A battery inspection device

Abstract

The utility model provides a kind of battery inspection device, including handle component, monitoring component, pneumatic component and data transmission unit.Handle component is operating reference and installation carrier;Monitoring component is detachably connected with handle component, including bearing, flexible detection body and pressure sensing unit, flexible detection body is adaptively assembled in bearing, and pressure sensing unit is distributed on its outer surface;Pneumatic component is installed in handle component, including airflow flow driving part and airflow transmission structure, and airflow transmission structure is communicated airflow driving part and flexible detection body to drive its telescopic deformation;Data transmission unit is electrically connected with pressure sensing unit to export detection signal.The device simplifies operation through integrated architecture, shortens inspection time, improves efficiency;Flexible detection body and pressure sensing point array cooperate edge encryption design, realize battery lateral wall full-area coverage detection, improve bulge identification accuracy, avoid edge missed detection.

Description

Technical Field

[0001] This utility model relates to the field of battery condition detection technology, specifically an inspection device that can adapt to different depth gaps and quickly and accurately identify bulges on the side walls of batteries. Background Technology

[0002] As a core energy storage component in new energy vehicles, energy storage power stations, and communication base stations, the operating status of batteries directly affects the reliability and safety of the equipment. During long-term charging and discharging, the internal chemical reaction of batteries is prone to imbalance, resulting in sidewall bulging. If not detected in time, this may lead to leakage, short circuit, or even fire and explosion. Therefore, regular condition inspections of battery packs are a crucial step in ensuring the safe operation of the system.

[0003] To improve space utilization, battery packs are generally installed in a stacked configuration, with a 5-20mm gap between adjacent batteries. The core function of this gap is ventilation and heat dissipation, preventing heat buildup during battery operation that could lead to performance degradation or thermal runaway. However, this design also presents inspection challenges: the narrow gaps and poor lighting make it impossible for operators to directly observe the inner walls of adjacent batteries from the outside. Traditional methods such as visual inspection and infrared thermography can only obtain information from the outer side of the battery, making it difficult to detect hidden faults such as bulges and deformations on the inner walls, creating blind spots in the inspection process.

[0004] Existing testing solutions lack effective solutions. Rigid testing tools cannot fit into narrow gaps, while flexible tools, though capable of accessing them, lack structural support and are prone to uneven contact between the sensing unit and the battery wall due to their own wrinkles, resulting in a high rate of missed detection, especially for bulges at the edge of the gap. Most devices require disassembling the battery pack or manually probing point by point, with each test taking several minutes, making it difficult to meet the rapid inspection needs of large-scale battery packs. Electromagnetic interference is strong within the gaps, and detection signals transmitted via traditional data cables are prone to distortion. Furthermore, existing devices are mostly of fixed length and cannot adapt to stacking gaps of different depths, requiring frequent tool replacements and increasing maintenance costs.

[0005] Therefore, developing a device that can penetrate deep into the stacking gaps, fully cover the inner walls, and quickly output accurate test results is of urgent practical significance for filling the industry's technological gaps and improving the operation and maintenance level of battery packs. Utility Model Content

[0006] This utility model provides a battery inspection device that solves the problems of low detection efficiency, incomplete coverage and poor adaptability of existing battery bulge detection, and achieves convenient operation, accurate detection and flexible adaptation to rapid inspection of battery bulges with different depths and gaps.

[0007] The solution to the technical problem of this utility model is as follows: a battery inspection device is adopted, comprising: a handle assembly, serving as an operating reference and mounting carrier; a monitoring assembly, detachably connected to the handle assembly, the monitoring assembly including a carrier, a flexible detection body, and a pressure sensing unit, the flexible detection body being adapted and assembled with the carrier, and the pressure sensing unit being distributed on the outer surface of the flexible detection body; a pneumatic assembly, mounted on the handle assembly, the pneumatic assembly including an airflow drive component and an airflow transmission structure, the airflow transmission structure being connected to the airflow drive component and the flexible detection body respectively, for driving the flexible detection body to extend and deform; and a data transmission unit, electrically connected to the pressure sensing unit, for exporting the detection signal from the pressure sensing unit; the flexible detection body is driven to conform to the side wall of the battery by the pneumatic assembly, and the pressure signal is collected by the pressure sensing unit and exported through the data transmission unit.

