CN112585807A - Lithium ion battery module and power box for electric forklift - Google Patents
Lithium ion battery module and power box for electric forklift Download PDFInfo
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- CN112585807A CN112585807A CN201980034167.0A CN201980034167A CN112585807A CN 112585807 A CN112585807 A CN 112585807A CN 201980034167 A CN201980034167 A CN 201980034167A CN 112585807 A CN112585807 A CN 112585807A
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- lithium ion
- battery module
- electric forklift
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- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 title claims abstract description 117
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 7
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F9/00—Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes
- B66F9/06—Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes movable, with their loads, on wheels or the like, e.g. fork-lift trucks
- B66F9/075—Constructional features or details
- B66F9/20—Means for actuating or controlling masts, platforms, or forks
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
- H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/61—Types of temperature control
- H01M10/613—Cooling or keeping cold
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/61—Types of temperature control
- H01M10/617—Types of temperature control for achieving uniformity or desired distribution of temperature
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
- H01M10/625—Vehicles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/65—Means for temperature control structurally associated with the cells
- H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
- H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
- H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/236—Hardness
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
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- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/258—Modular batteries; Casings provided with means for assembling
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Abstract
A lithium ion battery module and a power box for an electric forklift belong to the technical field of lithium ion batteries; the battery module comprises a shell and a battery pack in the shell, wherein the battery pack comprises battery cells (11), inter-cell heat insulation sheets (12), bottom surface insulation plates (13) on the periphery of the battery cells (11), side surface insulation plates (15), end surface insulation plates (14) and a busbar support (7) at the top, the battery cells (11) are square lithium iron phosphate batteries and adopt a grouping mode of 1-8 strings, protruding spacer sheets (18) are arranged on the surfaces of the side surface insulation plates (15) and the bottom surface insulation plates (13), and inter-cell connecting bars (4) and end connecting bars (6) are arranged on the busbar support (7); the power box comprises a box body (34), wherein a high-voltage box (35), a BMS and the lithium ion battery module for the electric forklift are arranged in the box body (34), a box cover (39) is arranged on the box body (34), and an exhaust valve (50) is arranged on the box cover (39). The lithium ion battery module and the power box have high reliability in the aspects of structure and thermal performance.
Description
Technical Field
The invention relates to a lithium ion battery module and a power box for an electric forklift, and belongs to the technical field of lithium ion batteries.
Background
According to market analysis and prediction of the global electric forklift industry in 2018-2023, the yield of the electric forklift in 2017 is estimated to be 2766.99 thousand, 4097.06 thousand electric forklifts are estimated to be reached at the end of 2023, and the composite annual growth rate from 2018 to 2023 is 6.6%. Global third Research agency platform persistent Market Research (hereinafter abbreviated PMR) was published in 2014 under the heading "global Market Research for forklifts: the asia-pacific region will demonstrate the highest growth in 2021 "and survey results show that the global forklift market value is $ 353 billion, and then the annual average compound growth rate (CAGR) of the electric forklift market is expected to be 6.9% in the forecast period and to $ 559 million by the end of 2021. The lithium ion battery system has the characteristics of high power density and energy density, long charging and discharging service life, no memory effect, no pollution and the like, and is a great trend to replace a lead-acid battery in the application of an electric forklift.
The exhaust emission of one diesel fork lift truck is approximately equivalent to the emission of 100 sedans. In contrast, the electric forklift is pollution-free and low in noise, and will certainly replace the traditional internal combustion forklift to become the main force in the future. The lithium ion battery is favored in the application aspect of the electric forklift because of the advantages of high working voltage, high power density and energy density, long charging and discharging life, no memory effect, no pollution and the like. At present, a plurality of mainstream forklift host plants such as a resultant force group, a noni group and a Hangzhou fork group are actively introduced to the application of lithium ion batteries, a plurality of huge enterprises such as Ningde times, Biyadi and Guoxing Xuan Gao are also actively developing the field of lithium ion forklifts, and well-known lithium ion enterprises such as Zhonghang lithium ion and Jiangsu Lixin can be matched battery module products of a battery system for forklifts. The electric forklift 'lithium electrochemical' is a trend developed at present. The high safety, high specific energy and long service life are the most critical performance requirements of the lithium ion battery system and are also hot spots and difficulties in industrial research. The reliability of structure and thermal management is two important factors for lithium ion battery pack design, and directly influences the performance, cost and safety of products.
Patent number CN208797070U discloses an electric fork-lift power lithium electric system, aims at solving the problem that traditional lead-acid storage battery's connection is loaded down with trivial details and difficult to maintain and when a plurality of battery modules are directly built each other, stability is not enough, the problem that the vibration resistance of equilibrium is low. The patent mainly describes the structure of the power supply box body, but does not refer to the internal structural design of the battery module. On its power supply box shell lateral wall, be provided with four great circular ports, the purpose is conveniently to the inside pencil of box install the radiating effect of dismantling, improving system simultaneously. However, the box body is provided with a plurality of large holes, so that the IP grade of the power box can be reduced, and particularly, when the electric forklift operates in a dust environment, the box body cannot effectively prevent dust from entering the box body, so that potential safety hazards exist.
