processing circuits to the characteristics of each sensor. A high-density PCB layout achieves a compact module design. The circuit design integrates anti-interference circuitry to reduce the performance impact of electromagnetic interference in the application environment. Simultaneously, the main control chip's software utilizes various existing algorithms to improve detection accuracy under various conditions.

[0009] To achieve the above objectives, the technical solution of this utility model is as follows: a detection module applied in the field of energy storage security includes a shell, an integrated sensor unit, a signal processing circuit and a main control chip are disposed inside the shell, and the integrated sensor unit is connected to the main control chip through the signal processing circuit.

[0010] Preferably, the integrated sensor unit includes a first gas sensor, a second gas sensor, a third gas sensor, a temperature sensor, and a smoke sensor, and the first gas sensor, the second gas sensor, the third gas sensor, the temperature sensor, and the smoke sensor are respectively connected to the main control chip through a signal processing circuit.

[0011] Preferably, the first gas sensor, the second gas sensor, the third gas sensor, the temperature sensor, the smoke sensor, the signal processing circuit, and the main control chip are all mounted on a PCB board, which is located inside the housing.

[0012] Preferably, the first gas sensor, the second gas sensor, and the third gas sensor are a CO sensor, an H2 sensor, and a VOC sensor, respectively.

[0013] Preferably, the VOC sensor, CO sensor, and H2 sensor are semiconductor sensors, catalytic sensors, or electrochemical sensors.

[0014] Preferably, the signal processing circuit includes a voltage divider circuit and a transimpedance amplifier circuit. The first gas sensor, the second gas sensor, and the smoke sensor are respectively connected to the main control chip through different transimpedance amplifier circuits, and the third gas sensor and the temperature sensor are respectively connected to the main control chip through different voltage divider circuits.

[0015] Preferably, the voltage divider circuit and the transimpedance amplifier circuit are each provided with a first anti-interference circuit at their front end, and the main control chip is also connected to a second anti-interference circuit. Both the first anti-interference circuit and the second anti-interference circuit are filter capacitors.

[0016] Preferably, the PCB board is surrounded by a copper foil to absorb interference signals.

[0017] Preferably, the main control chip supports UART interface, RS485 interface and CAN interface. The UART interface is connected to the UART output terminal, the RS485 interface is connected to the RS485 output terminal through the RS485 chip, and the CAN interface is connected to the CAN output terminal through the CAN chip.

[0018] Preferably, the outer casing is made of stainless steel.

[0019] The beneficial effects of this utility model are: This invention reduces the module size by using a small-volume sensor, a compact circuit layout, and a specially designed structural housing, making it easy to integrate and install, and adaptable to different application environments.

[0020] This invention uses multiple different types of sensors to comprehensively detect safety parameters in the event of thermal runaway and battery leakage.

[0021] This invention reduces the impact of environmental electromagnetic interference and environmental temperature and humidity on product functionality by implementing electromagnetic interference protection measures in the hardware and utilizing various signal processing algorithms in the software (such as zero-point tracking and temperature compensation) to address harsh temperature and humidity environments and sensor characteristics. This improves the accuracy of detection and the stability of communication during operation.

[0022] This invention integrates multiple types of sensors within a limited volume, utilizes existing intelligent algorithms to achieve efficient analysis of multi-source information, and possesses stable operation capabilities under complex working conditions, thereby providing earlier and more accurate safety warnings for energy storage systems.

[0023] This invention targets the detection of characteristic points generated during thermal runaway, solving the problem that existing solutions on the market do not comprehensively detect relevant parameters of safety hazards in this application environment and cannot provide timely feedback on abnormal information.

[0024] This invention features preventative safety functions, enabling early detection of precursors to thermal runaway in energy storage systems, thereby effectively reducing property damage. Its integrated design facilitates efficient operation and maintenance, reduces installation complexity, and is particularly suitable for distributed energy storage scenarios. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a graph showing the gas changes during thermal runaway.

