601525 polymer battery.How to avoid dangerous accidents caused by circuit explosion caused by battery management system hardware

　　First of all, when purchasing an electric vehicle, you should choose a brand with a good product reputation, and pay attention to quality always first. The quality of electric vehicle batteries from good manufacturers is relatively reliable. You must know that many electric vehicle accidents are caused by battery problems. Secondly, during use, pay attention to charging the battery according to the name brand instructions. Electric vehicles are also prone to fire during the charging process. Problems such as excessive power supply voltage, current, or mismatched charger may cause dangerous accidents such as battery explosion. At the same time, you should always pay attention to the maintenance of circuit lines during use to prevent aging of wires from causing accidents such as short circuits and spontaneous combustion. Common sense on battery usage: 1. Pay attention to product quality when purchasing, and choose qualified products produced by regular manufacturers; 2. Read the nameplate before use, strictly follow the instructions on the nameplate, choose a supporting or matching charger, and operate at the rated voltage, Safe charging under current; 3. Try to avoid overcharging or undercharging. Using it after the battery is charged can extend the service life of the battery and reduce the occurrence of unsafe accidents. Electric vehicles are vehicles that are powered in whole or in part by electric motors. At present, there are three main types of pure electric vehicles, hybrid electric vehicles and fuel cell vehicles. The commonly used power sources for electric vehicles currently come from lead-acid batteries, lithium batteries, nickel-metal hydride batteries, etc. Lithium batteries have high cell voltage, high specific energy and high energy density, and are currently the batteries with the highest specific energy. However, precisely because of the relatively high energy density of lithium batteries, safety accidents will occur when misuse or abuse occurs. The battery management system can solve this problem. When the battery is under charging overvoltage or discharging undervoltage, the management system can automatically cut off the charging and discharging circuit, and its power balancing function can ensure that the voltage difference of a single battery is maintained within a small range. In addition, it also has functions such as over-temperature, over-current, and remaining power estimation. What this article designs is a battery management system based on a single-chip microcomputer. 1Battery management system hardware consists of system-specific hardware circuits, which can be divided into MCU modules, detection modules, and balancing modules. 1.1MCU module MCU is the core of system control. The MCU used in this article is the GZ16 model of the M68HC08 series. All MCUs in this series use the enhanced M68HC08 central processing unit (CP08). The microcontroller has the following characteristics: (1) 8MHz internal bus frequency; (2) 16KB built-in FLASH memory; (3) 2 16-bit timer interface modules; (4) Clock generator supporting 1MHz ~ 8MHz crystal oscillator; (5 ) Enhanced Serial Communications Interface (ESCI) module. 1.2 Detection module In the detection module, the voltage detection, current detection and temperature detection modules will be introduced respectively. 1.2.1 Voltage detection module In this system, the microcontroller will detect the overall voltage and single cell voltage of the battery pack. There are two methods for detecting the overall voltage of the battery pack: (1) using a dedicated voltage detection module, such as a Hall voltage sensor; (2) using precision resistors to build a resistor voltage dividing circuit. Using a dedicated voltage detection module is more expensive, requires a specific power supply, and the process is complicated. Therefore, a voltage dividing circuit is used for detection. The voltage variation range of a 10-cell lithium manganate battery pack is 28V ~ 42V. Use 3.9M? and 300k? resistors to divide the voltage. The variation range of the collected voltage signal is 2V ~ 3V, and the corresponding AD conversion results are 409 and *. For the detection of single cells, flying capacitor technology is mainly used.

