A charging control device for a battery pack

Abstract

The application relates to a charging control device of a battery pack, which comprises a controller, a topology switching module and a plurality of voltage sensors, the topology switching module is electrically connected between a power supply and the battery pack, the plurality of voltage sensors are used for detecting the voltages of a plurality of batteries and sending detection signals to the controller, and the controller is used for monitoring the voltages of the batteries during the charging process and controlling the topology switching module to change the connection relationship to bypass at least one battery when the voltage of the at least one battery reaches a preset voltage, while the charging of the remaining batteries in the battery pack is continued. In the application, the controller, the voltage sensor and the topology switching module work together, the risk of overcharging of a single battery in the battery pack can be effectively reduced, the charging safety and the battery life can be effectively improved, meanwhile, the power of the power supply is continuously concentrated on the batteries that are not fully charged by bypassing the fully charged batteries one by one, so that the overall charging efficiency is remarkably improved.

Description

Technical Field

[0001] This application belongs to the field of battery charging technology, and in particular relates to a charging control device for a battery pack. Background Technology

[0002] Battery packs, as a common energy storage unit, are widely used in electric vehicles, uninterruptible power supply systems, energy storage power stations, and rail transportation, among other fields. In these applications, multiple individual battery cells are typically connected in series to meet voltage requirements.

[0003] Currently, one of the mainstream methods for charging series-connected battery packs is to use a constant voltage power supply for overall series charging. However, this traditional charging method has obvious limitations: due to differences in parameters such as capacity and internal resistance between individual batteries, some batteries may be fully charged before others during series charging. If charging continues, these fully charged batteries will face the risk of overcharging, which will damage battery health, shorten lifespan, and even cause safety problems.

[0004] Furthermore, in actual operation and maintenance, when individual cells in the battery pack experience performance degradation or low voltage and require additional power, the traditional series charging method cannot provide targeted charging for individual cells. Instead, the entire battery pack must be charged for an extended period of time, resulting in inflexible operation, low efficiency, and a serious impact on operation and maintenance efficiency. Utility Model Content

[0005] The purpose of this application is to provide a charging control device for a battery pack. The charging control device for a battery pack provided by this application can effectively reduce the risk of overcharging of a single battery in the battery pack, and can effectively improve charging safety and battery life. At the same time, by bypassing the fully charged batteries one by one, the power supply is continuously concentrated on the incompletely charged batteries, thereby significantly improving the overall charging efficiency. The technical solution provided in this application is as follows: A battery pack charging control device is provided for connecting to a power source and charging a battery pack comprising multiple batteries. The charging control device includes: a controller, a topology switching module, and multiple voltage sensors. The topology switching module is electrically connected between the power source and the battery pack; Multiple voltage sensors are used to detect the voltage of multiple batteries and send the detection signals to the controller; The controller is used to monitor the voltage of each battery during the charging process, and when the voltage of at least one battery reaches a preset voltage, control the topology switching module to change the connection relationship to bypass the at least one battery, while continuing to charge the remaining batteries in the battery pack.

[0006] Optionally, the topology switching module includes a first relay and a plurality of second relays; Each of the second relays is configured to correspond one-to-one with one of the batteries; The positive and / or negative terminals of the power supply are connected to a switching network composed of the plurality of second relays through the main normally open contact of the first relay. Each of the batteries is selectively connected to or bypassed in a series charging circuit via a corresponding second relay contact group; The controller is specifically configured to, during the charging process, have multiple second relays in a first state, so that all batteries are connected in series to form the series charging circuit, and when the voltage of at least one battery reaches a preset voltage, control the corresponding at least one second relay to switch to a second state to bypass the at least one battery.

[0007] Optionally, it may also include: a driver module; The drive module, controlled by the controller, is used to provide a drive signal to the coil of the second relay; Specifically, during the charging process, when the voltage of at least one battery reaches a preset voltage, the controller controls the drive module to energize the coil of at least one corresponding second relay, so that the corresponding second relay is energized to bypass the at least one battery.

