CN112549966A

CN112549966A - Sensor and monitoring method using the same

Info

Publication number: CN112549966A
Application number: CN202010078784.5A
Authority: CN
Inventors: 孙江涛; 方武; 刘潞钊; 郭林林
Original assignee: Sensata Technologies Inc
Current assignee: Zhonghui Ruide Sensing Technology Suzhou Co ltd
Priority date: 2020-02-03
Filing date: 2020-02-03
Publication date: 2021-03-26

Abstract

The present disclosure relates to a sensor for monitoring a state of a battery pack, characterized in that the sensor comprises: a sensing element that detects a state of the battery pack to obtain detection data and thereby obtain a profile of the detection data with respect to time; a sampling module defining a sampling period, the sampling module sampling the detection data at the sampling period based on the curve; and a decision module configured to output a warning signal when the sampled detection data is greater than a preset threshold and/or when a rate of change of the sampled detection data is greater than a preset rate of change threshold, the warning signal indicating that a thermal runaway condition may occur within the battery pack. The disclosure also relates to a battery module, a battery management module and an electric vehicle comprising the sensor, and a monitoring method for monitoring the state of the battery pack by using the sensor.

Description

Sensor and monitoring method using the same

Technical Field

The present disclosure generally relates to a sensor and a monitoring method for monitoring using the same. The present disclosure also relates to a battery module and a battery management assembly having the sensor. The present disclosure also relates to an electric vehicle having the sensor.

Background

Sensors find wide application in parameter monitoring. On the one hand, in some situations it is desirable that the sensor consumes as little power as possible to avoid the power supply of the sensor running out. For example, in a car, the sensors may typically be powered, for example, by a battery, which may be depleted if the sensors are consuming power all the time the car is stopped, thereby rendering the car unable to start. On the other hand, powering off the sensor may reduce its power consumption, but may result in the sensor not being able to properly monitor the change in the external parameter.

In automobiles where the battery pack used to provide power may be subject to thermal runaway during normal operation or during non-operation due to certain factors, it is also desirable that the sensors be able to monitor the condition of the battery pack to provide early warning of the thermal runaway phenomenon and/or to avoid the consequences of the thermal runaway.

Disclosure of Invention

In view of the above-mentioned problems in the prior art, it is an object of the present disclosure to provide a sensor that can correctly monitor parameter changes with low power consumption.

It is another object of the present disclosure to provide a sensor that can monitor the status of a battery pack in order to forewarn of a thermal runaway phenomenon and/or avoid the consequences of a thermal runaway.

It is still another object of the present disclosure to provide a battery module, a battery management assembly, and an electric vehicle including the sensor described above, and a monitoring method of the sensor.

According to a first aspect of the present invention, there is provided a sensor for monitoring the condition of a battery pack, the sensor comprising:

a sensing element that detects a state of the battery pack to obtain detection data and thereby obtain a profile of the detection data with respect to time;

a sampling module defining a sampling period, the sampling module sampling the detection data at the sampling period based on the curve; and

a decision module configured to output a warning signal when the sampled detection data is greater than a preset threshold and/or when a rate of change of the sampled detection data is greater than a preset rate of change threshold, the warning signal indicating that a thermal runaway condition may occur within the battery pack.

In an embodiment of the sensor, the sampling period is determined in dependence of an operating mode of the sensor.

In one embodiment of the sensor, the sampling module is configured to change the sampling period when the determination module outputs a warning signal.

In one embodiment of the sensor, the sampled detection data is compared with any one of the detection data in the sampling period with the preset threshold.

In one embodiment of the sensor, the sampled detection data is compared with the preset threshold value by taking an average value of a plurality of detection data within a sampling period.

In one embodiment of the sensor, the sampled detection data is obtained by comparing a change rate of a plurality of detection data in a plurality of sampling periods with the preset change rate threshold, wherein any one detection data is obtained in each sampling period.

In one embodiment of the sensor, the sampled detection data is obtained by comparing a change rate of a plurality of detection data in a plurality of sampling periods with the preset change rate threshold, wherein an average value of the plurality of detection data in each sampling period is obtained.

In one embodiment of the sensor, the sensor is powered by a separate power source, either wired or wireless.

In one embodiment of the sensor, the sensor is a pressure sensor and the sensed data is data indicative of pressure within the battery pack.

In one embodiment of the sensor, the preset threshold is determined by the sum of a standard atmospheric pressure value and a decision amplitude, wherein the decision amplitude is in the range from 0.5KPa to 50 KPa.

In one embodiment of the sensor, the preset threshold is determined by the sum of the current atmospheric pressure value and a decision amplitude, wherein the decision amplitude is in the range from 0.5KPa to 50 KPa.

In one embodiment of the sensor, the preset rate of change threshold is in a range from 0.1KPa/s to 10 KPa/s.

In one embodiment of the sensor, the preset rate of change threshold is in a range from 0.2KPa/s to 5 KPa/s.

In one embodiment of the sensor, the preset rate of change threshold is in a range from 0.5KPa/s to 1 KPa/s.

In one embodiment of the sensor, the preset rate of change threshold is 0.6 KPa/s.

In one embodiment of the sensor, the current barometric pressure value is measured by the sensing element or calculated according to the current environment in which the battery pack is located.

In one embodiment of the sensor, the sensor further comprises a controller, the sensing element is connected to the controller, the controller is configured such that the controller places the sensor in a normal operating mode when the sensor receives the enable signal, places the sensor in a power saving mode when the sensor does not receive the enable signal,

wherein, in the normal operation mode, the sensing element, the collection module and the determination module operate normally, the sensor continuously outputs a detection signal corresponding to detection data of the sensor to the outside, and

wherein, in the energy saving mode, the sensor is alternately in a wake-up period and a sleep period, in the wake-up period of the energy saving mode, the sensing element, the acquisition module and the determination module work normally, and when the determination module outputs a warning signal, the sensor outputs a wake-up signal to the outside, in the sleep period of the energy saving mode, the sensor is in sleep, and the sensing element, the acquisition module and the determination module do not work.

