Battery pack structure optimization device based on temperature detection and thermal imaging technology

Abstract

The utility model discloses a kind of battery pack structure optimization device based on temperature detection and thermal imaging technology belongs to battery pack structure optimization technical field, at least including temperature sensor and thermal imaging detector, the quantity of temperature sensor corresponds with the quantity of battery monomer in battery package to be measured, and it is installed on the negative pole column of battery monomer to measure the temperature of corresponding battery monomer;Thermal imaging detector is erected in the upper of the battery package to be measured by support frame, its detection range at least covers the distribution area of copper bar on battery package to be measured, to collect the temperature distribution image of copper bar distribution area;Two kinds of temperature collected in the present scheme not only exist correlation on time dimension, and have the correlation of "temperature area-corresponding battery temperature", avoid the deficiency existing in single-point temperature measurement, substantially improve the reference value of temperature data, can determine optimization direction according to the correlation, and then improve optimization efficiency, solve the existing deficiency.

Description

Technical Field

[0001] This utility model belongs to the field of battery pack structure optimization technology, and in particular relates to a battery pack structure optimization device based on temperature detection and thermal imaging technology. Background Technology

[0002] With the rapid development of new energy technologies, lead-carbon battery energy storage systems are increasingly widely used in energy storage and other fields. Typically, a lead-carbon battery energy storage system consists of multiple small lead-carbon batteries connected in parallel via copper busbars to form a pack. Multiple packs are then connected in series to form a battery cluster. This design not only improves the energy density of the system but also simplifies the overall structure.

[0003] In the design process of the pack structure, the copper busbar structure and battery arrangement directly affect the heat dissipation performance and temperature distribution of the pack, and are core elements of design optimization. However, existing pack structure design testing phases lack targeted temperature monitoring solutions: on the one hand, due to the dense arrangement of batteries, traditional temperature measurement methods mainly rely on measuring temperature in a single dimension (such as measuring only the battery surface or only a single point on the copper busbar), which cannot accurately reflect the temperature changes inside the battery and at key locations on the copper busbar, resulting in a lack of precise basis for optimizing the copper busbar structure and battery arrangement based on temperature data; on the other hand, temperature monitoring in the testing phase can only obtain the temperature of a single point on the battery or only the local temperature of the copper busbar, that is, existing testing methods cannot establish a correlation analysis between "battery temperature change" and "copper busbar heat dissipation performance", making it difficult to locate the specific optimization direction of the copper busbar structure or battery arrangement, and also making it difficult to form a complete temperature field analysis basis.

[0004] To address these issues, researchers have begun exploring new temperature monitoring methods. For example, some studies have proposed single-point temperature monitoring schemes, but these cannot reflect the overall temperature distribution. Other studies have used image-based temperature measurement technology, but it is difficult to obtain accurate temperatures at the core of the battery. At the same time, existing tests struggle to achieve coordinated monitoring of "accurate temperature measurement at key battery points" and "temperature distribution across the entire copper busbar," resulting in a lack of systematic temperature data support for the optimized design of the copper busbar and battery layout. Therefore, developing a pack structure optimization test scheme that achieves accurate analysis through multi-dimensional temperature measurement coordination has become particularly important.

[0005] Based on the above analysis, this application designs a battery pack structure optimization device based on temperature detection and thermal imaging technology. By complementing the advantages of the two temperature measurement methods, it provides complete temperature data for the optimization of copper busbar structure and battery arrangement. Utility Model Content

[0006] The purpose of this invention is to provide a battery pack structure optimization device based on temperature detection and thermal imaging technology for the battery pack structure design and testing stage, in order to optimize the copper busbar structure and battery arrangement. The device uses temperature sensor and thermal imaging combined temperature measurement technology to build a collaborative temperature measurement system for copper busbar and battery terminals, providing complete temperature field analysis data for the related structure of "battery heating-copper busbar heat dissipation", which can accurately locate the cause and location of the temperature rise, and provide a clear direction for design optimization.