Patent number CN207009575U discloses a battery pack design for electric fork-lift truck, its characterized in that: fixing the battery modules together and on the electric forklift through the designed fixed structure frame; a Battery Management System (BMS) module is directly stacked above the battery module; the heat management mode is forced air cooling and needs an external fan. The whole set of system architecture does not design the box, and the structure is open state, and battery module, BMS module and pencil expose outside, when receiving striking or extrusion, do not have the protection of box, have certain potential safety hazard. In terms of heat management, the forced air cooling design needs to consider the factors of installation and power consumption of a fan, noise reduction, additional wiring harness design and the like, but the patent does not describe the details. The above design factors will increase the cost of the product compared to natural cooling.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the defects of the prior art are overcome, the lithium ion battery module and the power box for the electric forklift are provided, and the lithium ion battery module and the power box have high reliability in the aspects of structure and thermal performance.
The lithium ion battery module for the electric forklift comprises a shell and a battery pack in the shell, wherein the battery pack comprises a battery cell, an inter-cell heat insulation sheet, a bottom surface insulation board, a side surface insulation board, an end surface insulation board and a busbar support at the top, the battery cell is a square lithium iron phosphate battery and adopts a grouping mode of 1-8 strings, protruding spacers are arranged on the surfaces of the side surface insulation board and the bottom surface insulation board, and an inter-cell connecting bar and an end connecting bar are arranged on the busbar support.
The lightweight design improves the energy density of the module; the design of the heat insulation sheet can effectively control the thermal runaway to spread among the electric cores; with a modular structure, capacity can be scaled up equally to meet commercial and industrial needs.
Preferably, the heat insulation sheet is soft polyethylene foam, and the bottom surface insulation plate, the side surface insulation plate and the end surface insulation plate are made of PC-ABS plastic plates.
The soft polyethylene foam has good buffering and shock-absorbing performance, and the cross-linked structure enables the foam to have certain rigidity, low hardness and high resilience, and can absorb the bulging stress of the battery, thereby playing a role in buffering. The bottom surface insulating plate, the side surface insulating plate and the end surface insulating plate are used for insulation. The lithium ion battery module is designed as a basic edition of the lithium ion battery module for the electric forklift, and has high cost performance.
Preferably, the shell comprises an end plate, a bottom plate, a side plate and an upper outer cover, wherein the upper edge and the lower edge of the side plate are provided with bending structures, and the front end and the rear end of the side plate are provided with bending parts; a fixing groove is formed in the edge of the busbar support, a clamping groove matched with the fixing groove is formed in the upper edge of the side plate, outer clamping grooves are formed in two sides of the upper outer cover, and outer clamping buckles matched with the outer clamping grooves are formed in the upper edge of the side plate; the bus bar support is also provided with a wire clip and an annular structure.
The quality of the joints of the side plates, the end plates and the bottom plate is better, the structural reliability is higher, and the annular structure is used for binding and rolling the belt to fix the wire harness.
Preferably, the four corners of the inter-cell connecting row and the end connecting row are rounded corners. For preventing a tip discharge.
Preferably, the front face of the end plate is provided with a heat dissipation groove, the side plate is provided with an oval groove, the end plate is made of carbon fiber composite materials, and the bottom insulating plate, the side insulating plate and the end face insulating plate are made of thermoplastic heat-conducting insulating plastics TCP 200-30-6A.
The design of the high-end version of the lithium ion battery module for the electric forklift is realized by changing the structural design and the material of the end plate, changing the material of the plastic part and changing the structure of the side plate; the high structural strength, the light weight and the high energy density are realized, and meanwhile, the heat dissipation effect is not weakened.
Preferably, the upper outer cover is provided with a total positive outer cover and a total negative outer cover, and the end connecting row comprises two total positive end connecting rows and two total negative end connecting rows which are respectively positioned below the total positive outer cover and the total negative outer cover.
The lithium ion power box for the electric forklift comprises a box body, wherein a high-voltage box, a BMS and the lithium ion battery module for the electric forklift are arranged in the box body, a box cover is arranged on the box body, and an exhaust valve is arranged on the box cover.
The battery box has a box body structure, can protect internal components such as a battery module, a high-voltage box and a BMS, and has higher product safety. Meanwhile, the design of the invention adopts natural cooling, compared with forced air cooling, the system has simple structure, no need of additional wire harness and energy consumption (for a motor), and no noise, thereby having lower heat management cost.
Preferably, the lithium ion battery modules for the electric forklift are provided with 6 groups, and the lithium ion battery modules are symmetrically arranged on the left side and the right side; the connection mode is 2-to-3 series, the modules on the same side are connected in series, and the modules on two sides are connected in parallel.
Through the lightweight design, module energy density has been improved.