In one embodiment of the sensor, the sensor further comprises a command receiving portion, a detection signal output portion, and a wake-up output portion, the command receiving portion, the detection signal output portion, and the wake-up output portion all being connected to the controller, the command receiving portion being configured to receive the enable signal, the detection signal output portion being configured to output the detection signal from the controller, the wake-up output portion being configured to output the wake-up signal from the controller.

In one embodiment of the sensor, the sensor further comprises a wireless transmitting and receiving module configured to wirelessly receive the enable signal, wirelessly output the detection signal from the controller, and wirelessly output the wake-up signal from the controller.

In one embodiment of the sensor, the sensor is configured to check whether the sensor receives the enable signal while outputting the wake-up signal to the outside, and to stop outputting the wake-up signal upon receiving the enable signal.

In an embodiment of the sensor, the sensor is configured such that the detection signal and/or the wake-up signal is measurable by the controller in order to cause the sensor to fault diagnose the detection signal and/or the wake-up signal and/or the detection signal output and/or the wake-up output.

In one embodiment of the sensor, the wireless transmitting and receiving module is configured to be able to send out a verification signal.

In one embodiment of the sensor, the sensing element and the controller are enclosed in a housing of the sensor.

In one embodiment of the sensor, the sensor is configured to automatically switch to a normal operation mode while outputting the wake-up signal to the outside.

In one embodiment of the sensor, said preset threshold is updated every predetermined time during said wake-up period of said power saving mode.

In one embodiment of the sensor, after the energy saving mode continues for a predetermined time, the controller places the sensor in a deep sleep mode in which the sensor is turned off, the sensing element, the acquisition module, and the determination module are not operated.

In one embodiment of the sensor, a sum of the duration of the wake-up period and the duration of the sleep period is less than 2 seconds.

In one embodiment of the sensor, the wake-up period has a duration of 1 to 50 milliseconds and the sleep period has a duration of 50 to 2000 milliseconds.

In one embodiment of the sensor, the sampling period is the sum of the duration of the wake-up period and the duration of the sleep period.

According to a second aspect of the present disclosure, there is provided a battery module including:

a battery pack; and

a sensor as described above for monitoring the condition of a battery pack.

According to a third aspect of the present disclosure, there is provided a battery management assembly comprising:

a battery management system; and

the sensor for monitoring the state of the battery, wherein the sensor receives an enable signal from the battery management system, and the warning signal is output to the battery management system so that the battery management system manages the battery pack.

In one embodiment of the battery management assembly, the battery management system has means for receiving a verification signal from the sensor.

According to a fourth aspect of the present disclosure, there is provided an electric vehicle including:

a battery pack;

a battery management system; and

the sensor for monitoring the state of the battery pack, wherein the sensor receives an enable signal from the battery management system, and the warning signal is output to the battery management system so that the battery management system manages the battery pack.

In one embodiment of the electric vehicle, the battery management system has means for receiving a verification signal from the sensor.

According to a fifth aspect of the present disclosure, there is provided a monitoring method of monitoring a state of a battery pack using the sensor as described above, the monitoring method comprising:

detecting a state of the battery pack using a sensing element to obtain detection data, and thereby obtaining a profile of the detection data with respect to time;

sampling the detection data with a sampling module at a sampling period based on the curve; and

when the sampled detection data is greater than a preset threshold value and/or when the change rate of the sampled detection data is greater than a preset change rate threshold value, the judgment module outputs a warning signal, and the warning signal indicates that a thermal runaway condition may occur in the battery pack.

In one embodiment of a monitoring method, the monitoring method comprises: the sensor is placed in a normal operating mode when the sensor receives the enable signal, and in a power saving mode when the sensor does not receive the enable signal.

In one embodiment of a monitoring method, the monitoring method comprises: and in the awakening period of the energy-saving mode, enabling the sensing element, the acquisition module and the judgment module to work normally.

In one embodiment of a monitoring method, the monitoring method comprises: and if the judging module outputs a warning signal, the sensor simultaneously outputs a wake-up signal and enables the sensor to be in a normal working mode.

In one embodiment of a monitoring method, the monitoring method comprises: and if the judging module does not output the warning signal, enabling the sensor to update the preset threshold value every preset time.

In one embodiment of a monitoring method, the monitoring method comprises: determining whether the sensor enters the energy-saving mode for more than a preset time, if so, enabling the sensor to enter a deep sleep mode, and if not, enabling the sensor to be in an awakening period and a sleep period alternately.

By adopting the sensor and the monitoring method thereof, the state in the battery pack can be monitored in an accurate and efficient manner, and the thermal runaway phenomenon can be effectively early warned in advance and/or the thermal runaway consequence can be avoided.

Due to the adoption of the structure, the sensor can be controllably switched between the normal working mode and the energy-saving mode so as to reduce power consumption, and meanwhile, the sensor can be independently awakened and automatically dormant in the energy-saving mode and externally awakened, so that parameters can be timely and accurately monitored. In addition, the sensor disclosed by the disclosure can also periodically update the threshold value in the threshold value judgment, confirm the external awakening and perform autonomous fault diagnosis on the detection signal and/or the awakening signal of the sensor, the detection signal output part and/or the awakening output part, so that the accuracy and the reliability of monitoring are improved.