[0008] Optionally, it also includes: a manual start switch; The manual start switch is connected in series in the coil power supply circuit of the first relay and is used to start charging; The first relay's coil power supply circuit also includes a self-holding branch connected in parallel, and the self-holding branch contains the first relay's auxiliary normally open contact connected in series.

[0009] Optionally, it also includes: a ready indicator light; The power supply circuit of the ready indicator light is connected in series with the auxiliary normally closed contact of the first relay.

[0010] Optionally, The coil power supply circuit of the first relay is provided with a contact network consisting of the auxiliary normally closed contacts of each of the second relays; The contact network is configured to cut off the coil power supply circuit of the first relay when all second relays are engaged.

[0011] Optionally, it also includes: multiple manual display switches; Each of the aforementioned manual display switches is configured to independently control whether or not the voltage value of the corresponding voltage sensor is displayed.

[0012] Optionally, it also includes: multiple manual cut-off switches; Each of the manual cut-off switches is connected in series in the coil power supply circuit of the corresponding second relay, forming a control path independent of the controller; Each of the manual cut-off switches is configured such that when the manual cut-off switch is closed, it can directly connect the coil power supply circuit of the corresponding second relay, so that the corresponding second relay is energized to bypass the corresponding battery.

[0013] Optionally, it also includes: a manual stop switch; The manual stop switch is connected in series in the coil power supply circuit of the first relay. When the user disconnects the manual stop switch, the coil of the first relay is de-energized, thereby resetting the first relay and stopping charging.

[0014] Optionally, it also includes: a circuit breaker; The circuit breaker is connected in series in the power supply circuit of the first relay to provide overcurrent protection for the power supply circuit.

[0015] Compared with existing technologies, this application provides a battery pack charging control device for connecting to a power source and charging a battery pack comprising multiple batteries. The charging control device includes a controller, a topology switching module, and multiple voltage sensors. The topology switching module is electrically connected between the power source and the battery pack. The multiple voltage sensors are used to detect the voltage of multiple batteries and send the detection signals to the controller. The controller monitors the voltage of each battery during the charging process and, when the voltage of at least one battery reaches a preset voltage, controls the topology switching module to change the connection relationship to bypass at least one battery while continuing to charge the remaining batteries in the battery pack. In this application, through the synergistic effect of the controller, voltage sensors, and topology switching module, the risk of overcharging of a single battery in the battery pack can be effectively reduced, and charging safety and battery life can be effectively improved. At the same time, by bypassing the fully charged batteries one by one, the power supply is continuously concentrated on the partially charged batteries, thereby significantly improving the overall charging efficiency. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application 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 application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a circuit diagram of a battery pack charging control device disclosed in an embodiment of this application; Figure 2This is a main circuit diagram of another battery pack charging control device disclosed in an embodiment of this application; Figure 3 This is a control circuit diagram of another battery pack charging control device disclosed in an embodiment of this application; Reference numerals: 100 - Battery; 200 - Topology switching module; 300 - Voltage sensor; KM1 - First relay; KM2 - Second relay; KM3 - Third relay; SB1 - Manual start switch; SB2 - Manual display switch; SB3 - Manual cut-off switch; SB4 - Manual stop switch; HR - Ready indicator; HG1 - Start indicator; HG2 - Full charge indicator; QF - Circuit Breaker. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly set on the other component; when a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to the other component.

[0020] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a plurality of" or "several" means two or more, unless otherwise explicitly specified.

[0022] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size should still fall within the scope of the technical content disclosed in this application, provided that they do not affect the effects and purposes that this application can produce.

[0023] like Figure 1 As shown in the figure, this application embodiment provides a battery pack charging control device for connecting to a power source and charging a battery pack including multiple batteries 100 (i.e., 100-1 to 100-N). The charging control device includes: a controller, a topology switching module 200, and multiple voltage sensors 300 (i.e., 300-1 to 300-N). The topology switching module 200 is electrically connected between the power source and the battery pack. The multiple voltage sensors 300 are used to detect the voltage of the multiple batteries 100 and send the detection signal to the controller. The controller is used to monitor the voltage of each battery 100 during the charging process, and when the voltage of at least one battery 100 reaches a preset voltage, control the topology switching module 200 to change the connection relationship to bypass at least one battery 100, while continuing to charge the remaining batteries 100 in the battery pack. In this embodiment, the controller is not shown in the figures.