[0027] Figure 2 This is a schematic diagram of the structure of this utility model. Detailed Implementation

[0028] 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.

[0029] like Figure 1As shown, the gas changes rapidly and drastically in the early stages of thermal runaway, accompanied by changes in smoke. Subsequently, the temperature rises and combustion occurs. This invention uses targeted sensors for safety detection, employing different principles (semiconductor, electrochemical, and optical) to implement a comprehensive solution. It comprehensively detects gas changes in the early stages of thermal runaway (such as H2 generated by battery leakage, CO generated by incomplete combustion, and abnormal odors generated by battery abnormalities), as well as the subsequent smoke and temperature changes. Based on the characteristic phenomena of different stages of thermal runaway, it reports abnormal information in a graded manner, providing timely feedback to facilitate backend processing and control of thermal runaway, thereby reducing the dangers and losses caused by thermal runaway.

[0030] like Figure 2 As shown, a detection module for energy storage security includes a housing, within which are an integrated sensor unit, a signal processing circuit, and a main control chip. The integrated sensor unit is connected to the main control chip via the signal processing circuit. The integrated sensor unit is used to collect physical or chemical signals of the object under test; the signal processing circuit is used to process the signals collected by the integrated sensor unit; and the main control chip is used to receive the processed signals and further analyze, process, and judge the signals according to preset existing programs and algorithms.

[0031] The integrated sensor unit includes a first gas sensor, a second gas sensor, a third gas sensor, a temperature sensor, and a smoke sensor. These sensors are connected to the main control chip via signal processing circuits. The first, second, and third gas sensors are used to collect different gas concentrations, the temperature sensor is used to collect the ambient temperature, and the smoke sensor is used to collect smoke signals.

[0032] The first gas sensor, second gas sensor, third gas sensor, temperature sensor, smoke sensor, signal processing circuit, and main control chip are all housed on a PCB board, which is located inside the housing. Integrating these components onto the PCB board results in a more compact layout and a smaller overall size.

[0033] The first gas sensor, the second gas sensor, and the third gas sensor are a CO sensor, an H2 sensor, and a VOC sensor, respectively. The integrated sensor unit can simultaneously detect five parameters: VOC, CO, H2, temperature, and smoke.

[0034] The signal processing circuit includes a voltage divider circuit and a transimpedance amplifier (TIA) circuit. The CO sensor, H2 sensor, VOC sensor, smoke sensor, and temperature sensor are all connected to the main control chip via the TIA circuit. The VOC, CO, and H2 sensors are semiconductor, catalytic, or electrochemical sensors. The voltage divider circuit divides the voltage between a fixed resistor and the sensor to obtain the sensor's voltage signal. The voltage divider circuit uses voltage-dividing resistors, typically 47KΩ. The TIA circuit converts the sensor's current signal into a voltage signal; the model of the TIA circuit is SGM8542.

[0035] In this embodiment, the VOC sensor is a semiconductor sensor with a detection range of 0~500ppm. The MP801 model can be used.

[0036] The CO sensor is an electrochemical sensor with a detection range of 0~1000ppm. A suitable model is ME2-CO φ14*5.

[0037] The H2 sensor is an electrochemical sensor with a detection range of 0~1000ppm. The MEv-GH01 model can be used.

[0038] The temperature sensor is a semiconductor sensor with a detection range of -40℃ to 85℃. A suitable model is FH-CWF52C103F3950FL20.

[0039] The smoke sensor employs an infrared optical sensor with a detection range of 0~1dB / m. The smoke sensor includes a housing, inside which are an emitting tube and a phototransistor arranged on the same horizontal line, fixed to both ends of the housing. The emitting tube is model IR333-A, and the phototransistor is model PD333-3C / H0 / L2.

[0040] Because the heat generated by semiconductor sensors can affect electrochemical sensors, semiconductor sensors are arranged far away from electrochemical sensors and temperature sensors. Specifically, VOC sensors are kept away from CO sensors, H2 sensors, and temperature sensors.