Preferably, a first relay, a second relay, a third relay, a pre-charging resistor, a first fuse, a second fuse and a current sensor are arranged in the high-voltage box, one path of the first fuse is connected with the first relay, the other end of the first relay is connected with the anode of the battery module, the other path of the first fuse is connected with the pre-charging relay, the other end of the pre-charging relay is connected with the pre-charging resistor, and the other end of the pre-charging resistor is connected with the anode of the battery module; the second fuse is connected with the second relay, and the other end of the second relay is connected with the anode of the battery module; the current sensor is connected with the third relay, and the third relay is connected with the negative electrode of the battery module.
The other end of the first fuse serves as a fast charging anode, the other end of the second fuse serves as an output anode, one path of the other end of the current sensor serves as a fast charging cathode, and the other path of the other end of the current sensor serves as an output cathode. The charge-discharge device is used for charge and discharge.
Preferably, the middle part left and right sides respectively is provided with the baffle in the box, and battery module, upper strata are placed to the baffle lower floor and high-pressure case and BMS are placed, and there is the cavity bottom half, and inside is filled and the compaction by steel panel as the counter weight, and bottom half thickness is greater than 10 times curb plate thickness, and bottom half thickness is greater than 20 times apron thickness.
The structure design and the heat management design are reasonable, and the reliability is high.
Compared with the prior art, the invention has the following beneficial effects:
1. through the lightweight design, the energy density of the lithium ion battery module for the electric forklift is improved, and the energy density is 20-26% higher than that of 4 similar products of aviation lithium batteries in battery enterprises known in the industry;
2. compared with the technology of a certain type of similar product of Jiangsu Li Xin of battery enterprises known in the industry, the lithium ion battery module for the electric forklift has better quality of the connection parts of the side plates, the end plates and the bottom plate and higher structural reliability;
3. compared with the technology of a certain type of similar product of Jiangsu Li Xin of battery enterprises known in the industry, the upper cover plate structure of the lithium ion battery module for the electric forklift has better design quality, greatly improves the mechanical property and the protectiveness;
4. compared with the technology of the patent No. CN208797070U, the lithium ion power supply box for the electric forklift has higher IP protection level, can better adapt to the working condition environment of dust, and has higher product safety. Meanwhile, a good natural cooling effect can still be ensured under the condition that the box body is not required to be provided with holes;
5. compared with the technology of the patent No. CN207009575U, the battery box has a box body structure, can protect internal components such as a lithium ion battery module, a high-voltage box and a BMS for the electric forklift, and is higher in product safety. Meanwhile, the design of the invention adopts natural cooling, compared with forced air cooling, the system has simple structure, no need of additional wire harness and energy consumption (for a motor) and no noise, thereby having lower heat management cost;
6. the high-efficiency natural cooling performance ensures wide temperature adaptability and high and low temperature consideration, and the temperature uniformity is good;
7. the high-efficiency heat insulation design can effectively control the thermal runaway to spread among the cells;
8. the lithium ion battery module for the electric forklift adopts a modular structure, and the capacity can be amplified in equal proportion so as to meet commercial and industrial requirements.
Drawings
Fig. 1 is a schematic diagram of an explosion structure of a lithium ion battery module for an electric forklift according to embodiment 1 of the present invention;
fig. 2 is a schematic view illustrating an explosion structure of the battery pack according to embodiment 1 of the present invention;
fig. 3 is a schematic view of an overall structure of a lithium ion battery module (basic version design) for an electric forklift according to embodiment 1 of the present invention;
FIG. 4 is a schematic view of the structure of the protruding spacer according to embodiment 1 of the present invention;
fig. 5 is a schematic structural view of a side plate according to embodiment 1 of the present invention;
fig. 6 is a schematic side view of a side plate and a bus bar support according to embodiment 1 of the present invention;
FIG. 7 is a schematic view of a bus bar support according to embodiment 1 of the present invention;
fig. 8 is a schematic structural view of a connection row according to embodiment 1 of the present invention;
FIG. 9 is a schematic view of the assembly of the connection row according to embodiment 1 of the present invention;
fig. 10 is a schematic structural view of the end connection row according to embodiment 1 of the present invention;
FIG. 11 is a schematic view of the assembly of the end connection bank in accordance with embodiment 1 of the present invention;
fig. 12 is a schematic view of an overall structure of a lithium ion battery module (high-end design) for an electric forklift according to embodiment 2 of the present invention;
fig. 13 is a front view of a lithium ion power supply box for an electric forklift according to embodiment 3 of the present invention;
fig. 14 is a side view of a lithium ion power supply box for an electric forklift according to embodiment 3 of the present invention;