[0024] In this embodiment, N is a positive integer greater than 1. The topology switching module 200 can be composed of multiple relays or other types of controlled electronic switches (such as metal oxide semiconductor field-effect transistors MOSFETs, insulated gate bipolar transistors IGBTs). The preset voltage is configured to be 95% to 100% of the rated full charge voltage of the battery 100. The power supply is preferably a constant voltage power supply. At least one means one or more. The battery pack includes two or more batteries 100. For example, in the application scenario of maglev trains, the battery pack may specifically include 6 or 8 battery 100 cells connected in series.

[0025] During the overall series charging of a battery pack consisting of multiple batteries 100 connected in series, the controller continuously monitors the voltage fed back by each voltage sensor 300. When the voltage of any target battery 100 reaches the preset voltage, it is determined that the target battery 100 is basically fully charged. Then, the topology switching module 200 is controlled to change the connection relationship, bypassing the target battery 100 from the main charging circuit. This allows the charging current to bypass the fully charged target battery 100, while continuing to charge the remaining uncharged batteries 100 in the battery pack. This method effectively prevents the target battery 100 from being overcharged, thereby improving the charging safety and cycle life of the entire battery pack.

[0026] In actual operation and maintenance, if the performance of a single battery 100 in the battery pack deteriorates or the voltage is too low, this device also has the ability to respond flexibly. The controller can activate a specific maintenance mode and, through the dynamic reconfiguration of the topology switching module 200, prioritize or specifically supplement the charging of the low-voltage battery 100, without having to perform a time-consuming and lengthy full charging process for the entire battery pack as in the traditional way. This greatly enhances the targeting and flexibility of operation and maintenance, significantly improves maintenance efficiency, and reduces operating costs.

[0027] Compared with the prior art, this application provides a battery pack charging control device for connecting to a power source and charging a battery pack including multiple batteries 100. The charging control device includes a controller, a topology switching module 200, and multiple voltage sensors 300. The topology switching module 200 is electrically connected between the power source and the battery pack. The multiple voltage sensors 300 are used to detect the voltage of the multiple batteries 100 and send the detection signals to the controller. The controller is used to monitor the voltage of each battery 100 during the charging process, and when the voltage of at least one battery 100 reaches a preset voltage, it controls the topology switching module 200 to change the connection relationship to bypass at least one battery 100, while continuing to charge the remaining batteries 100 in the battery pack. In this application, through the synergistic effect of the controller, voltage sensors 300, and topology switching module 200, the risk of overcharging of a single battery 100 in the battery pack can be effectively reduced, and the charging safety and battery life of the battery 100 can be effectively improved. At the same time, by bypassing the fully charged batteries 100 one by one, the power supply is continuously concentrated on the partially charged batteries 100, thereby significantly improving the overall charging efficiency.

[0028] like Figure 2 As shown, in one embodiment of this application, the topology switching module 200 includes a first relay KM1 and multiple second relays KM2; the multiple second relays KM2 are configured one-to-one with multiple batteries 100; the positive and / or negative terminals of the power supply are connected to a switching network composed of multiple second relays KM2 through the main normally open contact of the first relay KM1; each battery 100 is selectively connected to or bypassed in a series charging circuit through the contact group of the corresponding second relay KM2; the controller is specifically used to, during the charging process, have multiple second relays KM2 in a first state, so that all batteries 100 are connected in series to form a series charging circuit, and when the voltage of at least one battery 100 reaches a preset voltage, control the corresponding at least one second relay KM2 to switch to a second state to bypass at least one battery 100.