[0008] Preferably, the carrier of the monitoring component includes a base and a frame, the base and the frame are fixedly connected, the base has a hollow area, and the flexible detection body is an airbag structure, which is fitted into the hollow area.

[0009] Preferably, the pressure sensing unit is assembled on both sides of the flexible detection body, and the pressure sensing unit is a sensor dot matrix structure, which is distributed along the outer surface of the flexible detection body.

[0010] Preferably, the sensor dot matrix structure has a higher distribution density in the edge region than in the central region of the flexible detection body.

[0011] Preferably, the flexible detector is fitted with a rigid frame around its perimeter, the rigid frame being used to maintain the flexible detector in a flat state.

[0012] Preferably, the data transmission unit includes a flexible data cable, a signal adapter, and an output interface. The flexible data cable is covered with a shielding layer. One end of the flexible data cable is connected to the pressure sensing unit, and the other end is connected to the output interface via the signal adapter.

[0013] Preferably, the pneumatic assembly further includes a guide structure, which includes a guide seat and a guide rod. The guide rod is fixedly connected to the moving part of the airflow drive component, and the guide rod is slidably assembled in the guide channel of the guide seat.

[0014] Preferably, the airflow transmission structure includes a connecting seat and an air nozzle assembly. The connecting seat is a sealed transition component, and the air nozzle assembly includes a first air nozzle and a second air nozzle that are adapted to each other. The first air nozzle is connected to the airbag structure, and the second air nozzle is sealed to the connecting seat.

[0015] Preferably, the handle assembly includes a base, a connecting seat, and a stop seat. The connecting seat and the stop seat are fixed in different directions on the base. The connecting seat is used to connect the monitoring component, and the stop seat is used to support the top surface of the battery gap.

[0016] Preferably, it also includes an extension component, which includes an extension rod and a fixing structure. The extension rod is detachably mounted between the handle assembly and the monitoring assembly to extend the detection depth of the monitoring assembly.

[0017] The beneficial effects of this invention are as follows: The integrated collaborative architecture simplifies the operation process, allowing operators to complete the inspection simply by holding and pressing the sensor, significantly shortening the time for each inspection and solving the problems of cumbersome and inefficient traditional inspection procedures, thus achieving the goal of rapid inspection. The combination design of the flexible detection body and the pressure sensor array, along with the edge-densified distribution method, achieves full-area coverage inspection of the battery sidewall, significantly improving the accuracy of bulge identification and effectively avoiding the omission of bulges in edge areas, thus achieving the purpose of accurate detection.

[0018] The pneumatic drive provides rapid response, enabling quick contact and separation of the detection body while requiring minimal effort and reducing manual labor. Simultaneously, the guiding structure ensures motion stability, further guaranteeing the reliability of the test results. Detachable expansion components allow the device to flexibly adapt to different depth testing scenarios without requiring additional specialized equipment, significantly improving its versatility and practicality, and reducing the investment cost of testing equipment. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of the inspection device of this utility model; Figure 2 yes Figure 1 A schematic diagram of the assembly relationship; Figure 3 yes Figure 1 The front view; Figure 4 yes Figure 3 Internal structure diagram; Figure 5 yes Figure 4 Schematic diagram of the cross-sectional structure of the middle BB section; Figure 6 yes Figure 4 Enlarged structural diagram of section A in the middle.