[0007] To address the aforementioned issues, this application provides a battery pack structure optimization device based on temperature detection and thermal imaging technology, comprising at least temperature sensors and a thermal imaging detector. The number of temperature sensors corresponds to the number of individual battery cells in the battery pack under test, and they are installed on the negative terminal of each individual battery cell to measure the temperature of that cell. The thermal imaging detector is mounted above the battery pack under test via a support frame, and its detection range at least covers the distribution area of ​​the copper busbars on the battery pack under test to acquire temperature distribution images of the copper busbar distribution area.

[0008] As a preferred embodiment: the support frame includes uprights and crossbeams. Two sets of uprights are symmetrically arranged, and the distance between the two sets of uprights is greater than the width or length of the battery pack to be tested. The crossbeams are fixed to the top of the two sets of uprights to form a portal frame, and a mounting base for installing the thermal imaging detector is provided on the crossbeams.

[0009] As a preferred embodiment, the upright and / or the crossbeam is a telescopic sleeve structure.

[0010] As a preferred embodiment: when the crossbeam is a telescopic sleeve structure, the crossbeam includes a middle outer sleeve and an end inner sleeve. The fixing seat is disposed on the middle outer sleeve, and the end inner sleeve is sleeved on both ends of the middle outer sleeve to ensure that the position of the middle outer sleeve remains constant when the length of the crossbeam is adjusted.

[0011] As a preferred embodiment, the fixing seat is a flange seat or a snap fastener.

[0012] As a preferred embodiment, the system further includes a data processor, which comprises a data analysis unit and a display. The data analysis unit is electrically connected to the temperature sensor, the thermal imaging detector, and the display. The data analysis unit is capable of converting the temperature data collected by the temperature sensor and the thermal imaging detector into a different format and then displaying it on the display.

[0013] As a preferred embodiment, the temperature sensor is provided with an OT terminal, the inner diameter of which is adapted to the outer diameter of the negative terminal, and the temperature sensor can be fixed on the negative terminal with the help of a stud.

[0014] As a preferred embodiment, the temperature sensor is an NTC thermistor or a PT100 platinum resistance thermometer.

[0015] As a preferred embodiment, the thermal imaging detector is either FLIR A655sc or FLIR AX8.

[0016] Compared with existing technologies, the advantages of this battery pack structure optimization device based on temperature detection and thermal imaging technology are as follows: 1. By simultaneously monitoring the temperature of the negative electrode post of the battery cell and the temperature distribution of the copper busbar of the entire battery pack, a correlation model of "battery heating - copper busbar heat dissipation" can be established. This allows for precise identification of the cause of the temperature rise, determining whether it is due to localized overheating caused by an unreasonable copper busbar structure (i.e., heat dissipation) or a heat dissipation blind spot caused by dense battery arrangement. On the other hand, it can accurately locate the area or location of the temperature rise without additional data conversion, shortening the decision-making cycle from testing to optimization, and providing a clear direction for design optimization.

[0017] 2. The contact-type high-frequency sampling temperature collected by the temperature sensor (reflecting dynamic temperature changes) and the thermal imaging spatial distribution data collected by the thermal imaging detector 30 (reflecting temperature field patterns) complement each other. They can capture instantaneous temperature fluctuations and analyze overall heat dissipation trends. The combination of the two avoids the limitations of single-point temperature measurement and makes up for the lack of local numerical accuracy in thermal imaging, forming a "point-area" collaborative temperature measurement system. This greatly improves the reference value of temperature data and achieves the goal of synergistic efficiency in data dimensions. Attached Figure Description

[0018] Figure 1 The schematic diagram of the battery pack structure optimization device based on temperature detection and thermal imaging technology provided in this embodiment.

[0019] Figure 2 This is a schematic diagram of the connection between the temperature sensor and the negative terminal of the battery cell provided in this embodiment.

[0020] Figure 3 This is a schematic diagram showing the position and structure of the thermal imaging detector and battery pack provided in this embodiment.

[0021] Figure 4 This is a schematic diagram of a telescopic sleeve structure for the crossbeam provided in this embodiment.