[0029] In this embodiment, the first relay KM1 may be equipped with two linked normally open main contacts, which are connected in series with the positive and negative terminals of the power supply, respectively. Each battery 100 may have its first end connected to the series charging circuit through the normally closed main contact of the corresponding second relay KM2, and its second end connected to the series charging circuit through the normally open main contact of the corresponding second relay KM2. The controller is specifically used to close the normally closed main contact of the second relay KM2 during the charging process, so that the constant voltage power supply performs series constant voltage charging on the entire battery pack. When the voltage signal detected by the voltage sensor 300 corresponding to the target battery 100 is equal to the preset voltage, the controller controls the coil of the corresponding second relay KM2 to be energized, so that the normally closed main contact of the corresponding second relay KM2 is opened and the normally open main contact is closed, so as to bypass the target battery 100.

[0030] The above design based on normally closed / normally open relay contacts has multiple beneficial effects: First, it has high safety and reliability: In the initial state and in the power failure state, the main normally closed contact of the second relay KM2 is in the closed state, ensuring that all batteries 100 can be connected in series to the circuit normally, avoiding connection uncertainty problems that may occur due to loss of control signals or during the power-on initialization of the device, and improving the inherent safety level of the device.

[0031] Secondly, seamless switching and uninterrupted charging are achieved: by controlling the energization and de-energization of the coil of the second relay KM2, the battery 100 can be quickly and smoothly switched from the connected state to the bypass state. This process will not cause the main charging circuit to be open, thereby maintaining continuous and uninterrupted charging of the other batteries 100 in the battery pack and improving charging efficiency.

[0032] like Figure 2 and Figure 3 As shown, in one embodiment, this application further includes: a driving module; the driving module, controlled by a controller, is used to provide a driving signal to the coil of the second relay KM2; the controller is specifically used to control the driving module during the charging process, when the voltage of at least one battery 100 reaches a preset voltage, to energize the coil of the corresponding at least one second relay KM2, so that the corresponding second relay KM2 is energized to bypass at least one battery 100. In this embodiment, the driving module is not shown in the accompanying drawings.

[0033] In this embodiment, the drive module may be located inside the controller. The drive module may include multiple third relays KM3 (i.e., KM3-1 to KM3-N). The multiple third relays KM3 are configured one-to-one with multiple batteries 100. The normally open contact of each third relay KM3 is connected in series in the coil power supply circuit of the corresponding second relay KM2. Specifically, during the charging process, the multiple second relays KM2 are in a reset state, i.e., the coil is de-energized, so that all batteries 100 are connected in series to form a series charging circuit. When the voltage of the target battery 100 is equal to the preset voltage, the controller controls the third relay KM3 corresponding to the target battery 100 to be energized, i.e., the coil of the third relay KM3 corresponding to the target battery 100 is energized, so that the normally open contact of the third relay KM3 is closed, so that the coil of the corresponding second relay KM2 connected in series with the normally open contact of the second relay KM2 is energized, so that the coil of the corresponding second relay KM2 is energized, so that the main normally closed contact of the corresponding second relay KM2 is opened and the main normally open contact is closed, so as to bypass the target battery 100.

[0034] This embodiment, by introducing a drive module composed of a third relay KM3, brings the following significant benefits: First, it achieves the isolation and amplification of control signals: The output port driving capability of the controller (usually a low-power microprocessor unit) is limited. By setting the third relay KM3, the controller only needs to provide a small power signal to control the coil of the third relay KM3, while the contacts of the third relay KM3 carry and switch the large load current required to drive the coil of the second relay KM2. This effectively isolates the control unit from the power circuit, protects the controller from electrical shocks, and improves the reliability and lifespan of the device.

[0035] Secondly, the modularity and scalability of the device are enhanced: the one-to-one correspondence setting method makes the bypass control path of each battery 100 independent of each other. This structure facilitates the modular design and maintenance of the device. When the battery pack scale is expanded, only the same second and third relay KM3 units need to be added accordingly, which has good scalability.

[0036] like Figure 3 As shown, in one embodiment, this application further includes: a manual start switch SB1; the manual start switch SB1 is connected in series in the coil power supply circuit of the first relay KM1 for starting charging; a self-holding branch is also connected in parallel in the coil power supply circuit of the first relay KM1, and an auxiliary normally open contact of the first relay KM1 is connected in series in the self-holding branch.