Drawings

Various aspects of the disclosure will be better understood upon reading the following detailed description in conjunction with the drawings in which:

FIG. 1 is a schematic diagram of a sensor according to a first embodiment of the present disclosure;

FIG. 2 is a schematic diagram of a sensor according to a second embodiment of the present disclosure;

FIG. 3 is a schematic diagram of a sensor according to a third embodiment of the present disclosure;

FIG. 4 is a schematic view of a sensor according to a fourth embodiment of the present disclosure;

FIG. 5 is a schematic view of a sensor according to a fifth embodiment of the present disclosure;

FIG. 6 is a schematic view of a sensor according to a sixth embodiment of the present disclosure;

FIG. 7 is a schematic illustration of an electric vehicle having a sensor according to the present disclosure;

FIG. 8 is a flow chart of a detection method using a sensor for monitoring according to the present disclosure; and

FIG. 9 is a flow chart of another detection method for monitoring using a sensor according to the present disclosure.

Detailed Description

The present disclosure will now be described with reference to the accompanying drawings, which illustrate several embodiments of the disclosure. It should be understood, however, that the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, the embodiments described below are intended to provide a more complete disclosure of the present disclosure, and to fully convey the scope of the disclosure to those skilled in the art. It is also to be understood that the embodiments disclosed herein can be combined in various ways to provide further additional embodiments.

It is to be understood that the terminology used in the description is for the purpose of describing particular embodiments only, and is not intended to be limiting of the disclosure. All terms (including technical and scientific terms) used in the specification have the meaning commonly understood by one of ordinary skill in the art unless otherwise defined. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

As used in this specification, the singular forms "a", "an" and "the" include plural referents unless the content clearly dictates otherwise. The terms "comprising," "including," and "having," as used in this specification, specify the presence of stated features, but do not preclude the presence or addition of one or more other features. The term "and/or" as used in this specification includes any and all combinations of one or more of the associated listed items.

In the specification, an element is referred to as being "connected" to another element, and unless otherwise specified, it is directly connected to the other element, indirectly connected to the other element through intervening elements, or wirelessly connected by wireless communication. In contrast, when an element is referred to as being "directly connected" to another element, there are no intervening elements present.

Each feature of the examples and embodiments of the present disclosure may be used alone or in combination with other features or applied to any other examples and embodiments alone or in combination with other features without being contradicted by description.

The systems described herein may also utilize one or more controllers to receive information and transform the received information to generate output. The controller may comprise any type of computing device, computing circuitry, or any type of processor or processing circuitry capable of executing a series of instructions stored in a memory. The controller may include multiple processors and/or multicore Central Processing Units (CPUs) and may include any type of processor, such as a microprocessor, digital signal processor, microcontroller, Application Specific Integrated Circuit (ASIC), single chip, and the like. The controller may also include a memory to store data and/or algorithms to execute a series of instructions.

Any of the methods, programs, algorithms or code described in this specification can be converted or expressed in a programming language or computer program. "programming language" and "computer program" are any language used to designate instructions to a computer, and include (but are not limited to) these languages and their derivatives: assembly language, Basic, batch files, BCPL, C + +, Delphi, Fortran, Java, JavaScript, machine code, operating system command language, Pascal, Perl, PL1, scripting language, Visual Basic, its own meta-language specifying programs, and first, second, third, fourth, and fifth generation computer languages. Also included are databases and other data schemas, as well as any other meta-language. For purposes of this definition, no distinction is made between languages that are interpreted, compiled, or languages that use both compiled and interpreted methods. For the purposes of this definition, no distinction is made between compiled and source versions of a program. Thus, reference to a program in a programming language that may exist in more than one state (such as a source state, a compiled state, an object state, or a linked state) is a reference to any and all such states. The definition also contains valid instructions and the intent of those instructions.

A first embodiment of the sensor 1 of the present disclosure is explained below with reference to fig. 1. The sensor 1 may include a sensor housing 10, a sensing element 101, a controller 102, a command receiving section 103, a detection signal output section 104, a wake-up output section 105. Sensor 1 may also include signal processing chip 1091, voltage regulator 106, power pin 107, and ground pin 108.

The sensing element 101 is used to detect an external parameter and output a sensing signal, and may be various known sensing elements such as a pressure sensing element, a temperature sensing element, a voltage sensing element, a current sensing element, and/or a smoke sensing element. The signal processing chip 1091 may be configured to convert the sensing signal processing output by the sensing element 101 into a measurement signal of a current or voltage type or the like that can be processed by the controller 102. The sensing element 101 may be connected to the controller 102 through a signal processing chip 1091, and the signal processing chip 1091 sends the measurement signal to the controller 102 and receives an instruction from the controller 102.

The command receiving section 103 is configured to receive an enable signal from, for example, the outside of the sensor and transmit the enable signal to the controller 102. One end of the command receiving part 103 may be connected to an external control system that generates the enable signal, and the other end of the command receiving part 103 may be connected to the controller 102. The command receiving portion may be interface circuitry and/or wiring as is known in the art.

The detection signal output section 104 may be connected to the controller 102 for outputting a detection signal corresponding to the detection result of the sensor from the controller 102 under the control of the controller. The wake-up output 105 may be connected to the controller 102 for outputting a wake-up signal from the controller 102 to the outside (e.g., to the external control system) under the control of the controller. The detection signal output 104 and the wake-up output 105 may be interface circuits and/or wiring as known in the art.

The power supply pin 107 is used to receive power from a power supply source and supply power to the detection signal output section 104 and the wake-up output section 105. The power pin 107 may also supply power to the controller 102 and the signal processing chip 1091 through the voltage regulator 106.

The controller 102 is configured to execute the following control.

When the command receiving section 103 receives an enable signal (e.g., a high level signal) from, for example, an external control system, the command receiving section 103 transfers the enable signal to the controller 102. In this case, the controller 102 puts the sensor 1 in a normal operation mode. In the normal operation mode, the controller 102 samples and converts the measurement signal of the signal processing chip 1091 into a calculation process at an appropriate sampling period (for example, 10ms), and controls the detection signal output section 104 to continuously output the detection signal.