[0020] Numbering in the diagram: 1-Handle assembly; 2-Monitoring assembly; 3-Pneumatic assembly; 4-Data transmission unit; 5-Extension assembly; 11-Handle; 12-Tube column; 13-Base; 14-Connector; 15-Stop seat; 21-Integrated base; 22-Frame body; 23-Disc airbag; 24-Moving frame; 25-Membrane carrier; 26-Pressure sensor array; 27-Connection hole; 31-Bag valve; 32-Seat valve; 33-Connecting inner seat; 34-Inner air tube; 35-Cylinder; 36-Telescopic rod; 37-Rod handle seat; 38-Guide seat; 39-Guide rod; 41-Flexible data cable; 42-Internal connector; 43-Output interface; 51-Extension screw; 52-Extension rod fixing hole. Detailed Implementation

[0021] The specific embodiments of this utility model are described in detail below with reference to the accompanying drawings. These embodiments are only used to illustrate the technical implementation path of this utility model and are not intended to limit the protection scope of this utility model. Conventional adjustments made by those skilled in the art under the technical concept of this utility model are all within the protection scope of this utility model.

[0022] It should be noted that the accompanying drawings in this embodiment are merely simplified structural schematic diagrams of the rapid inspection device for battery bulging, used only to clearly illustrate the key structures related to the core principles and creative contributions of the technical solution, and do not constitute a limitation on the complete details of the device. The technical solution described in this embodiment focuses on the main structures, assembly relationships, fitting methods, and implementation processes that play a crucial role in achieving the purpose of the utility model. While auxiliary designs such as dust prevention, lubrication, and sealing required for the normal operation of the device, as well as details such as specific component models, precise dimensional parameters, and conventional connection processes, are not described in detail, this does not mean that this technical solution has not considered such details, nor does it mean that such details are not within the scope of implementation of this technical solution. All details not mentioned above are contents that can be reasonably determined and implemented by those skilled in the art based on common knowledge, and should naturally be included within the protection and implementation scope of this technical solution.

[0023] Example 1: The core of this utility model's rapid inspection device for battery bulging is that the handle assembly provides operational support, the pneumatic assembly provides driving force, the monitoring assembly detects bulging, the data transmission unit completes signal export, and the expansion assembly adapts to different detection scenarios. All components work together to achieve the purpose of rapid and accurate inspection. Its specific structure, assembly relationship and implementation process are as follows.

[0024] like Figures 1-5 As shown, the device mainly consists of a handle assembly 1, a monitoring assembly 2, a pneumatic assembly 3, a data transmission unit 4, and an expansion assembly 5. The components are mechanically fixed and sealed to form an organic whole, ensuring operational stability and detection reliability.

[0025] The handle assembly 1 serves as the operating reference and mounting carrier for the entire device, and the assembly of its components directly affects the operating feel and structural stability. The handle 11 is located at the top of the device for the operator to grip and apply force. The tubing column 12 is vertically oriented, with its upper part fixedly connected to the guide seat 38 of the pneumatic assembly 3, its middle section being a hollow structure to accommodate the internal air tube 34, and its lower part fixed to the base 13 via threaded connection or welding to ensure the strength of the connection. The base 13 is a block structure, with a connecting seat 14 bolted to its longitudinal direction. This connecting seat 14 supports the monitoring assembly 2, while a stop seat 15 is integrally formed or bolted to its transverse direction. The end face of the stop seat 15 is machined to a flat surface to stably support the top surface of the gap between adjacent batteries during testing, providing a testing reference for the device.

[0026] The monitoring component 2 is the core execution unit for bulge detection, and its assembly must balance flexible detection with structural rigidity. The integrated base 21 and frame 22 are bolted together. A large hollow area is provided at the center of the integrated base 21, the size of which matches the shape of the disc-shaped airbag 23. The disc-shaped airbag 23 is fitted into this hollow area and secured by vulcanization or clamps to ensure no relative displacement between the airbag and the integrated base 21. Membrane carriers 25 are attached and fixed to both sides of the disc-shaped airbag 23. In this embodiment, the membrane carrier 25 is preferably made of polyimide film or silicone rubber film. These materials combine good flexibility, toughness, and environmental resistance, allowing them to deform synchronously with the expansion of the disc-shaped airbag 23 and providing a stable mounting base for the pressure sensor array 26, preventing the sensor from falling off or being damaged during deformation.