[0022] Figure Labels

[0023] 10 is the battery pack; 11 is the battery cell; 12 is the copper busbar; 20 is the temperature sensor; 21 is the OT terminal; 22 is the M6 ​​stud; 23 is the wire; 30 is the thermal imaging detector; 41 is the upright; 42 is the crossbeam; 421 is the middle outer sleeve; 422 is the end inner sleeve; 43 is the base; 44 is the mounting base. Detailed Implementation

[0024] The present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be emphasized that the following description is merely exemplary and not intended to limit the scope and application of the present invention.

[0025] This embodiment provides a battery pack structure optimization device based on temperature detection and thermal imaging technology. It should be noted that this device is mainly used in the design and testing stage of the battery pack structure to optimize the copper busbar 12 structure and battery arrangement, and is not used in the formal energy storage system.

[0026] The device includes at least a temperature sensor 20 and a thermal imaging detector 30. The temperature sensors 20 are preferably contact sensors, and their number corresponds one-to-one with the number of battery cells 11 in the battery pack 10 under test. They are installed on the negative terminal of each battery cell 11 to measure the temperature of that battery cell 11. It should be noted that the purpose of connecting the temperature sensors 20 to the negative terminal of the battery cell 11 is twofold: First, during charging and discharging, the insertion and extraction reactions of ions at the negative terminal generate a thermal effect, meaning the negative terminal temperature can accurately reflect the heat generated by the internal chemical reaction of the battery cell 11. Second, in most cases, the battery casing (usually metal) is at the same potential or directly connected to the negative terminal (i.e., grounded), even if the insulation layer of the temperature sensor 20... Wear and tear and short circuits in the casing will not cause high point differences, thus improving safety during use. Of course, the above are the advantages of using the negative terminal as the temperature acquisition end in this embodiment. In other specific embodiments of this embodiment, when it is ensured that the temperature sensor 20 is intact, the temperature sensor 20 can also be connected to the positive terminal of the battery cell 11. The thermal imaging detector 30 is mounted on the battery pack 10 under test through a support frame. Its detection range covers at least the distribution area of ​​the copper busbar 12 on the battery pack 10 under test. In this embodiment, the detection range of the thermal imaging detector 30 preferably covers the entire upper part of the battery pack 10 to collect temperature distribution images of the copper busbar 12 distribution area. It can be understood that the probe of the thermal imaging detector 30 should be facing the parallel copper busbar 12 of the battery pack 10.

[0027] It is understood that the temperature data of the battery cell 11 and the temperature distribution image of the copper busbar 12 distribution area collected by the temperature sensor 20 and the thermal imaging detector 30 will be uploaded to an existing control mechanism for processing and display. For example, the temperature data collected by the temperature sensor 20 can be uploaded to an existing battery management unit (BMU) for processing and display, and the temperature distribution image collected by the thermal imaging detector 30 can be directly displayed through a display connected to it. This allows the measurement data to be displayed intuitively, making it easier for staff to quickly locate temperature anomalies and their causes. Of course, a dedicated data processor can also be set up for processing. This embodiment is preferably the latter, that is, the device also includes a data processor, which includes a data analysis unit and a display. The data analysis unit is electrically connected to the temperature sensor 20, the thermal imaging detector 30 and the display. The data analysis unit can convert the temperature data collected by the temperature sensor 20 and the thermal imaging detector 30 into a format and then display it on the display. It is understood that the technical means of converting the temperature data into a format and then displaying it is an existing and mature technology. Therefore, the conversion program involved is not within the protection scope of this embodiment.