When the command receiving unit 103 does not receive the enable signal (for example, the command receiving unit is in a low level state), the controller 102 puts the sensor 1 in a power saving mode (low power consumption mode). In the power saving mode, the sensor 1 is alternately in a wake-up period and a sleep period. In the sleep period of the power saving mode, the sensor is in sleep. In the wake-up period of the power saving mode, the controller 102 controls the sensing element 101 to perform detection, and the controller 102 compares a detection value obtained from the sensing element 101 with a threshold value, if the detection value is judged to exceed the threshold value, the controller 102 sends an instruction to the wake-up output 105 to cause the wake-up output 105 to send out a wake-up signal, and if the detection value is judged not to exceed the threshold value, the sensor 1 is continuously placed in the power saving mode to be alternately placed in the wake-up period and the sleep period. The wake-up signal may be, for example, a square wave, a triangular wave, a sine wave, or any other suitable wave signal. Preferably, in the case where it is determined that the detection value exceeds the threshold value, the controller 102 causes the sensor 1 to exit the energy saving mode and return to the normal operation mode.

The duration of the sleep period is much greater than the duration of the wake-up period. For example, the duration of the sleep period may be preferably 50ms to 2000ms, more preferably 400ms to 800ms, further preferably 600ms, and the duration of the wake-up period may be preferably 1ms to 50ms, more preferably 10ms to 30ms, further preferably 15ms, or preferably 1ms to 15ms, more preferably 7ms to 8 ms. The above listed durations are only examples and any other duration may be fully employed by the skilled person.

In this way, the sensor 1 can switch between the normal operating mode and the energy saving mode in a controllable manner according to the enable signal, thereby reducing power consumption, and can autonomously sense parameter changes during the energy saving mode and further wake up an external control system, thereby realizing timely and correct monitoring of parameters.

The threshold may be a preset value. For example, the threshold value may be equal to the reference value plus the decision amplitude value. The reference value may be, for example, a detection value of the sensor under a prescribed normal condition, and the determination magnitude may be, for example, selected according to a degree of allowable deviation from the prescribed normal condition. Further preferably, an initial value of the threshold is a preset value, and the threshold is updated every predetermined time in the wake-up period of the power saving mode. Preferably, the updating may be performed according to a detection value obtained from the sensing element 101. For example, the updated threshold may be set to the current normal value plus the decision magnitude. Wherein the current normal value is a detection value of the sensor under normal conditions under the current environment. Further preferably, the threshold value may be updated according to a change rate of the detection value or by another algorithm. The predetermined time may be 1 minute, 5 minutes, 10 minutes, 20 minutes, or 1 hour or any other suitable time. By enabling the sensor to update the threshold value automatically at regular time, the influence of environmental change on the automatic judgment of the sensor can be counteracted.

When the sensor 1 is a pressure sensor, the threshold value may be a pressure value and/or a rate of change of pressure and/or other algorithm derived value. Preferably, the threshold value may be updated according to the obtained pressure detection values from the sensing element 101 and/or the rate of change of the pressure detection values and/or by other algorithms. Accordingly, when said sensor 1 is a force sensor, a temperature sensor, a current sensor, a voltage sensor, a smoke sensor and/or any other type of sensor, the threshold value may accordingly be a magnitude of force, a temperature value, a current value, a voltage value, a smoke composition/concentration value and/or other corresponding detected value, and said updating may be performed in dependence of the magnitude of force obtained from the sensing element 101, the temperature value, the current value, the voltage value, the smoke composition/concentration value and/or other corresponding detected value and/or a rate of change thereof and/or by other algorithms.

When the wakeup output unit 105 outputs a wakeup signal for waking up the external control system to the external control system, it may check whether the command receiving unit 103 receives the enable signal. Preferably, it may be checked at the end of one or more periods of the wake-up signal whether the command receiving part 103 receives the enable signal. When outputting the wake-up signal, if it is detected that the command receiving part 103 receives the enable signal, the output of the wake-up signal is stopped. In this way, the sensor 1 can confirm that the external control system has been autonomously awakened, thereby increasing the system reliability.

The sensor may also have an autonomous fault diagnosis function. Specifically, the controller 102 may autonomously detect the detection signal and/or the wake-up signal transmitted by the detection signal output part 104 and/or the wake-up output part 105 to determine whether the detection signal output part 104 and/or the wake-up output part 105 is in a normal operating state. Optionally, the detection signal and/or the wake-up signal autonomously detected by the controller 102 may be provided with a check code. Preferably, the detection signal output part 104 and/or the wake-up output part 105 may also send the detection signal and/or the wake-up signal with a check code to the outside for signal verification by an external control system. This process may be performed when the sensor 1 detects the enable signal or at any other time. In this way, the sensor 1 has an autonomous diagnostic function, and it is possible to prevent the output portion of the sensor 1 from malfunctioning without being discovered and affecting the correct monitoring of the sensor.

A second embodiment and a third embodiment of the sensor 1 of the present disclosure are explained below with reference to fig. 2 and 3. In the description and drawings of the embodiments, the same reference numerals as those of the previous embodiments denote the same components, and only the differences of the embodiments from the first embodiment will be described and the description of the same components, structures, functions, parameters and logic will be omitted for the sake of brevity. Those skilled in the art will appreciate that the components, structures, functions, parameters and logic of all other embodiments of the disclosed sensors may be applied to this embodiment unless otherwise specified.

In the second embodiment shown in fig. 2, the signal processing chip 1091 in the first embodiment is replaced with a signal amplifier 1092. The signal amplifier 1092 is configured to amplify the signal sensed by the sensing element 101 and input the amplified signal to the controller 102. In this embodiment, the controller 102 may be used to implement the functions of further processing of the signals (e.g., signal conversion, computational processing, etc.).