[0027] A movable frame 24 is fixed to the periphery of the membrane carrier 25 by bolts or adhesive. The movable frame 24 is made of a lightweight, rigid material and its function is to improve the overall rigidity of the membrane carrier 25, prevent wrinkles from forming when the membrane carrier 25 is not supported by air pressure, and ensure that it always remains flat, providing uniform detection contact conditions for the pressure sensor array 26. The pressure sensor array 26 is fixed to the outer surface of the membrane carrier 25 in a uniform array distribution. Specifically, the sensor array consists of several miniature pressure sensor units with consistent spacing between each sensor unit, fully covering the entire outer surface of the membrane carrier 25. In the edge area of ​​the membrane carrier 25, the distribution density of the sensor units is appropriately increased to eliminate detection blind spots and ensure that bulges on the edge of the battery sidewall can also be accurately detected.

[0028] The pneumatic assembly 3 provides the expansion driving force for the monitoring assembly 2. Its core assembly principle is to ensure the airtightness of the airflow channel and the guiding function of the moving parts. The guide seat 38 is bolted to the top of the column 12. A mounting hole is provided in the center of the guide seat 38, into which the cylinder 35 is embedded and fixed. The end of the telescopic rod 36 at the upper end of the cylinder 35 is welded and fixed to the handle seat 37. The handle seat 37 is then bolted to the handle 11, allowing the operator to directly drive the telescopic rod 36 to perform axial telescopic movement when pressing the handle 11. An inner air pipe 34 is installed in the inner cavity of the column 12. The upper section of the inner air pipe 34 is sealed and connected to the lower air chamber of the cylinder 35 via a threaded joint, while the lower section is connected to the connecting inner seat 33.

[0029] The connecting inner seat 33 is fitted at the connection point between the bottom of the tube column 12 and the base 13. It has a stepped structure and serves as a sealing transition component. The upper section is sealed to the bottom of the inner air tube 34 via a sealing ring, while the lower section has a tapered interface to allow for the sealed insertion of the seat nozzle 32. The seat nozzle 32 is a rigid tubular component fixed within the cavity of the base 13. One end of it is fitted with the tapered interface of the connecting inner seat 33, while the other end has a pre-drilled interface for the insertion of the bag nozzle 31. The other end of the bag nozzle 31 communicates with the disc-shaped airbag 23. Through this assembly, a complete airflow channel is formed. Furthermore, a guide channel is provided within the guide seat 38, and a guide rod 39 is correspondingly fixed to the rod handle seat 37. The guide rod 39 is fitted within this guide channel, ensuring that the telescopic rod 36 moves axially during extension and retraction, preventing deflection.

[0030] The data transmission unit 4 is responsible for exporting the detection signals from the pressure sensor array 26. Its assembly must consider both signal transmission stability and anti-interference capabilities. One end of the flexible data cable 41 is fixed to the middle of the upper frame of the moving frame 24 by welding or a connector. This position avoids the deformation area of ​​the membrane carrier 25 to prevent the data cable from being pulled when the airbag expands. The flexible data cable 41 is preferably a bend-resistant shielded data cable with an external shielding layer, which can effectively resist external electromagnetic interference and adapt to the wiring path inside the device. The other end of the flexible data cable 41 is connected to the inner cable holder 42, which is fixed to the lower root of the connecting seat 21, providing a fixed support point for the data cable and avoiding messy wiring. The inner cable holder 42 extends the data cable from inside the device, avoiding the moving parts and airflow channels of the pneumatic component 3 during the wiring process to prevent the data cable from being squeezed or pulled. Finally, the data cable is connected to the output interface 43, which is fixed to the side wall of the column 12 and adopts a standard industrial interface form for easy and quick docking with external testing equipment.

[0031] The extension component 5 is used to adapt to the detection of deeper areas when batteries are stacked. Its assembly method is simple and it is detachable. The top of the integrated base 21 has multiple connection holes 27, which are evenly distributed around the circumference of the integrated base 21. The connecting base 14 has corresponding extension rod fixing holes 52. The extension screw 51 can pass through the connection holes 27 and the extension rod fixing holes 52. By installing locking nuts on the upper and lower sides of the extension rod fixing holes 52, the extension screw 51 is firmly fixed, thereby extending the effective detection length of the entire device and enabling the monitoring component 2 to penetrate deeper into the gaps between batteries.