[0037] In this embodiment, the manual start switch SB1 is preferably a normally open push button switch. When the user presses the push button switch, the coil power supply circuit of the first relay KM1 is connected, causing the coil of the first relay KM1 to be energized and attracted, thereby closing the main normally open contact of the first relay KM1 and starting charging. At the same time, the auxiliary normally open contact of the first relay KM1 connected in parallel with the manual start switch SB1 also closes, forming an independent self-holding power supply branch. Therefore, when the user releases the manual button, the coil of the first relay KM1 is continuously energized through this self-holding power supply branch, maintaining the operation of the device.

[0038] This design has the following beneficial effects: First, it achieves safe and reliable one-button start: by using a combination of normally open push-button switch and self-holding circuit, the operator only needs to make a momentary pressing action to start the device and make it run stably. This effectively avoids start-up failure caused by operator error (such as releasing too early) or the need to maintain the switch closed for a long time, greatly improving the reliability of operation and the user-friendliness of human-machine interaction.

[0039] Secondly, it ensures the continuity and stability of the charging process: The self-holding circuit establishes an independent hardware logic latching mechanism. Once activated, the device's operating state no longer depends on the continuous closing of the manual switch. This design fundamentally prevents the charging process from being interrupted due to accidental shaking of the manual switch, accidental disconnection, or the operator leaving, thus ensuring the integrity of the charging process and the consistency of the battery pack's charging effect.

[0040] In this embodiment of the application, it also includes: a start indicator light HG1; the start indicator light HG1 and the manual start switch SB1, when the manual start switch SB1 is closed, the start indicator light HG1 is lit, the lit state of the start indicator light HG1 serves as a visual signal to clearly indicate to the user that the device has entered the start-up ready state.

[0041] like Figure 3 As shown, in one embodiment of this application, the system further includes: a ready indicator light HR; the power supply circuit of the ready indicator light HR is connected in series with an auxiliary normally closed contact of the first relay KM1.

[0042] In this embodiment, the power supply circuit of the ready indicator light HR is connected in series with the auxiliary normally closed contact of the first relay KM1. When the user presses the manual start switch SB1, the coil of the first relay KM1 is energized and closes, the auxiliary normally closed contact of the first relay KM1 opens, cuts off the power supply to the ready indicator light HR, and turns it off. This off state serves as a clear visual signal to indicate to the user that the main charging circuit of the device has been connected and the charging preparation work has been completed.

[0043] This embodiment achieves the following beneficial effects by setting the ready indicator light HR, which is controlled by the auxiliary normally closed contact of the first relay KM1: First, it provides clear and intuitive device status indication: the on / off status of the Ready indicator light HR provides operators with a direct visual signal as to whether the device has been successfully started and entered the ready state, avoiding users from performing repeated operations or mistakenly believing that the start-up has failed due to the inability to judge the device status, thus improving the efficiency and reliability of human-computer interaction. Secondly, it enhances the safety of equipment operation: clear status indicators help prevent misoperation. For example, when the light is off (indicating that the device has started), the user knows that the main charging circuit is about to be connected or has already been connected, thus becoming more cautious; conversely, when maintenance is required, the light being on (indicating that the device has stopped) is a safety signal, which adds a visual guarantee for the safe operation of the equipment.

[0044] like Figure 3 As shown, in one embodiment of this application, the coil power supply circuit of the first relay KM1 is provided with a contact network consisting of the auxiliary normally closed contacts of each of the second relays KM2; wherein, the contact network is configured to cut off the coil power supply circuit of the first relay KM1 when all the second relays KM2 are energized.

[0045] In this embodiment, the coil power supply circuit of the first relay KM1 is connected in series with a parallel branch consisting of the auxiliary normally closed contacts of each second relay KM2 connected in parallel. During the charging process of the battery pack, as the target battery 100 is successively fully charged and bypassed, its corresponding second relay KM2 is energized and its auxiliary normally closed contact is opened. When the last battery 100 is also fully charged and bypassed, all second relays KM2 are in the energized state, and all auxiliary normally closed contacts in the parallel branch are opened, thereby reliably cutting off the coil power supply circuit of the first relay KM1, causing the coil of the first relay KM1 to lose power, causing the normally open contact of the first relay KM1 to open, and the total constant voltage power supply is cut off.