In the third embodiment shown in fig. 3, the signal processing chip 1091 in the first embodiment is omitted, so that the sensing element 1 is connected to the controller 102 without passing through the signal processing chip and the signal amplifier. In this embodiment, the controller 102 may integrate signal amplification, conversion, calculation processing, and the like. In this way, the sensor 1 can be made more integrated, and thus can be made smaller.

Fig. 4-6 illustrate embodiments of the sensor 1 of the present disclosure for transmitting and receiving signals in a wireless communication manner.

A fourth embodiment of the sensor 1 of the present disclosure is explained below with reference to fig. 4. In the description and illustration of this embodiment, the same reference numerals as those of the previous embodiment denote the same components, and only the differences from the first embodiment will be described for the sake of brevity, and the description of the same components, structures, functions, parameters, and logic will be omitted. Those skilled in the art will appreciate that the components, structures, functions, parameters and logic of all other embodiments of the disclosed sensors may be applied to this embodiment unless otherwise specified.

In the fourth embodiment shown in fig. 4, the sensor 1 includes a wireless transmission and reception module 1010 instead of the command receiving section 103, the detection signal output section 104, and the wake-up output section 105 in the first embodiment. The wireless transmitting and receiving module 1010 is connected to the controller 102. The wireless transmitting and receiving module 1010 is configured to wirelessly receive the enable signal, wirelessly output the detect signal, and wirelessly output the wake-up signal. The wireless transmitting and receiving module can be realized by any wireless communication mode such as WiFi, 2G/3G/4G/5G mobile communication, Bluetooth, Zigbee, LPWAN and the like.

The power supply pin 107 may supply power to the signal processing chip 1091, the controller 102, and the wireless transmitting and receiving module 1010 through the voltage regulator 106. The sensing element 101 may be connected to the controller 102 through a signal processing chip 1091.

One end of the wireless transmitting and receiving module 1010 may be connected to an external control system that generates the enable signal. The wireless transmit and receive module 1010 may receive the enable signal and communicate the enable signal to the controller 102 in a wireless communication.

The controller 102 is configured to execute the following control.

When the wireless transmitting and receiving module 1010 receives an enable signal, for example, from an external control system, the wireless transmitting and receiving module 1010 transfers the enable signal to the controller 102. In this case, the controller 102 puts the sensor 1 in a normal operation mode. In the normal operation mode, the controller 102 samples and converts the measurement signal of the signal processing chip 1091 into a calculation processing at an appropriate sampling period (e.g., 10ms), and controls the wireless transmitting and receiving module 1010 to continuously output the detection signal in a wireless communication manner.

When the wireless transmitting and receiving module 1010 does not receive the enable signal, the controller 102 puts the sensor 1 in a power saving mode (low power consumption mode). In the power saving mode, the sensor 1 is alternately in a wake-up period and a sleep period. In the sleep period of the power saving mode, the sensor is in sleep. In the wake-up period of the power saving mode, the controller 102 controls the sensing element 101 to perform detection, and the controller 102 compares a detection value obtained from the sensing element 101 with a threshold value, if the detection value is judged to exceed the threshold value, the controller 102 sends an instruction to the wireless transmitting and receiving module 1010 to cause the wireless transmitting and receiving module 1010 to send out a wake-up signal in a wireless communication manner and simultaneously automatically switch to the normal operation mode, and if the detection value is judged not to exceed the threshold value, the sensor 1 continues to be in the power saving mode and is alternately in the wake-up period and the sleep period. The wake-up signal may be, for example, a square wave, a triangular wave, a sine wave, or any other suitable wave signal. Preferably, in the case where it is determined that the detection value exceeds the threshold value, the controller 102 causes the sensor 1 to exit the energy saving mode and return to the normal operation mode.

In this way, in addition to the effect described in the first embodiment of the present disclosure, compared to the first to third embodiments, pins and connections for detecting signals, wake-up signals, and enable signals can be omitted, so that the sensor meets the requirements of wireless transmission occasions.

When the wireless transmitting and receiving module 1010 outputs a wake-up signal for waking up the external control system to the external control system in a wireless communication manner, it may be checked whether the wireless transmitting and receiving module 1010 receives the enable signal. Preferably, it may be checked at the end of one or more periods of the wake-up signal whether the wireless transmit and receive module 1010 receives the enable signal. And if the wireless transmitting and receiving module 1010 detects that the enable signal is received while outputting the wake-up signal, stopping outputting the wake-up signal. In this way, the sensor 1 can confirm that the external control system has been autonomously awakened, thereby increasing the system reliability.

Preferably, the wireless transmitting and receiving module 1010 may further send a signal with a check code to an outside for an external system to determine whether an error occurs in the enabling signal and/or the detecting signal during the wireless transmission. This process may be performed when the sensor 1 detects the enable signal or at any other time.

Fifth and sixth embodiments of the sensor 1 of the present disclosure are described below with reference to fig. 5-6. In the description and drawings of these embodiments, the same reference numerals as those of the previous embodiments denote the same components, and only the differences of this embodiment from the fourth embodiment will be described for the sake of brevity, omitting the description of the same components, structures, functions, parameters, and logic. Those skilled in the art will appreciate that the components, structures, functions, parameters and logic of all other embodiments of the disclosed sensors may be applied to this embodiment unless otherwise specified.

In the fifth embodiment shown in fig. 5, the signal processing chip 1091 in the fourth embodiment is replaced with a signal amplifier 1092. The signal amplifier 1092 is configured to amplify the signal sensed by the sensing element 101 and input the amplified signal to the controller 102. In this embodiment, the controller 102 may be used to implement the functions of further processing of the signals (e.g., signal conversion, computational processing, etc.).

In the sixth embodiment shown in fig. 6, the signal processing chip 1091 in the fourth embodiment is omitted, so that the sensing element 1 is connected to the controller 102 without passing through the signal processing chip and the signal amplifier. In this embodiment, the controller 102 may integrate signal amplification, conversion, calculation processing, and the like. In this way, the sensor 1 can be made more integrated, and thus can be made smaller.