[0032] Before using the above-mentioned device, first complete the assembly of the handle assembly 1: fix the tube column 12 to the base 13, and then fix the connecting seat 14 and the stop seat 15 to the longitudinal and transverse directions of the base 13 respectively; then assemble the pneumatic assembly 3: fix the guide seat 38 above the tube column 12, install the cylinder 35 and connect the telescopic rod 36 to the rod handle seat 37, fix the rod handle seat 37 to the handle 11, and at the same time install the inner air tube 34 in the inner cavity of the tube column 12, fit the connecting inner seat 33 into the connection position between the tube column 12 and the base 13, and fix the seat nozzle 32 in the inner cavity of the base 13; then assemble the monitoring... Component 2: Fix the integrated base 21 to the frame 22, install the disc-shaped airbag 23 and fix the membrane carrier 25, fix the moving frame 24 around the membrane carrier 25, fix the pressure sensor array 26 to the outer surface of the membrane carrier 25, fix the integrated base 21 to the connecting base 14 with fixing bolts, and then seal the airbag nozzle 31 into the seat nozzle 32; then assemble the data transmission unit 4: connect the flexible data cable 41 to the moving frame 24 and the inner cable base 42, complete the internal wiring and connect the output interface 43; if it is necessary to extend the detection depth, the extension screw 51 can be installed and fixed by locking the nut.

[0033] In use, the operator holds the handle 11, aligns the monitoring component 2 with the gap between adjacent batteries and inserts it, so that the stop seat 15 presses against the outer end face of the adjacent battery, at which point the device obtains a stable detection benchmark. Pressing the handle 11 forward, the handle 11 drives the telescopic rod 36 to compress inward through the rod handle seat 37, thereby squeezing the lower air chamber of the cylinder 35, causing the airflow to flow along the preset airflow channel: passing sequentially through the inner air tube 34, the connecting inner seat 33, the seat air nozzle 32, and the bladder air nozzle 31, and finally entering the disc airbag 23, pushing the disc airbag 23 to expand to the left and right sides.

[0034] During the inflation of the disc-shaped airbag 23, the membrane carriers 25 on both sides extend outward synchronously. Due to the support of the moving frame 24, the membrane carriers 25 remain flat, and the pressure sensor array 26 on its outer surface comes into contact with and presses against the side wall of the adjacent battery. At this time, the pressure sensor array 26 begins to collect the pressure signal of the battery side wall. Each sensor unit converts the detected pressure data into an electrical signal, which is transmitted to the inner connector 42 through the flexible data line 41, then transmitted to the output interface 43 through internal wiring, and finally exported to the external testing equipment.

[0035] If a bulge exists on the side wall of the battery, the bulge will exert greater pressure on the pressure sensor unit in the corresponding area, causing a difference in the detection values ​​of the pressure sensor array 26 on both sides. External testing equipment can determine whether the battery has a bulge and whether the bulge exceeds the limit by analyzing this data difference. After the test is completed, the handle 11 is released. Under the action of the return spring in the cylinder 35, the cylinder 35 begins to draw air. The airflow flows in the opposite direction from the disc-shaped air bag 23 and returns to the cylinder 35 along the original airflow channel. The disc-shaped air bag 23 contracts, and the operator can remove the device from the gap in the battery to complete one inspection.

[0036] In the signal transmission process of the pressure sensor array 26, the shielding layer of the flexible data cable effectively isolates external electromagnetic interference, preventing pressure signal distortion during transmission. Internal wiring avoids the movement paths and airflow channels of pneumatic components, preventing damage to the data cable from moving parts and avoiding indirect impacts of airflow on signal transmission. The output interface uses a standard industrial interface, ensuring compatibility with different models of external testing equipment. Signal export is achieved quickly without additional adapters, improving testing efficiency. Simultaneously, the sensor units of the pressure sensor array 26 employ parallel transmission, ensuring all test data is uploaded synchronously, avoiding detection errors caused by data delays.