[0046] This embodiment achieves global shutdown logic by setting up a parallel contact network composed of the normally closed auxiliary contacts of each second relay KM2, bringing the following multiple beneficial effects: First, it achieves a fully automatic charging process and intelligent shutdown: This design enables the entire charging process to be fully automated. After manual startup, the device can automatically complete the sequential charging and bypassing of all batteries 100 in the battery pack without human intervention, and automatically cut off the main power supply after all batteries 100 are charged. This achieves intelligent charging management and energy saving, and avoids continuous energy waste after charging is completed.

[0047] Secondly, it provides core hardware safety protection: This is a hardware-based safety interlock mechanism that does not rely on the controller's software judgment. Even if the controller experiences a program crash or other faults, the hardware circuit can reliably cut off the main power supply when the final state is met, providing the last layer of extremely reliable safety protection for the entire device and preventing the equipment from being in an unnecessary power-on state for a long time.

[0048] Finally, to prevent heat buildup and potential short-circuit risks: when all batteries 100 are bypassed, if the constant voltage power supply continues to output, the relays and circuits may still be subjected to voltage and generate certain heat loss. Automatically cutting off the total constant voltage power supply can completely avoid long-term heat buildup and potential insulation risks of the relays and power supply under such extreme conditions, extend equipment life, and improve safety.

[0049] like Figure 2 As shown, in one embodiment, this application also includes: a plurality of manual display switches SB2 (i.e., SB2-1 to SB2-N); each manual display switch SB2 is configured to independently control whether the voltage value of the corresponding voltage sensor 300 is displayed.

[0050] In this embodiment, the manual display switch SB2 can be a normally open button. Each manual display switch SB2 is connected in series in the power supply circuit of the local display unit (e.g., a digital tube or LCD screen integrated on the sensor housing) of the corresponding voltage sensor 300. When the operator needs to check the voltage of a battery, he only needs to press the corresponding manual display switch SB2 to turn on the power to the local display unit of the voltage sensor 300 and make it display the current voltage value.

[0051] The beneficial effects brought about by setting multiple manual display switches SB2 in this embodiment are as follows: First, it achieves a balance between low power consumption and on-demand display: by manually controlling the power supply of the display units, the power consumption of all display units can be completely shut off during most standby periods when monitoring is not required, significantly reducing the overall standby power consumption of the device. This is particularly suitable for long-term operation applications with strict energy consumption requirements. The display function is only activated when the user needs to query data, achieving optimal energy efficiency control with instant display upon pressing and instant shutdown upon releasing.

[0052] Secondly, it extends the lifespan of the display unit: by reducing the unnecessary power-on time of the display unit, it can effectively prevent light decay and aging, especially for components such as LED digital tubes, which can significantly extend their effective lifespan and reduce the frequency and cost of maintenance and replacement.

[0053] like Figure 3As shown, in one embodiment, this application further includes: multiple manual cut-off switches SB3 (i.e., SB3-1 to SB3-N); each manual cut-off switch SB3 is connected in series in the coil power supply circuit of the corresponding second relay KM2 to form a control path independent of the controller; each manual cut-off switch SB3 is configured such that when the manual cut-off switch SB3 is closed, it can directly connect the coil power supply circuit of the corresponding second relay KM2, so that the corresponding second relay KM2 is energized to bypass the corresponding battery 100.

[0054] In this embodiment, a manual cut-off switch SB3 (e.g., a push-button switch or toggle switch with self-locking function) is connected in series in the coil drive circuit of each second relay KM2. This circuit path is completely parallel to and independent of the automatic control path formed by the controller and its drive module (such as the third relay KM3).