[0028] like Figure 1 The diagram shown is a schematic diagram of the optimized device in this embodiment. As can be seen from the diagram, the thermal imaging detector 30 is connected to the data analysis unit via a network cable, multiple temperature sensors 20 are connected to the data analysis unit via an RS485 bus, and the display is connected to the data analysis unit via an HDMI interface. The data analysis unit can convert the raw temperature data (analog voltage values ​​collected by the temperature sensors 20 and digital video streams collected by the thermal imaging detector 30) from the temperature sensors 20 and the thermal imaging detector 30 into a unified format, which can be digital temperature values ​​and JPEG image frames. The processed temperature data can be displayed on the display, and the specific display method may be determined according to actual needs. In this embodiment, a picture-in-picture display is preferred. The main screen is a thermal image, and the sidebar displays real-time temperature values ​​and historical curves collected by multiple temperature sensors 20. Based on the thermal image, the staff can intuitively identify the areas of concentrated heat in the distribution area of ​​the copper busbar 12. Then, by combining the temperature values ​​collected by multiple temperature sensors 20, they can not only accurately locate the cause of the temperature rise, determining whether it is due to local overheating caused by an unreasonable structure of the copper busbar 12 (which can be improved by adjusting the heat dissipation structure of the copper busbar 12), or heat dissipation blind spots caused by dense battery arrangement (which can be improved by adjusting the arrangement density of battery cells 11), but also accurately locate the area or location of the temperature rise, providing a clear direction for design optimization.

[0029] Understandably, when necessary, the processor may also include memory to store historical temperature data, providing a data foundation for subsequent analysis.

[0030] In a preferred embodiment, the temperature sensor 20 is an NTC thermistor or a PT100 platinum resistance thermometer, preferably an NTC thermistor. This NTC thermistor has an OT terminal 21. It is understood that the OT terminal 21 can be integrated with the NTC thermistor at the factory or added later. The inner diameter of the OT terminal 21 is compatible with the outer diameter of the negative terminal. With the help of an M6 stud 22, the temperature sensor 20 can be fixed to the negative terminal. Figure 2 As shown.

[0031] As a preferred embodiment, the thermal imaging detector 30 is either FLIR A655sc or FLIR AX8, and can be selected according to actual needs, such as the size of the battery pack 10.

[0032] In a preferred embodiment, the thermal imaging detector 30 is mounted above the battery pack 10 under test via a support frame, wherein the support frame includes a vertical rod 41 and a horizontal beam 42, as shown below. Figure 3 As shown, two sets of uprights 41 are symmetrically arranged. The distance between the two sets of uprights 41 should be greater than the width or length of the battery pack 10 to be tested, so as to ensure that it can be erected at both ends of the battery pack 10. The crossbeam 42 is fixed to the top of the two sets of uprights 41 to form a portal frame. A mounting seat 44 for installing the thermal imaging detector 30 is provided on the crossbeam 42. The thermal imaging detector 30 can be fixed on the crossbeam 42 through the mounting seat 44. The mounting seat 44 can be a flange seat or a buckle, depending on the structure of the bottom of the thermal imaging detector 30. It can be understood that the thermal imaging detector 30 should be installed in the middle position of the crossbeam 42.

[0033] In this embodiment, in order to improve the stability of the support frame, it is preferable that the bottom of the column is provided with a base 43, which is a frustum structure.

[0034] As a preferred embodiment, in order to adapt to battery packs 10 of different sizes, the upright 41 and / or the crossbeam 42 are telescopic sleeve structures. In this embodiment, it is preferred that both the upright 41 and the crossbeam 42 are telescopic sleeve structures, that is, both the upright 41 and the crossbeam 42 are composed of an outer sleeve and an inner sleeve, wherein the inner sleeve can telescopically move relative to the outer sleeve. This structure is an existing mature structure, such as an umbrella handle structure. Therefore, this embodiment does not specifically limit the connection structure and sliding fit structure between the inner sleeve and the outer sleeve.

[0035] In this embodiment, when the crossbeam 42 is a telescopic sleeve structure, the crossbeam 42 includes a middle outer sleeve 421 and an end inner sleeve 422. A fixing seat 44 is disposed on the middle outer sleeve 421, and the end inner sleeves 422 are fitted onto both ends of the middle outer sleeve 421 to ensure that the position of the middle outer sleeve 421 remains constant when adjusting the length of the crossbeam 42. Figure 4 As shown.