[0037] Based on the above scheme, the cooperation between the moving frame 24 and the membrane carrier 25 ensures the flatness of the membrane carrier 25 without affecting its flexible deformation with the disc-shaped airbag 23, providing a stable and flexible detection carrier for the pressure sensor array 26. The airflow drive method of the pneumatic component 3 achieves forward and reverse airflow through mechanical pressing, with a simple structure and rapid response, enabling rapid contact or separation between the membrane carrier 25 and the battery sidewall. The uniform array distribution and edge densification design of the pressure sensor array 26 ensure comprehensive detection coverage and avoid missing bulge areas. The shielding design and reasonable wiring of the data transmission unit 4 ensure stable transmission of detection signals. The detachable design of the expansion component 5 allows the device to adapt to detection scenarios of different depths, improving the device's versatility. The cooperation of these technologies forms a complete rapid inspection solution for battery bulges, achieving the technical effects of convenient operation, accurate detection, and strong adaptability.

Claims

1. A battery inspection device, characterized in that, include: The handle assembly serves as both the operating reference and the mounting platform; A monitoring component is detachably connected to the handle assembly. The monitoring component includes a carrier, a flexible detection body, and a pressure sensing unit. The flexible detection body is adapted to the carrier and the pressure sensing unit is distributed on the outer surface of the flexible detection body. A pneumatic assembly is mounted on the handle assembly. The pneumatic assembly includes an airflow drive component and an airflow transmission structure. The airflow transmission structure is connected to the airflow drive component and the flexible detection body respectively, and is used to drive the flexible detection body to extend and deform. The data transmission unit is electrically connected to the pressure sensing unit and is used to export the detection signal from the pressure sensing unit. A flexible detection body is driven by a pneumatic component to fit against the side wall of the battery, and a pressure sensing unit collects pressure signals and exports them through a data transmission unit.

2. The battery inspection device according to claim 1, characterized in that, The carrier of the monitoring component includes a base and a frame, the base and the frame are fixedly connected, the base has a hollow area, and the flexible detection body is an airbag structure, which is fitted into the hollow area.

3. The battery inspection device according to claim 1, characterized in that, The pressure sensing unit is mounted on both sides of the flexible detection body. The pressure sensing unit is a sensor dot matrix structure, which is distributed along the outer surface of the flexible detection body.

4. The battery inspection device according to claim 3, characterized in that, The sensor dot matrix structure has a higher density at the edge region than in the central region of the flexible detector.

5. The battery inspection device according to claim 1, characterized in that, The flexible detector is surrounded by a rigid frame, which is used to keep the flexible detector flat.

6. The battery inspection device according to claim 1, characterized in that, The data transmission unit includes a flexible data cable, a signal adapter, and an output interface. The flexible data cable is covered with a shielding layer. One end of the flexible data cable is connected to the pressure sensing unit, and the other end is connected to the output interface via the signal adapter.

7. The battery inspection device according to claim 1, characterized in that, The pneumatic assembly further includes a guide structure, which includes a guide seat and a guide rod. The guide rod is fixedly connected to the moving part of the airflow drive component, and the guide rod is slidably assembled in the guide channel of the guide seat.

8. The battery inspection device according to claim 1, characterized in that, The airflow transmission structure includes a connector and an air nozzle assembly. The connector is a sealed transition component. The air nozzle assembly includes a first air nozzle and a second air nozzle that are adapted to each other. The first air nozzle is connected to the airbag structure, and the second air nozzle is sealed to the connector.

9. The battery inspection device according to claim 1, characterized in that, The handle assembly includes a base, a connecting seat, and a stop seat. The connecting seat and the stop seat are fixed in different directions on the base. The connecting seat is used to connect the monitoring component, and the stop seat is used to support the top surface of the battery gap.

10. The battery inspection device according to claim 1, characterized in that, It also includes an extension component, which includes an extension rod and a fixing structure. The extension rod is detachably mounted between the handle assembly and the monitoring assembly to extend the detection depth of the monitoring assembly.

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