[0055] The beneficial effects of setting multiple manual cut-off switches SB3 in this embodiment are as follows: First, it provides a hardware-level emergency bypass independent of the controller: This design creates a pure hardware emergency channel that does not rely on controller software, power supply, or logic judgment. When the controller fails, the program crashes, or communication is interrupted, but the device still needs to urgently stop charging a certain battery 100, the maintenance personnel can manually operate the corresponding physical switch to directly and forcibly disconnect the problematic battery 100 from the charging circuit. This provides the device with the most reliable emergency means and greatly enhances the device's fault response capability.

[0056] Secondly, it supports flexible offline maintenance and battery 100 replacement: When performing battery pack maintenance, if it is necessary to disconnect one or more batteries 100 from the device for measurement, replacement or individual processing, there is no need to change the control logic or program of the entire device. The maintenance personnel can safely isolate the target battery 100 from the series circuit by manually disconnecting the SB3 bypass switch. This achieves true hot-swappable maintenance, greatly improves the flexibility and safety of maintenance operations, and reduces the overall downtime.

[0057] In this embodiment, the system further includes: multiple fully charged indicator lights HG2; the auxiliary normally open contact of the second relay KM2, the normally open contact of the third relay KM3, and the manual cut-off switch SB3 are connected in parallel and then connected in series with the corresponding fully charged indicator lights HG2, so that when the battery 100% charge reaches a preset threshold, the corresponding relay contact or the manual cut-off switch SB3 is closed to illuminate the fully charged indicator lights HG2 connected in series, so as to provide graded charge indication.

[0058] like Figure 3As shown, in one embodiment, this application also includes: a manual stop switch SB4; the manual stop switch SB4 is connected in series in the coil power supply circuit of the first relay KM1. When the user disconnects the manual stop switch SB4, the coil of the first relay KM1 is directly de-energized, so that the first relay KM1 is reset and charging is stopped.

[0059] In this embodiment, the manual stop switch SB4 can be a normally closed contact button or an emergency stop switch. The manual stop switch SB4 is connected in series in the coil power supply circuit of the first relay KM1 and is located upstream of the self-holding branch. This means that regardless of whether the system is in the state before startup or in the state of startup and self-holding, the manual stop switch SB4 can directly control the on / off state of the coil circuit of the first relay KM1.

[0060] The beneficial effects of setting the manual stop switch SB4 in this embodiment are as follows: First, it provides the highest priority emergency interruption function: the manual stop switch SB4 constitutes an independent, direct, and highest priority hardware shutdown path. During the charging process, regardless of whether the controller is working properly or what charging stage each battery 100 is in, once the operator discovers an abnormality, they can disconnect this switch to instantly cut off the power supply to the coil of the first relay KM1, causing its main contacts to open, thereby immediately stopping the entire charging process. This provides the fastest and most reliable response mechanism for dealing with emergencies.

[0061] Secondly, it enables a safe and convenient global system reset: This switch is used not only for emergency stops but also for normal system shutdowns. When charging needs to be stopped or maintenance is required, shutting down the system via this switch ensures that the first relay KM1 and the entire system reliably return to the initial power-off state. That is, all main circuits and indicator circuits controlled by the first relay KM1 are reset. This provides a clear, power-free reference state for subsequent safe operation and maintenance, avoiding the risk of false shutdown caused by software logic or self-holding circuits.

[0062] like Figure 3 As shown, in one embodiment, this application further includes: a circuit breaker QF; the circuit breaker QF is connected in series in the power supply circuit of the first relay KM1 for overcurrent protection of the power supply circuit.

[0063] In this embodiment, the circuit breaker QF can be an air switch or a miniature circuit breaker. The circuit breaker QF is connected in series to the front end of the power supply circuit of the coil of the first relay KM1. Specifically, the input terminal of the circuit breaker QF is connected to an external power supply through a power terminal. The circuit breaker QF acts as the main switch and protection device of the control circuit and continuously monitors the circuit current.

[0064] This embodiment provides reliable overcurrent and short-circuit protection by setting a circuit breaker QF, preventing the fault from escalating. When a short circuit or insulation damage occurs in the coil power supply circuit of the first relay KM1 or its downstream circuits (such as self-holding branches, stop / start switches, etc.), the current will rise sharply. The circuit breaker QF can quickly detect this abnormal overcurrent and automatically trip, instantly cutting off the power supply to the entire control circuit. This effectively prevents the risk of overheating and melting of the control harness due to local circuit faults, or even causing a fire, limiting the fault to a minimum.