The sensor 1 according to embodiments of the present disclosure may be a pressure sensor, a temperature sensor, a smoke sensor, a voltage sensor, a current sensor, or any other sensor.

As a specific application, the sensor 1 according to embodiments of the present disclosure may be used for monitoring the status of a battery pack, in particular for monitoring the status of a battery pack in an electric vehicle, for example for monitoring whether a thermal runaway is about to and/or has occurred in the battery pack.

Fig. 7 schematically shows the electric vehicle 4. The electric vehicle 4 may include the sensor 1, the battery pack 2, and the battery management system 3 according to various embodiments of the present disclosure. The battery management system 3 is used for monitoring and managing the state of the battery in the battery pack 2 (e.g., the state of charge, the thermal state of the battery, etc.) and the state of the vehicle, and comprehensively controlling the battery pack and the vehicle according to the monitored conditions. The battery management system 3 may employ any existing Battery Management System (BMS). The sensor 1 is mounted in the battery pack 2, on the battery pack 2, or near the battery pack 2, and is used to monitor whether thermal runaway is about to occur and/or has occurred in the battery pack by monitoring various parameters of the battery pack (e.g., gas pressure, temperature, current, voltage, and/or smoke, etc.). The sensor 1 may employ any of the components, structures, functions, parameters and logic of the sensor 1 described hereinbefore and, for the sake of brevity, some of the description which has been made hereinbefore is omitted from the following description.

The battery management system 3 may be connected to the sensor 1. When the vehicle is in a running state or a charging state, for example, the battery management system 3 is in an operating state, and the enable signal will be output to the command receiving section 103 of the sensor 1 or the wireless transmitting and receiving module 1010. In this case, as described above, the sensor 1 will be placed in the normal operation mode, and the detection signal output part 104 or the wireless transmitting and receiving module 1010 of the sensor 1 may continuously output the detection signal to the battery management system 3 for the comprehensive judgment and control of the battery management system. When the vehicle is, for example, in a stopped state, the battery management system 3 is in a sleep period, and the enable signal will not be output. In this case, sensor 1 would be placed in the power saving mode as previously described. In the energy saving mode, as described above, the sensor 1 is not always in the sleep state, but is alternately in the wake-up period and the sleep period, and performs detection and threshold determination in the wake-up period, and if the detection value in the wake-up period exceeds the threshold value, the wake-up output unit 105 or the wireless transmission and reception module 1010 of the sensor 1 outputs a wake-up signal to the battery management system 3 to return the battery management system 3 to the operating state. In this way, the sensor 1 can autonomously sleep, autonomously wake up, and wake up an external system under the condition of low power consumption, thereby enabling timely and accurate monitoring with lower power consumption.

When the wake-up output part 105 or the wireless transmission and reception module 1010 of the sensor 1 outputs the wake-up signal to the battery management system 3, it may be checked whether the command reception part 103 or the wireless transmission and reception module 1010 receives the enable signal, as described above. Upon detecting that the command receiving part 103 or the wireless transmitting and receiving module 1010 receives the enable signal, i.e., confirming that the battery management system 3 has been awakened, the sensor stops outputting the awakening signal.

The following describes in detail the sensor 1 according to an embodiment of the present disclosure with respect to monitoring the state of the battery pack to early warn of a thermal runaway phenomenon and/or to avoid the occurrence of a thermal runaway consequence. The sensor 1 comprises a sensing element 101, a sampling module and a decision module. Generally, the sensing element 101 is used to obtain data related to the state in the battery pack, the sampling module samples the obtained data, and the determination module performs determination based on the sampled data to obtain a determination result to determine whether a thermal runaway condition occurs in the battery pack.

In one embodiment, the sensor 1 according to the present disclosure may be powered by a separate power source, such as a battery module, and not a lead-acid battery in a vehicle. On the one hand, it is possible to avoid consuming the energy of the battery and affecting the operation of the other parts of the vehicle, and on the other hand, it is possible to facilitate the management of this separate power supply, in order to avoid affecting the operation of the sensor due to the exhaustion of the battery. In addition, the separate power source may provide power to the sensor in a wired or wireless manner, and preferably may provide power wirelessly to simplify construction and ease of installation and assembly.

In the normal operation mode, the sensing element 101, the sampling module, and the determination module operate normally, and the sensor continuously outputs a detection signal corresponding to detection data of the sensor to the outside. That is, the sensor is continuously operated, so that it is possible to continuously determine whether a thermal runaway condition occurs in the battery pack.

As described above, in the power saving mode, the sensor is alternately in the wake-up period and the sleep period. Accordingly, in the wake-up period, the sensing element 101, the sampling module and the determination module operate normally, and the sensor continuously outputs a detection signal corresponding to detection data of the sensor to the outside, and at the same time, in the wake-up period, the sensor can determine whether a thermal runaway condition occurs in the battery pack. In the sleep period, the sensor is in sleep, and the sensing element 101, the sampling module, and the determination module are not operated.

As described above, the sensing element 101 may be used to detect the state of the battery pack and obtain detection data. On the basis of this, the sensor 1 can obtain its profile with respect to time from these detection data.

The sampling module is used for sampling the detection data to obtain sampling data. The sampling module may define a sampling period, which may be determined according to an operating mode of the sensor, e.g., the sampling period in a normal operating mode may be smaller than the sampling period in a power saving mode. In general, the sampling module samples the detection data at a set sampling period based on a plot of the detection data against time.

After the sampling module samples, the determination module may determine whether a thermal runaway condition exists within the battery pack based on the sampled detection data. The determination module may set a preset threshold, and when the sampled detection data is greater than the preset threshold, the determination module outputs a warning signal indicating that a thermal runaway condition may occur in the battery pack. And when the sampled detection data is not greater than the preset threshold, the determination module may, for example, take no action or may output a signal indicating that the battery pack is operating properly.