[0041] The outer casing is made of stainless steel to resist salt spray.

[0042] The voltage divider circuit and transimpedance amplifier (TIA) circuit are also equipped with an anti-interference circuit at their front end. The main control chip is also connected to the anti-interference circuit, which consists of filter capacitors installed at the input and output terminals to filter out interference signals. A copper foil ring is wrapped around the PCB board to absorb interference signals, and the test results meet the electromagnetic compatibility requirements of GB / T 15322.1. The anti-interference circuit is used to protect the entire circuit from electromagnetic interference, enhance the stability of the detection module in complex electromagnetic environments, and combat electromagnetic interference.

[0043] The main control chip supports three output interfaces: UART, RS485, and CAN. UART is the main control chip's USART interface, directly connected to the UART output terminal. RS485 is the main control chip's USART interface, connected to the RS485 chip, and then to the RS485 output terminal. CAN is the main control chip's USART interface, connected to the CAN chip, and then to the CAN output terminal. UART, RS485, and CAN outputs are common centralized output methods in energy storage applications, allowing customers to easily receive all information using any one of them in secondary development.

[0044] The main control chip is a 12-bit high-precision ADC with 48 pins and 64k large storage space. The specific model is CS32F103CBT7. The high precision is mainly used for sensor signal acquisition, which can more accurately acquire sensor output signals. The multiple pins can realize more functions and control logic. The large storage space can better support the writing of complex algorithms and ensure accurate detection and output in various environments.

[0045] The program inside the main control chip includes existing temperature compensation algorithms, which are constructed through a voltage divider circuit connected to the temperature sensor in hardware. Temperature compensation is achieved by combining the preset program and algorithm with the hardware circuit.

[0046] The principle of this invention is as follows: When thermal runaway and battery leakage occur, the CO sensor, H2 sensor, VOC sensor, smoke sensor, and temperature sensor collect data in real time. The transimpedance amplifier circuit converts the CO sensor signal into a corresponding electrical signal and transmits it to the main control chip. The transimpedance amplifier circuit converts the H2 sensor signal into a corresponding electrical signal and transmits it to the main control chip. The first voltage divider circuit converts the VOC sensor signal into a corresponding electrical signal and transmits it to the main control chip. The transimpedance amplifier circuit converts the smoke sensor signal into a corresponding electrical signal and transmits it to the main control chip. The second voltage divider circuit converts the temperature sensor signal into a corresponding electrical signal and transmits it to the main control chip. The main control chip processes the received electrical signals. Based on the collected voltage signals and the linear relationship stored at the factory, the main control chip performs gas concentration detection and over-threshold alarm judgment. According to the judgment result, the corresponding UART, RS485, and CAN protocol outputs are output, and the corresponding LED lights are controlled to achieve various functions. During the detection process, the anti-interference circuit provides anti-interference protection for the entire circuit, realizing comprehensive detection of safety parameters.

[0047] This invention utilizes sensors based on different principles to specifically detect different gases emitted during thermal runaway scenarios. Through signal processing circuits and anti-interference circuits, it identifies abnormal situations, provides early warnings, and reduces losses caused by thermal runaway.

[0048] When the battery malfunctions, the concentrations of VOC, H2, and CO will increase, accompanied by an abnormal increase in temperature, eventually leading to combustion and smoke. During this process, the above parameters will be monitored in real time. If VOC, H2, and CO exceed 200 ppm, the temperature exceeds 70 degrees Celsius, or the smoke exceeds 0.2 dB / m³, corresponding alarm messages will be issued.

[0049] Based on the characteristic phenomena of different stages of thermal runaway, abnormal information is reported in different levels. The more parameters that alarm simultaneously, the higher the abnormality level. Timely feedback facilitates backend processing and control of thermal runaway, reducing the dangers and losses caused by thermal runaway.