[0065] It should be understood that the use of terms such as "system," "device," "unit," and / or "module" in this application is merely one method of distinguishing different components, elements, parts, sections, or assemblies at different levels. However, if other terms can achieve the same purpose, they may be replaced by other expressions.

[0066] The embodiments in this specification are described in a progressive manner, with each embodiment focusing on the aspects related to... For any differences between the embodiments, or for the same or similar parts between the embodiments, please refer to each other.

[0067] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A charging control device for a battery pack, characterized in that, The charging control device, used for connecting to a power source and charging a battery pack comprising multiple batteries, includes: a controller, a topology switching module, and multiple voltage sensors; The topology switching module is electrically connected between the power source and the battery pack; Multiple voltage sensors are used to detect the voltage of multiple batteries and send the detection signals to the controller; The controller is used to monitor the voltage of each battery during the charging process, and when the voltage of at least one battery reaches a preset voltage, control the topology switching module to change the connection relationship to bypass the at least one battery, while continuing to charge the remaining batteries in the battery pack.

2. The charging control device according to claim 1, characterized in that, The topology switching module includes a first relay and multiple second relays; Each of the second relays is configured to correspond one-to-one with one of the batteries; The positive and / or negative terminals of the power supply are connected to a switching network composed of the plurality of second relays through the main normally open contact of the first relay. Each of the batteries is selectively connected to or bypassed in a series charging circuit via a corresponding second relay contact group; The controller is specifically configured to, during the charging process, have multiple second relays in a first state, so that all batteries are connected in series to form the series charging circuit, and when the voltage of at least one battery reaches a preset voltage, control the corresponding at least one second relay to switch to a second state to bypass the at least one battery.

3. The charging control device according to claim 2, characterized in that, Also includes: Driver module; The drive module, controlled by the controller, is used to provide a drive signal to the coil of the second relay; Specifically, the controller is used to control the drive module to energize the coil of at least one second relay when the voltage of at least one battery reaches a preset voltage during the charging process, so as to activate the corresponding second relay and bypass the at least one battery.

4. The charging control device according to claim 2, characterized in that, Also includes: Manual start switch; The manual start switch is connected in series in the coil power supply circuit of the first relay and is used to start charging; The first relay's coil power supply circuit also includes a self-holding branch connected in parallel, and the self-holding branch contains the first relay's auxiliary normally open contact connected in series.

5. The charging control device according to claim 2, characterized in that, Also includes: Ready indicator light; The power supply circuit of the ready indicator light is connected in series with the auxiliary normally closed contact of the first relay.

6. The charging control device according to claim 2, characterized in that, The coil power supply circuit of the first relay is provided with a contact network consisting of the auxiliary normally closed contacts of each of the second relays; The contact network is configured to cut off the coil power supply circuit of the first relay when all second relays are engaged.

7. The charging control device according to claim 1, characterized in that, Also includes: Multiple manual display switches; Each of the aforementioned manual display switches is configured to independently control whether or not the voltage value of the corresponding voltage sensor is displayed.

8. The charging control device according to claim 2, characterized in that, Also includes: Multiple manual cut-off switches; Each of the manual cut-off switches is connected in series in the coil power supply circuit of the corresponding second relay, forming a control path independent of the controller; Each of the manual cut-off switches is configured such that when the manual cut-off switch is closed, it can directly connect the coil power supply circuit of the corresponding second relay, so that the corresponding second relay is energized to bypass the corresponding battery.

9. The charging control device according to claim 2, characterized in that, Also includes: Manually stop the switch; The manual stop switch is connected in series in the coil power supply circuit of the first relay. When the user disconnects the manual stop switch, the coil of the first relay is de-energized, thereby resetting the first relay and stopping charging.

10. The charging control device according to claim 2, characterized in that, Also includes: breaker; The circuit breaker is connected in series in the power supply circuit of the first relay to provide overcurrent protection for the power supply circuit.

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