fig. 15 is a top view of a lithium ion power supply box for an electric forklift according to embodiment 3 of the present invention;
fig. 16 is a schematic view of the overall structure of a lithium ion power supply box for an electric forklift according to embodiment 3 of the present invention;
FIG. 17 is a schematic structural view of a high pressure tank according to embodiment 3 of the present invention;
fig. 18 is a schematic diagram of a high voltage tank circuit according to embodiment 3 of the present invention;
fig. 19 is a comparison (symbol) of the cell simulation results (solid line) and specification data according to the present invention;
fig. 20 is a simulation result of temperature distribution and heat generation of the battery cell of the present invention after discharging at 0.5C, 1C, and 2C magnifications at an ambient temperature of 25 ℃;
fig. 21 is a simulation result of discharge heat at a magnification of 1C at an ambient temperature of 25 ℃ of the lithium ion battery module for the electric forklift described in embodiments 1 and 2 of the present invention, where b and e are cross sections, and C and f are longitudinal sections;
fig. 22 is a simulation result of thermal runaway of a lithium ion battery module for an electric forklift at a 1C magnification at an ambient temperature of 25 ℃ according to embodiments 1 and 2 of the present invention, where b and e are cross sections, and C and f are longitudinal sections;
fig. 23 is a temperature simulation result of 1C discharge at 25 ℃ of the lithium ion power box for the electric forklift using the lithium ion battery module for the electric forklift in example 1 according to example 3 of the present invention;
fig. 24 is a temperature simulation result of 1C discharge thermal runaway of the lithium ion power supply box for the electric forklift using the lithium ion battery module for the electric forklift in example 1 at 25 ℃ according to example 3 of the present invention;
fig. 25 is a deformation simulation of the lithium ion power box for the electric forklift using the lithium ion battery module for the electric forklift in example 1 according to embodiment 3 of the present invention under an applied force of a vertical acceleration of 3 g;
fig. 26 is a deformation simulation of the lithium ion battery module for the electric forklift described in the embodiment 1 and the embodiment 2 of the present invention under the vertical acceleration acting force of 3 g;
fig. 27 is a result of simulation of random vibration 1 σ stress of the lithium ion power supply box for the electric forklift using the lithium ion battery module for the electric forklift in example 1 according to example 3 of the present invention: a, vibrating along an X axis, b, and c, vibrating along a Y axis;
fig. 28 is a fatigue accumulation damage coefficient after the lithium ion power supply box for the electric forklift, which employs the lithium ion battery module for the electric forklift in example 1 according to example 3 of the present invention, vibrates randomly along the Z axis;
fig. 29 is a simulation result of collision of the lithium ion power supply box for the electric forklift using the lithium ion battery module for the electric forklift in embodiment 1 in embodiment 3 of the present invention: the a load parameter is ABCD in a table 8, and the b load parameter is EFGH in the table 8;
fig. 30 is a simulation result of the impact of the lithium ion power supply box for the electric forklift using the lithium ion battery module for the electric forklift in embodiment 1 in embodiment 3 of the present invention, where the time when the maximum stress point occurs in the impact of the 3 rd time is: a is stress and b is deformation;
fig. 31 shows the results of drop simulation of the lithium ion battery modules for the electric forklift described in embodiments 1 and 2 of the present invention, where a and c are stress, and b and d are strain.
Wherein: 1. a total positive outer cover; 2. an outer cover is arranged; 3. a total negative outer cover; 4. a connecting row; 5. fastening a bolt; 6. end connection rows; 7. a busbar support; 8. an end plate; 9. a base plate; 10. a side plate; 11. an electric core; 12. a heat insulating sheet; 13. a bottom insulating plate; 14. an end face insulating plate; 15. a side insulating plate; 16. riveting; 17. a long rod screw; 18. a protruding spacer; 19. a bending structure; 20. a bending part; 21. fixing the groove; 22. a card slot; 23. an outer clamping groove; 24. an outer buckle; 25. a wire clip; 26. an annular structure; 27. round corners; 28. adapting the bolt; 29. a protrusion structure; 30. a support structure; 31. a pole column; 32. a heat dissipation groove; 33. a groove; 34. a box body; 35. a high pressure tank; 36. a master control BMS; 37. a slave BMS; 38. a battery module; 39. a box cover; 40. hoisting holes; 41. a partition plate; 42. a first relay; 43. a second relay; 44. a third relay; 45. a pre-charging relay; 46. pre-charging a resistor; 47. a first fuse; 48. a second fuse; 49. a current sensor; 50. and (4) exhausting the valve.
Detailed Description
Example 1
As shown in fig. 1 to 3, the lithium ion battery module for an electric forklift includes a housing and a battery pack in the housing, wherein the battery pack includes electric cores 11, heat insulating sheets 12 between the electric cores 11, bottom insulating plates 13 around the electric cores 11, end insulating plates 14, side insulating plates 15, and a bus bar support 7 at the top, and the electric cores 11 are square lithium iron phosphate batteries and adopt a grouping mode of 1-8 strings. Be provided with connecting bar 4 and end connecting bar 6 between electric core 11 on the busbar support 7, the shell includes end plate 8, bottom plate 9, curb plate 10, goes up enclosing cover 2. The end plate 8 is connected with the side plate 10 through a rivet 16, and the bottom plate 9 is connected with the side plate 10 through a long screw. The end connection row 6 comprises an overall positive connection row 4 and an overall negative connection row 4 of identical construction.