[0036] In practical use, the two ends of the crossbeam 42 can be fixed to the ends of the upright 41 by welding or plugging. Then, according to the length or width of the battery pack 10 to be tested, the inner sleeves 422 at both ends of the middle outer sleeve 421 are adjusted synchronously to ensure that the overall length of the crossbeam 42 meets the requirements (adjusting the length of the crossbeam 42 also adjusts the distance between the two uprights 41). It can be understood that when the lengths of the two sets of inner sleeves 422 are adjusted synchronously, the position of the middle outer sleeve 421 can be kept constant. Even if the battery pack 10 to be tested is replaced, the thermal imaging detector 30 can always be placed directly above the battery pack 10 to be tested, which facilitates the adjustment of the coverage area of ​​the thermal imaging detector 30 in the future.

[0037] Understandably, adjusting the height of the pole 41 is necessary not only to meet the height requirements of the battery pack 10 under test, but also to adjust the focusing range of the thermal imaging detector 30, thereby improving the adaptability of the optimization device.

[0038] In this embodiment, the preferred battery pack 10 is a test lead-carbon battery pack 10, which is composed of multiple battery cells 11 connected in parallel to simulate the battery configuration of an actual pack. The lead-carbon battery pack 10 includes a battery casing, electrode terminals (terminals) and an insulating base. The parallel copper busbar 12 is made of copper and connects the electrode terminals of each battery cell 11 to realize the parallel connection of the battery cells 11. Its structure can be changed according to test requirements to verify the heat dissipation performance of different design schemes.

[0039] The following are two specific test implementation examples provided in this embodiment: Example 1

[0040] In this embodiment, the battery pack 10 under test is a lead-carbon battery pack 10, which is composed of 20 lead-carbon battery cells 11 connected in parallel. Each battery cell 11 is connected by a parallel copper busbar 12 made of copper (simulating a certain copper busbar 12 design scheme). The copper busbar 12 is 2mm thick.

[0041] There are 20 contact temperature sensors 20 (NTC thermistors), which are installed one by one on the negative terminal of each battery cell 11 and fixed by OT terminal 21 and M6 stud 22. Each temperature sensor 20 is connected to the data processor through wire 23, with a sampling frequency of 1Hz, and is used to collect the temperature of the negative terminal of each battery cell 11.

[0042] The thermal imaging detector 30 is fixed above the battery pack 10 under test using a support frame. Specifically, the two uprights 41 of the support frame are placed on the ground on both sides of the battery pack 10, with a spacing of 1.2m and a support height of 1.2m. The top crossbeam 42 is 1.5m long, and the thermal imaging detector 30 (preferably FLIR A655sc) is fixed in the middle of the crossbeam 42. The lens is 1m vertically away from the surface of the battery pack 10, and the radiation field completely covers the parallel copper busbar 12 and the top area of ​​the battery pack 10. The thermal imaging detector 30 is connected to the data processor via a Cat5e network cable, with a frame rate of 30fps.

[0043] During testing, a 1C discharge current was applied to battery pack 10, and the data processor recorded the data simultaneously. Temperature sensor 20 data: Temperature change curves of each battery cell's 11 terminals (accurate to ±0.5℃). Thermal imaging data: Temperature distribution heatmap of area 12 of copper busbar (temperature resolution 0.05℃).

[0044] Correlation analysis revealed that when thermal imaging showed that the temperature in the middle area of ​​the copper busbar 12 was 10°C higher than the surrounding area, the temperature of the negative electrode post of the three battery cells 11 at the corresponding location rose by 2-3°C. This indicated that the heat dissipation area of ​​the copper busbar 12 in this area was insufficient. Based on this, the structure of the copper busbar 12 was optimized (by adding heat dissipation fins in the middle). Secondary testing showed that the temperature difference in this area was reduced to less than 3°C.

[0045] Example 2

[0046] The battery pack 10 under test in this embodiment consists of 36 lead-carbon battery packs 10 (arranged in 6 rows, 6 in each row), connected by parallel copper busbars 12 made of copper material (thickness 1.8mm). During the test, two battery cell spacing schemes of 10mm and 15mm were used respectively.

[0047] There are 36 contact temperature sensors (20 in total), each corresponding to a negative terminal of the battery cell (11). The connection wires are connected to the data processor, and the sampling frequency is 1Hz.