Additionally or alternatively, the determination module may set a preset rate of change threshold, and when the rate of change of the sampled detection data is greater than the preset rate of change threshold, the determination module outputs a warning signal indicating that a thermal runaway condition may occur within the battery pack. And when the rate of change of the sampled detection data is not greater than the preset rate of change threshold, the determination module may, for example, take no action or may output a signal indicating that the battery pack is operating properly.

In one embodiment, the warning signal may be transmitted to the battery management system 3 so that the battery management system 3 manages the battery pack to avoid a possible thermal runaway condition or to reduce damage caused by thermal runaway.

At the same time that the decision module outputs the warning signal, the sensor may output a wake-up signal as described above to switch the sensor to the normal operating mode.

In one embodiment, when the determination module outputs a warning signal indicating that a thermal runaway condition may occur in the battery pack, the sampling module may change the sampling period to enhance the measurement of the sensor and obtain more and more accurate data for the battery management system to manage the battery pack.

The sampling mode of the sampling module may be any suitable sampling mode and thus may cooperate with the decision module in different ways. For example, for each sampling period, any one of the detection data within the sampling period may be taken as the sampled detection data to be compared with the preset threshold. Or alternatively, for each sampling period, an average value of a plurality of detection data within the sampling period may be taken as the sampled detection data to be compared with a preset threshold.

In another embodiment, the sampling may be performed for a plurality of sampling periods, and any one of the detection data is taken in each sampling period, so as to obtain a plurality of sampled detection data, and the change rate of the plurality of detection data is compared with the preset change rate threshold. Or alternatively, a plurality of detection data are averaged in each sampling period, so that a plurality of sampled detection data are obtained, and the change rate of the plurality of detection data is compared with a preset change rate threshold value. For example, in one embodiment, three sampling periods may be sampled to obtain the rate of change of three detected data to compare to a preset rate of change threshold. In an exemplary embodiment, the preset rate of change threshold may be in a range, for example, from 0.1KPa/s to 10KPa/s, preferably in a range from 0.2KPa/s to 5KPa/s, more preferably in a range from 0.5KPa/s to 1 KPa/s. In one embodiment, the preset rate of change threshold is 0.6 KPa/s.

Preferably, the sensor 1 for monitoring whether thermal runaway is about to and/or has occurred in the battery pack is a pressure sensor for monitoring the gas pressure in the battery pack. The advantage of using monitored gas pressure to monitor thermal runaway is that there is little delay in the conduction of gas pressure inside the battery pack, so that thermal runaway that may occur can be quickly and accurately monitored. In the case where the sensor 1 is a pressure sensor, the preset threshold value may be, for example, the sum of a standard atmospheric pressure value and a determination amplitude value or the sum of a factory-time atmospheric pressure value or a current atmospheric pressure value and a determination amplitude value. The decision amplitude may be chosen according to the degree of deviation from normal allowed, for example in the range of 0.5KPa to 50KPa, for example 10KPa, 20KPa, 30KPa, 40KPa, 50KPa or any other suitable value. For example, in the wake-up period of the energy saving mode, the threshold value is updated to the sum of the current atmospheric pressure value and the determination amplitude value every predetermined time. The current atmospheric pressure value may be detected by the sensing element 101 or may be calculated according to the current environment of the battery pack, for example, according to factors such as altitude.

Of course, as previously mentioned, the sensors herein are also not limited to pressure sensors, but may be any other type of sensor such as temperature sensors, current sensors, voltage sensors, smoke sensors, etc.

In one embodiment, the preset threshold and/or the preset rate of change threshold may be updated every predetermined time during the wake-up period of the power saving mode in order to more truly reflect the current state of the battery pack. This predetermined time may be selected according to the needs of the actual application, and may be, for example, 5 minutes or any other suitable time. Because the preset threshold and/or the preset change rate threshold can be updated based on preset time, even if the automobile is transported or used in a place with variable altitude or atmospheric pressure, the thermal runaway which may occur can be more accurately monitored, and false alarm are avoided.

In one embodiment, after the power saving mode continues for a predetermined time, at which time it may be substantially determined that the battery pack is in a stable state, the sensor may be placed in a deep sleep mode. In this deep sleep mode, the sensor is turned off and the sensing element 101, the acquisition module and the decision module are not operated. The predetermined time may be selected according to the requirements of the actual application, and may be 24 hours or any other suitable time.

Preferably, the battery management system 3 may further be provided with a wireless receiving device for receiving a verification signal with a verification code sent by the wireless transmitting and receiving module 1010 so as to diagnose the fault of the sensor. Preferably, the battery management system 3 may also be provided with means for receiving a verification signal with a verification code sent by the detection signal output 104 and/or the wake-up output 105 in order to diagnose a malfunction of the sensor.

A monitoring method using the sensor 1 of the present disclosure is explained below with reference to fig. 8. Any of the components, structures, functions, parameters and logic of the sensors of the various embodiments and implementations previously mentioned may be used in the method, and therefore the details that have been previously discussed will not be repeated below.

The monitoring method may be used to monitor pressure, temperature, current, voltage, smoke or any other parameter. The monitoring method may be used for monitoring the status of a battery pack, in particular for monitoring whether a thermal runaway is about to occur and/or has occurred in a battery pack in an electric vehicle.