As shown in fig. 6, the upper and lower edges of the side plate 10 are provided with bent structures 19, and the front and rear ends of the side plate 10 are provided with bent portions 20.
The battery cell 11 selects 3.2V 206Ah lithium iron phosphate square battery monomer, and adopts a grouping mode of 1 parallel to 8 strings (1P 8S). The large module and the integrated design are beneficial to improving the grouping efficiency of the modules, reducing the weight of structural members shared by each battery cell 11 and improving the overall energy density of the system; the number of accessory accessories is reduced from the system level, and the manufacturing cost is reduced.
TABLE 1 Battery cell parameters
The side plates 10, the end plates 8, and the bottom plate 9 may be made of 3003(H12) aluminum alloy. As the light material which is most applied at present, the aluminum alloy has mature related technologies: good mechanical properties; light weight (about 1/3 for steel density); the processing is easy; the heat conductivity and the corrosion resistance are good; the strength is high; good energy absorption performance; the surface treatment is easier, the aesthetic degree is higher, and the coloring can be realized by adopting an electrophoresis process. The edge of the end plate 8 is thinned, so that the end surface of the end plate 8 and the side plate 10 after being jointed is flat, and the size is not increased additionally. The side plates 10 are connected to the end plates 8 by rivets 16.
As shown in FIG. 7, for easy manual assembly and disassembly, the bus bar support 7 has fixing grooves 21 at both side edges thereof for being caught by catching grooves 22 at the upper edges of the side plates 10. In addition, the two sides of the upper outer cover 2 are connected with the side plates 10 through the outer buckles 24, so that the upper outer cover 2 is convenient to mount and dismount while the connection is firm.
As shown in fig. 4-5, protruding spacers 18 are disposed on the surfaces of the side insulating plates 15 and the bottom insulating plate to clamp the battery cell 11, so as to better fix the battery cell 11 and limit the battery cell 11 from moving back and forth. The folded structures 19 at the upper and lower edges of the side plate 10 clamp the stacked battery cell 11 and the insulating plate to prevent the battery cell from being vertically staggered; the bending parts 20 at the front end and the rear end clamp the battery cell 11 and the end plate 8; in addition, after the edge of the bus bar and the upper edge of the side plate 10 are clamped with each other, the limitation of the movement freedom of the battery cell 11 is completed.
The battery module upper outer cover 2, the bus bar support 7, the total positive outer cover 1 and the total negative outer cover 3 are made of PC-ABS materials, round corners 27 are formed on parts, and the phenomenon of uneven shrinkage during processing is avoided. The bottom surface insulating plate 13, the side surface insulating plate 15 and the end surface insulating plate 14 on the periphery of the battery cell 11 are made of PC-ABS plastic plates for insulation. As modified engineering plastics, PC-ABS combines the mechanical property, impact resistance and temperature resistance of PC and the formability of ABS materials, has better comprehensive performance, and is widely used for structural members such as battery supports, frames and the like.
As shown in fig. 8, the bus bar support 7 is further provided with a wire clip 25 and a ring structure 26, and the distance between two adjacent wire clips 25 is less than 8cm, so that the wiring harness can be effectively prevented from being warped when the wiring harness is moved. The bus bar output is secured to the ring structure 26 by a tie. The sampling wire harness is positioned above the module and can extend by 5-10cm, so that the wire harness is convenient to connect. For fixing the sampling lines to the connection row 4 between the cells 11, a plating process may be performed on the connection row 4, and after welding, a spot sealing adhesive (forming a hermetic condition, blocking electrochemical corrosion) may be used. The total positive connection row 4 and the total negative connection row 4 can also be plated, after welding, with spot sealing (forming a hermetic condition, blocking electrochemical corrosion).
As shown in fig. 8, the connection row 4 between the electric cores 11 is made of soft aluminum bars (tin plating), and has light weight and low tolerance requirement during manufacturing. The cross-sectional area of the connecting row 4 is 34mm x 3mm to ensure an excess flow, low temperature rise. As shown in fig. 10, the total positive connection row 4 and the total negative connection row 4 are provided with a transit bolt 28, and the corners are rounded 27 to prevent point discharge. As shown in fig. 9 and 11, the connecting bar 4 and the end connecting bar 6 are positioned by the surface protrusion structure 29 on the bus bar support 7 at the time of mounting. In addition, as for the end connection bar 6, it is shown that the support structure 30 on the busbar support 7 and the square structure of the head of the fastening bolt 5 provide support for the end connection bar 6 so that it is not easily deformed when subjected to vertical pressure. The positive pole and the negative pole 31 are positioned above the bus bar support 7 and are connected conveniently by using an M8 screw.
The basic version that this embodiment was designed as lithium ion battery module for electric fork-lift, to ordinary market demand, the sexual valence relative altitude. The bill of materials is shown in Table 2.