[0048] The thermal imaging detector 30 is fixed above the battery pack 10 under test using a support frame. Specifically, the support frame stands on the ground on both sides of the battery pack 10 with a spacing of 1.5m and a support height of 1.3m. The thermal imaging detector 30 (model FLIR AX8) is fixed in the middle of the crossbeam 42. The lens is 1m vertically away from the surface of the battery pack 10, and the field of view completely covers the parallel copper busbar 12 and the top area of ​​the battery pack 10. Data is transmitted to the data processor via a network cable at a frame rate of 15fps.

[0049] During testing, temperature data from different layout schemes were compared: In the 8mm spacing scheme, thermal imaging shows that the temperature of the copper busbar 12 area corresponding to the middle row of batteries is 8℃ higher than that of the edge, and the contact probe shows that the temperature of the middle row of battery terminals is 5℃ higher on average. In the 10mm spacing scheme, thermal imaging shows that the temperature difference is reduced to 4℃, corresponding to a decrease in the battery terminal temperature difference to 2℃.

[0050] Based on this, 10mm was determined to be the optimal spacing for battery arrangement, verifying the influence of battery arrangement on heat dissipation.

[0051] In summary, this embodiment can acquire temperature field data of the copper busbar 12 through the thermal imaging detector 30, and acquire the real-time temperature of each battery cell 11 through multiple temperature sensors 20. The two temperatures are not only related in the time dimension, but also have a correlation of "temperature area - corresponding battery temperature", which avoids the shortcomings of single-point temperature measurement and greatly improves the reference value of temperature data. Based on this correlation, it can be determined whether the local overheating is caused by unreasonable heat dissipation of the copper busbar 12 or by heat dissipation blind spots caused by dense battery arrangement, providing a clear direction for design optimization, thereby improving optimization efficiency and solving the existing shortcomings.

[0052] The above descriptions are merely embodiments of this utility model, and common knowledge regarding specific structures and characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various improvements without departing from this utility model, and these improvements should also be considered within the scope of protection of this utility model. These improvements will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of the claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A battery pack structure optimization device based on temperature detection and thermal imaging technology, characterized in that: It includes at least a temperature sensor and a thermal imaging detector. The number of temperature sensors corresponds to the number of battery cells in the battery pack under test, and they are installed on the negative terminal of the battery cells to measure the temperature of the corresponding battery cells. The thermal imaging detector is mounted above the battery pack under test via a support frame, and its detection range covers at least the distribution area of ​​the copper busbars on the battery pack under test to acquire temperature distribution images of the copper busbar distribution area.

2. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 1, characterized in that: The support frame includes uprights and crossbeams. Two sets of uprights are symmetrically arranged, and the distance between the two sets of uprights is greater than the width or length of the battery pack to be tested. The crossbeams are fixed to the top of the two sets of uprights to form a portal frame, and a mounting base for the thermal imaging detector is provided on the crossbeams.

3. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 2, characterized in that: The uprights and / or the crossbeams are telescopic sleeve structures.

4. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 3, characterized in that: When the crossbeam is a telescopic sleeve structure, the crossbeam includes a middle outer sleeve and an end inner sleeve. The fixing seat is disposed on the middle outer sleeve, and the end inner sleeve is sleeved on both ends of the middle outer sleeve to ensure that the position of the middle outer sleeve remains constant when the length of the crossbeam is adjusted.

5. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 2, characterized in that: The mounting base is a flange or a snap fastener.

6. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 1, characterized in that: It also includes a data processor, which includes a data analysis unit and a display. The data analysis unit is electrically connected to the temperature sensor, the thermal imaging detector and the display. The data analysis unit can convert the temperature data collected by the temperature sensor and the thermal imaging detector into a different format and then display it on the display.

7. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 1, characterized in that: The temperature sensor is provided with an OT terminal, the inner diameter of which is adapted to the outer diameter of the negative terminal. With the help of a stud, the temperature sensor can be fixed on the negative terminal.

8. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 1, characterized in that: The temperature sensor is an NTC thermistor or a PT100 platinum resistance thermometer.

9. The battery pack structure optimization device based on temperature detection and thermal imaging technology according to claim 1, characterized in that: The thermal imaging detector is either FLIR A655sc or FLIR AX8.

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