In the method, after the monitoring starts (S1), the sensor first determines whether an enable signal is received (S2). The enable signal may be from a battery management system. If the sensor receives the enable signal (YES at S2), the sensor enters a normal operation mode (S3). In the normal operation mode, the sensor is caused to continuously output a detection signal to the outside (e.g., to a battery management system). If the sensor does not receive the enable signal (NO at S2), the sensor is put into a power saving mode (S4). In the power saving mode, the sensor will be alternately in awake periods and sleep periods. In the power saving mode, if the sensor is in the sleep period (no at S5), the sensor sleeps (S6), and then the sensor enters the wake-up period after the sleep period ends. In the power saving mode, if the sensor is in the wake-up period (yes at S5), the sensing element 101, the sampling module, and the determination module of the sensor 1 operate (S7). The determination module of the sensor 1 then makes a determination based on the sampled detection data (S8). If the determination module outputs a warning signal (yes at S8), the sensor outputs a wake-up signal to the outside (e.g., to the battery management system 3) (S9), and at this time, the sensor is preferably put in a normal operation mode; if the determination module does not output the warning signal (NO at S8), the sensor returns to the sleep state and continues the power saving mode (i.e., returns to S6). Preferably, after outputting the wake-up signal, it may be checked whether the sensor 1 receives the enable signal (S10), if the enable signal is received (yes at S10), that is, it is confirmed that the outside (e.g., the battery management system 3) has been awakened, the sensor stops outputting the wake-up signal (S11), and the sensor 1 will be in the normal operation mode at this time due to the reception of the enable signal (S3); if the enable signal is not received (no at S10), i.e., the external part (e.g., the battery management system 3) is not wakened, the sensor continues to output a wake-up signal to the external part (e.g., to the battery management system 3) (back to S9).

Furthermore, preferably, the method further comprises the step of updating the threshold value periodically and the step of sending the wake-up signal and/or the detection signal to the sensor itself for autonomous fault diagnosis. Since the updating of the threshold value and the self-checking of the sensor have been discussed in detail above, they are not described in detail here.

Fig. 9 shows a flow chart of another monitoring method using the sensor 1 of the present disclosure for monitoring.

In the method, after the monitoring starts (S1), the sensor first determines whether an enable signal is received (S2). The enable signal may be from a battery management system. If the sensor receives the enable signal (YES at S2), the sensor enters a normal operation mode (S3). In the normal operation mode, the sensor is caused to continuously output a detection signal to the outside (e.g., to a battery management system). If the sensor does not receive the enable signal (NO at S2), the sensor is put into a power saving mode (S4). In the power saving mode, the sensor will be alternately in awake periods and sleep periods. In the power saving mode, if the sensor is in the sleep period (no at S5), the sensor sleeps (S6), and then the sensor enters the wake-up period after the sleep period ends. In the power saving mode, if the sensor is in the wake-up period (yes at S5), the sensing element 101, the sampling module, and the determination module of the sensor 1 operate (S7). The determination module of the sensor 1 then makes a determination based on the sampled detection data (S8). If the determination module outputs a warning signal (yes at S8), the sensor outputs a wake-up signal to the outside (e.g., to the battery management system 3) (S9), and at this time, the sensor is preferably put in a normal operation mode; if the determination module does not output the warning signal (no at S8), the sensor determines whether a period of time for which the preset threshold value and/or the preset rate-of-change threshold value is updated has reached a predetermined time, for example, 5 minutes (S10), and if the predetermined time is reached, the preset threshold value and/or the preset rate-of-change threshold value is updated (S11), and then the sensor determines whether the energy saving mode duration time exceeds the predetermined period of time (S12); if the sensor determines that the period of time for which the preset threshold value and/or the preset rate of change threshold value is updated does not reach the predetermined time, it is determined whether the energy saving mode duration exceeds the predetermined period of time (S12). If it is determined in S12 that the predetermined period of time has not been reached, the sensor returns to the sleep state, continues the power saving mode (i.e., returns to S6), and if it is determined that the predetermined period of time has been reached, the sensor is brought into the deep sleep mode (S15). Preferably, after outputting the wake-up signal, it may be checked whether the sensor 1 receives the enable signal (S13), if the enable signal is received (yes at S13), that is, it is confirmed that the outside (e.g., the battery management system 3) has been awakened, the sensor stops outputting the wake-up signal (S14), and the sensor 1 will be in the normal operation mode at this time due to the reception of the enable signal (S3); if the enable signal is not received (no at S13), i.e., the external part (e.g., the battery management system 3) is not wakened, the sensor continues to output a wake-up signal to the external part (e.g., to the battery management system 3) (back to S9).

Although exemplary embodiments of the present disclosure have been described, it will be understood by those skilled in the art that various changes and modifications can be made to the exemplary embodiments of the present disclosure without substantially departing from the spirit and scope of the present disclosure. Accordingly, all changes and modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. The disclosure is defined by the following claims, with equivalents of the claims to be included therein.

Claims

1. A sensor for monitoring a condition of a battery pack, the sensor comprising:

2. The sensor of claim 1, wherein the sampling period is determined according to an operating mode of the sensor.

3. The sensor of claim 1, wherein the sampling module is configured to change a sampling period when the determination module outputs a warning signal.

4. The sensor of claim 1, wherein the sampled detection data is compared with the preset threshold value at any one of the detection data within the sampling period.

5. The sensor of claim 1, wherein the sampled detection data is compared to the preset threshold by taking an average of a plurality of detection data over a sampling period.

6. The sensor of claim 1, wherein the sampled sensed data is compared to the preset rate of change threshold for a plurality of sensed data over a plurality of sampling periods, wherein any one sensed data is taken for each sampling period.

7. The sensor of claim 1, wherein the sampled sensed data is averaged over a plurality of sampling periods with a rate of change of the plurality of sensed data compared to the preset rate of change threshold.

8. The sensor of claim 1, wherein the sensor is powered by a separate power source, either wired or wireless.

9. The sensor of claim 1, wherein the sensor is a pressure sensor and the sensed data is data indicative of pressure within the battery pack.

10. The sensor of claim 9, wherein the preset threshold is determined by the sum of a standard atmospheric pressure value and a decision amplitude, wherein the decision amplitude is in the range from 0.5KPa to 50 KPa.