Table 2 bill of materials for example 1 of the invention
| Serial number | Component part | Number of | Material of | Yield strength (MPa) | Tensile strength (MPa) |
| 1 | Total positive |
1 | PC-ABS | - | 40 |
| 2 | Upper |
1 | PC-ABS | - | 40 |
| 3 | Total negative |
1 | PC-ABS | - | 40 |
| 4 | |
7 | 3003(H12) aluminium alloy (tinned) | 125 | 130 |
| 5 | |
2 | 3003(H12) aluminium alloy (tinned) | 125 | 130 |
| 7 | |
1 | PC-ABS | - | 40 |
| 6 | |
1 | 3003(H12) aluminium alloy (tinned) | 125 | 130 |
| 8 | |
2 | 3003(H12) aluminum alloy | 125 | 130 |
| 9 | |
1 | 3003(H12) aluminum alloy | 125 | 130 |
| 10 | |
2 | 3003(H12) aluminum alloy | 125 | 130 |
| 11 | |
8 | EFP54175200 | - | - |
| 12 | |
7 | Heat insulation cotton | - | - |
| 13 | |
1 | PC-ABS | - | 40 |
| 14 | |
2 | PC-ABS | - | 40 |
| 15 | |
2 | PC-ABS | - | 40 |
| 16 | |
12 | Stainless steel, |
207 | 517 |
| 17 | |
4 | Stainless steel, |
207 | 517 |
Example 2
For realizing high structural strength, lightweight, high energy density of lithium ion battery module for electric fork-lift, do not weaken the radiating effect again simultaneously, designed this embodiment on embodiment 1's basis: 1) the structural design and the material of the end plate 8 are changed; 2) changing the material of the plastic parts, namely an upper outer cover 2, a total positive and negative insulating cover, a bus bar bracket 7, a bottom insulating plate 13, an end surface insulating plate 14 and a side surface insulating plate 15; 3) the structure of the side plate 10 is changed.
As shown in fig. 12, the end plate 8 is made of a carbon fiber composite material, which is different from example 1, and utilizes its excellent mechanical properties. The end plate 8 is a structure having the largest weight ratio of the module excluding the core 11, and generally occupies about 5% of the power battery pack, and therefore, is a member that is prioritized for light weight design. Compared with high-strength steel and aluminum alloy, the carbon fiber composite material has the advantages of low density, high strength, high temperature resistance, friction resistance, shock resistance and low thermal expansion coefficient, and has absolute advantages in impact resistance, sealing property and weight reduction. In the appearance structure, the heat dissipation grooves 32 which are arranged in a rectangular shape are added on the front surface of the end plate 8, so that the weight is reduced, and the heat dissipation is facilitated. The end plate 8 and the side plate 10 are connected together through rivets 16, and meanwhile, metal rings can be embedded in screw holes in the carbon fiber end plate 8 to fix the rivets 16.
Because the material of the end plate 8 is changed from metal 3003(H12) aluminum alloy to plastic material with relatively low heat conductivity coefficient, in order to ensure the whole heat dissipation performance, the materials of the upper outer cover 2, the total positive outer cover 1, the total negative outer cover 3, the bus bar support 7, the bottom surface insulating plate 13, the side surface insulating plate 15 and the end surface insulating plate 14 are changed from PC-ABS to thermoplastic heat-conducting insulating plastic TCP200-30-6A with higher heat conductivity coefficient, the heat conductivity can reach 3W/m/K which is 15 times of PC-ABS, and the density is only increased by 50 percent compared with PC-ABS.
The side plates 10 and the bottom plate 9 are made of aluminum alloy, so that the aluminum alloy is easy to machine and form, high-temperature corrosion resistant and good in heat transfer performance. To further reduce weight, an array of oval-shaped recesses 33 is added to the side plate 10, as shown in fig. 12, the recesses 33 may be 1mm deep. The side plates 10 and the end plates 8 are connected and fixed together through rivets 16.
The high-end version that this embodiment was designed as lithium ion battery module for electric fork-lift has more advanced technological level, improves structural strength, lightweight, high energy density once more, does not weaken the radiating effect simultaneously again. The bill of materials is shown in Table 3.
Table 3 bill of materials for example 2 of the invention
Example 3
As shown in fig. 13 to 16, the lithium ion power supply box for an electric forklift according to the present invention includes a box body 34, a high voltage box 35 and a BMS are provided in the box body 34, and further includes a lithium ion battery module 38 for an electric forklift of embodiment 1 or 2. The battery modules 38 are arranged in 6 groups and symmetrically arranged on the left side and the right side; the connection mode is 2-to-3 series, the modules on the same side are connected in series, and the modules on two sides are connected in parallel.