　　1.2.2 Current sampling circuit When sampling current, the parameters in the battery management system are an important basis for battery overcurrent protection. The current sampling circuit in this system is shown in Figure 2. When the battery is discharged, a constantan wire is used to detect the current signal, and the detected voltage signal is amplified by a differential mode amplifier and converted into a voltage signal of 0~5V and sent to the microcontroller. If the discharge current is too large and the voltage signal detected by the microcontroller is relatively large, it will drive the transistor to change the gate voltage of the MOS tube and turn off the discharge circuit. For example, for a 36V lithium manganate battery, the protection current is set to 60A. The resistance of constantan wire is about 5mΩ. When the current reaches 60A, the voltage of the constantan wire reaches about 300mV. In order to improve the accuracy, the voltage is amplified 10 times through the amplifier and sent to the microcontroller for detection. 1.2.3 Temperature detection During the charging and discharging process of the battery pack, part of the energy is released in the form of heat. If this part of the heat is not removed in time, it will cause the battery pack to overheat. If the temperature of a single nickel-metal hydride battery exceeds 55°C, the battery characteristics will deteriorate, and the charge and discharge balance of the battery pack will be disrupted, resulting in permanent damage or explosion of the battery pack. In order to prevent the above situation from happening, the battery pack temperature needs to be monitored in real time and heat dissipated. A thermistor is used as a temperature sensor for temperature sampling. Thermistor is a heat-sensitive semiconductor resistor whose resistance value decreases as the temperature increases. The resistance temperature characteristics can be approximately expressed by the following formula: 1.3 Balancing module Commonly used balancing methods in battery packs include shunt method, flying capacitor balancing charging method, inductor energy transfer method, etc. In this system, more I/O ports are needed to drive the switch tubes, and the I/O ports of the microcontroller are limited, so the charging balancing method of converting full charge to single charge is adopted. The schematic is shown in Figure 3. Q4 is the switch that controls the overall charging of the battery pack, and Q2, Q3, and Q5 are the switches that control the charging of a single battery. Taking a 10-cell lithium manganate battery pack as an example, the voltage at both ends of the main coil of the transformer is 42V, and the voltage of the secondary coil is the battery's rated voltage of 4.2V. At the beginning, Q4 is turned on, Q2, Q3, and Q5 are turned off. The voltage of a single battery continues to rise. When it is detected that the voltage of a certain battery reaches the rated voltage 4.2V, the voltage detection chip sends a driving signal, turns off Q4, and turns on Q2. , Q3, Q5, the entire system enters the single charging stage, and the battery that is not fully charged continues to be charged, so that the battery that reaches the rated voltage keeps the rated voltage unchanged. After testing, the voltage difference will not exceed 50mV. 2SOC power detection In lithium-ion battery management systems, commonly used SOC calculation methods include open circuit voltage method, Coulomb calculation method, impedance measurement method, and comprehensive table lookup method. (1) The open circuit voltage method is the simplest measurement method, which mainly determines the size of the SOC based on the size of the battery's open circuit voltage. It can be seen from the operating characteristics of the battery that there is a certain corresponding relationship between the open circuit voltage of the battery and the remaining capacity of the battery. (2) The Coulomb calculation method measures the charging and discharging current of the battery, integrates the product of the current value and the time value, and then calculates the amount of electricity charged and discharged by the battery, and uses this to estimate the SOC value. (3) The impedance measurement method uses a certain linear relationship between the internal resistance of the battery and the state of charge SOC, and calculates the internal resistance of the battery by measuring the voltage and current parameters of the battery, thereby obtaining an estimate of the SOC. (4) In the comprehensive look-up table method, the remaining capacity SOC of the battery is closely related to the voltage, current, temperature and other parameters of the battery. By setting up a related table and inputting parameters such as voltage, current, temperature, etc., the remaining capacity value of the battery can be queried. In this design, the software programming method is adopted from the aspects of circuit integration, cost, and performance of the selected MCU. Combining several methods, it is more appropriate to use the Coulomb calculation method. (1) Use C to represent the total power released when the lithium battery pack drops from 42V to 32V. (2) Use eta to represent the ratio of the amount of electricity released to C after the current i has passed time t. Among them, CRM is the remaining power. Let ΔCi = i × Δt, which represents the discharge amount of the battery pack discharged by i during the stationary time t; or the charging amount of the battery pack charged by i. The remaining capacity is actually the calculation and accumulation of ΔCi. Set an appropriate sampling time Δt, measure the current current value, and then calculate the product to obtain the change in the remaining capacity CRM within Δt time, so as to continuously update the value of CRM to achieve SOC power detection. 3 Test results: Charge and discharge tests were performed on the lithium manganate battery pack through the battery management system. The discharge current is 8A. When the battery pack voltage drops to 32V, the discharge MOS tube is turned off. Four hours after charging ends, equalization is completed.

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