[0050] This invention addresses the performance issues caused by electromagnetic interference and temperature / humidity. For electromagnetic interference in such environments, the hardware incorporates electromagnetic interference protection measures. For harsh temperature and humidity environments and sensor characteristics, the software employs various signal processing algorithms (such as zero-point tracking and temperature compensation) to ensure detection accuracy and communication stability during operation. For example, when some interfering gases are present in the environment, the existing zero-point tracking algorithm will process minor signal anomalies, avoiding the impact of these gases on concentration detection. When the temperature and humidity are high or low, the sensor sensitivity will be affected. Based on the environmental conditions, the existing temperature compensation algorithm performs coefficient compensation correction for the concentration, ensuring detection accuracy.

[0051] Concentration information, gas alarm status, and sensor fault status are output via UART, RS485, and CAN communication. The detection module outputs the information to the main control device, and the working, alarm, and fault statuses are simultaneously output via LEDs.

[0052] This invention is also applicable to fields such as automotive batteries and security systems that require detection of similar feature points. With proper design, the objectives of this application can also be achieved. A new alternative can replace the existing sensor with a detection sensor for other gases in the same application environment. Based on the sensor's principles and characteristics, the signal processing circuit and the processing algorithm within the main control chip are redesigned. Simultaneously, the structural housing and anti-interference circuit are redesigned to achieve this objective.

[0053] 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, improvements, etc., 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 detection module applied in the field of energy storage security, characterized in that, The device includes a housing, within which are housed an integrated sensor unit, a signal processing circuit, and a main control chip. The integrated sensor unit is connected to the main control chip via the signal processing circuit.

2. The detection module for energy storage security as described in claim 1, characterized in that, The integrated sensor unit includes a first gas sensor, a second gas sensor, a third gas sensor, a temperature sensor, and a smoke sensor. The first gas sensor, the second gas sensor, the third gas sensor, the temperature sensor, and the smoke sensor are respectively connected to the main control chip through a signal processing circuit.

3. The detection module for energy storage security as described in claim 2, characterized in that, The first gas sensor, the second gas sensor, the third gas sensor, the temperature sensor, the smoke sensor, the signal processing circuit, and the main control chip are all mounted on a PCB board, which is located inside the housing.

4. The detection module for energy storage security as described in claim 2 or 3, characterized in that, The first gas sensor, the second gas sensor, and the third gas sensor are a CO sensor, an H2 sensor, and a VOC sensor, respectively.

5. The detection module for energy storage security as described in claim 4, characterized in that, The VOC sensor, CO sensor, and H2 sensor are of the type of semiconductor sensor, catalytic sensor, or electrochemical sensor.

6. The detection module for energy storage security as described in claim 2 or 3, characterized in that, The signal processing circuit includes a voltage divider circuit and a transimpedance amplifier circuit. The first gas sensor, the second gas sensor, and the smoke sensor are connected to the main control chip through different transimpedance amplifier circuits, and the third gas sensor and the temperature sensor are connected to the main control chip through different voltage divider circuits.

7. The detection module for energy storage security as described in claim 6, characterized in that, The voltage divider circuit and the transimpedance amplifier circuit are both equipped with a first anti-interference circuit at their front ends. The main control chip is also connected to a second anti-interference circuit. Both the first and second anti-interference circuits are filter capacitors.

8. The detection module for energy storage security as described in claim 3, characterized in that, The PCB board is surrounded by a copper foil to absorb interference signals.

9. The detection module for energy storage security as described in claim 7 or 8, characterized in that, The main control chip supports UART, RS485 and CAN interfaces. The UART interface is connected to the UART output terminal, the RS485 interface is connected to the RS485 output terminal through the RS485 chip, and the CAN interface is connected to the CAN output terminal through the CAN chip.

10. The detection module applied to the field of energy storage security according to claim 1 or 2, characterized in that, The outer casing is made of stainless steel.

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