The box 34 can be 1127mm long, 669mm wide and 686mm high, made of Q235a carbon steel, 176mm thick at the bottom, 16mm thick at the periphery and 5mm thick at the cover plate. In order to increase the weight, the bottom of the box body 34 is provided with a cavity, the interior of the box body is filled with steel plates and compacted to be used as the weight, the thickness of the bottom of the box body 34 is more than 10 times of the thickness of the side plates, and the thickness of the bottom of the box body 34 is more than 20 times of the thickness of the cover plate. The box 34 is divided into an upper layer and a lower layer by a left 5mm clapboard 41 and a right 5mm clapboard 41, and the clapboards 41 are steel plates fixed by screws. The battery module 38 is placed to the lower floor, and high-voltage box 35 and BMS are placed to the upper floor, and the BMS includes 1 master control BMS36 and 2 slave control BMS 37. Further, a case cover 39 is provided on the case 34. The box cover 39 is provided with a charging and discharging interface and a communication interface, and is provided with a PUW-EPTFE exhaust valve 50, and the box cover 39 is fixedly connected with the box body 34 through screws. The surface of the box body 34 is not provided with holes, so that dust particles can not enter the battery pack when the electric forklift works under the dust environment condition.
The mass of the lithium ion battery module 38 for the electric forklift in example 1 was 36.3kg, and the mass of the lithium ion battery module 38 for the electric forklift in example 2 was 35.9 kg. In addition, the high voltage box weighed 9.06kg, the master BMS weighed 0.84kg, and the two slave BMSs weighed 0.46kg, respectively. The weight of the box body 34 of the lithium ion battery module 38 for the electric forklift in the embodiment 1 can be controlled to be 1149kg-1294kg by adjusting the weight of the counterweight at the bottom of the lithium ion power box for the electric forklift; the weight of the case 34 using the lithium ion battery module 38 for an electric forklift in example 2 can be controlled to 1151kg to 1296 kg. The total weight of the system is 1378kg to 1522kg, and the energy density of the lithium ion power box for the electric forklift is improved through lightweight design.
The top ends of the left side and the right side of the box body 34 are respectively provided with two hoisting holes 40 for hoisting.
By optimizing the structure of the lithium ion battery module 38 for the electric forklift, the structure of the box body 34 and the internal layout, the temperature of the battery cell 11 in the box body 34 can be maintained in an ideal working temperature range (the highest temperature of the battery cell 11 basically does not exceed 55 ℃) under the natural heat dissipation condition, and the temperature uniformity among the battery cells 11 is higher (the temperature difference delta T is less than or equal to 5 ℃).
As shown in fig. 17-18, a first relay 42, a second relay 43, a third relay 44, a pre-charge relay 45, a pre-charge resistor 46, a first fuse 47, a second fuse 48, and a current sensor 49 are disposed in the high-voltage box 35, one path of the first fuse 47 is connected to the first relay 42, the other end of the first relay 42 is connected to the positive electrode of the battery module 38, the other path of the first fuse 47 is connected to the pre-charge relay 45, the other end of the pre-charge relay 45 is connected to the pre-charge resistor 46, and the other end of the pre-charge resistor 46 is connected to the positive electrode; the second fuse 48 is connected with the second relay 43, and the other end of the second relay 43 is connected with the positive electrode of the battery module 38; the current sensor 49 is connected to the third relay 44, and the third relay 44 is connected to the negative electrode of the battery module 38.
The other end of the first fuse 47 is used as a fast charging anode, the other end of the second fuse 48 is used as an output anode, one path of the other end of the current sensor 49 is used as a fast charging cathode, and the other path is used as an output cathode.
The model of the second relay 43 can be EVR250-12V, the model of the first relay 42 and the third relay 44 can be EVR400-12V, the model of the pre-charging relay 45 can be EVR10-12V, the model of the pre-charging resistor 46 can be RXG24-100W, and the model of the first fuse 47 and the second fuse 48 can be RS308-HB-3N 350A. Adopt braided strap copper flexible coupling, its advantage includes that the compliance is good, easily dispel the heat, resistant crooked, the electric conductivity is strong, and simple to operate. The joint adopts a copper braided wire or a copper stranded wire as a conductor, and the joint of the two ends is sleeved and compacted by a copper pipe.
Example 4
In order to verify the design concept of the invention, numerical simulation including thermal fluid simulation and structural simulation is performed to verify the performance of the designed module and the battery pack in the aspects of heat dissipation and structure. The thermal fluid simulation comprises the electrochemical thermal simulation of a battery cell 11, the thermal simulation of a lithium ion battery module for the electric forklift and the thermal simulation of a lithium ion power supply box for the electric forklift; the structural simulation includes static analysis, modal analysis, random vibration and fatigue analysis and drop analysis of the lithium ion battery module for the electric forklift, and static analysis, modal analysis, random vibration and fatigue analysis, mechanical impact and simulation collision analysis of the lithium ion power supply box structure for the electric forklift.
By performing electrochemical simulation on the battery cell 11, the heat released by the battery cell 11 during charging and discharging can be calculated, the heat is represented as a function changing along with time, and then the function is led into a thermal model of the lithium ion battery module for the electric forklift and is used as a heat source item in the model, so that the thermal behavior of the lithium ion battery module for the electric forklift is simulated. For the 206Ah square LFP electric core 11 used in this embodiment, fig. 19 shows the charge-discharge curve simulation result of the electric core 11 under different multiplying powers, which is well matched with the experimental data, and the maximum relative error does not exceed 3%, so as to verify the accuracy of the model simulation result. From this calculation of the electrochemical model of the battery cell 11, fig. 20 illustrates the temperature distribution and the heat generation amount of the battery cell 11 when discharged at different rates at an ambient temperature of 25 ℃.
The simulation data of the heat generation amount of the battery Cell 11 is imported into a thermal model of the lithium ion battery module for the electric forklift, the thermal simulation of the lithium ion battery module for the electric forklift is carried out, and the battery Cell 11 in the lithium ion battery module for the electric forklift is numbered from left to right from Cell 1 to Cell 8. Simulation verification proves that when the CFRP end plate 8 is adopted to realize light weight design, the thermal conductivity of CFRP is lower than that of aluminum alloy, but TCP200-30-6A (with the thermal conductivity of 3W/m/K) with high thermal conductivity is used as a plastic part material to replace PC-ABS (with the thermal conductivity of 0.21W/m/K), so that good heat dissipation performance of the lithium ion battery module for the electric forklift in the embodiment 2 is ensured. Taking 1C discharge at 25 ℃ as an example, as shown in fig. 21, in example 1 and example 2, the temperature difference between the cells 11 in both the cross section and the longitudinal section was less than 3 ℃, and good temperature uniformity was achieved. In addition, when thermal runaway occurs, the heat dissipation effect of example 2 is superior to that of example 1. After the battery module was discharged at 25 ℃ for 10 minutes at 1C, thermal runaway occurred in Cell 1 and Cell 6, and discharge was maintained for 1 hour, assuming that the heat generation rate was increased by a factor of 10, as shown in FIG. 22, cross section T of example 1max115 ℃ longitudinal section TmaxThe temperature is 115 ℃; example 2 cross section TmaxLongitudinal section T at 108 ℃ max112 ℃. The maximum temperature on the cross section of the comparative cell 11, example 2, 7 ℃ lower than example 1; comparing the maximum temperature at the longitudinal interface,example 2 was 3 ℃ lower than example 1.
Table 4 compares the temperature distribution simulation results of lithium ion battery modules for different electric forklifts under thermal runaway:
JC 1: the metal plate is made of Q235, and the plastic part is PC/ABS;
JC2 (example 1): namely, the metal plate is 3003(H12) aluminum, and the plastic part is PC/ABS;
GD 1: the end plate 8 is made of carbon fiber composite material CFRP, the metal plate is made of 3003(H12) aluminum, and the plastic part is made of PC/ABS;
GD2 (example 2): the end plate 8 is made of carbon fiber composite material CFRP, the metal plate is made of 3003(H12) aluminum, and the plastic component is TCP 200-30-6A.
By contrast, when the battery cell 11 is thermally runaway, the surface temperature of the battery cell 11 of the GD2 is the lowest, and the heat dissipation effect is the best.
Table 4 temperature distribution simulation results of lithium ion battery modules for different electric forklifts under thermal runaway
In table 4, 8 cells 11 in the lithium ion battery module for an electric forklift are numbered Cell 1 to Cell 8, where Cell 1 and Cell 6 are set to be thermally runaway. The ambient temperature was 25 ℃. Example 5
By adopting the lithium ion battery module for the electric forklift in the embodiment 1, the thermal simulation result of 1C discharge of the lithium ion power box for the electric forklift at different environmental temperatures is as follows:
1) as shown in fig. 23, the maximum temperature inside the module is 38.7 ℃ and the maximum temperature difference Δ T between the battery cells 11 is less than or equal to 5 ℃ in an environment of 25 ℃;
2) under the environment of 40 ℃, the highest temperature in the module is 53.7 ℃, and the maximum temperature difference delta T between the battery cores 11 is less than or equal to 5 ℃;
3) under the environment of 45 ℃, the highest temperature in the module is 56.1 ℃, and the maximum temperature difference delta T between the battery cores 11 is less than or equal to 5 ℃;
4) under the environment of-10 ℃, the highest temperature in the module is 8.2 ℃, and the maximum temperature difference delta T between the battery cores 11 is less than or equal to 7 ℃.
The thermal simulation result of the charging of the lithium ion power box for the electric forklift at 25 ℃ is as follows:
1)1C charging, wherein the highest temperature in the module is 39.2 ℃, and the maximum temperature difference delta T between the battery cores 11 is less than or equal to 5 ℃;
2) charging at 0.5 ℃, wherein the highest temperature in the module is 32.3 ℃, and the maximum temperature difference delta T between the battery cores 11 is less than or equal to ℃.
The thermal simulation results verify that the highest temperature of the battery cell 11 in the lithium ion battery module for the electric forklift is basically not more than 55 ℃ under the natural cooling condition, the temperature uniformity of the battery cell 11 is good within the acceptable range of the working temperature of the battery cell 11, and the temperature difference delta T is not more than 5 ℃. On the other hand, as shown in fig. 24, when thermal runaway occurs, the thermal insulating sheet 12 between the battery cells 11 can effectively block heat transfer between the battery cells 11 and reduce the influence of the runaway battery cell 11 on the temperature of the surrounding battery cells 11.
In addition to the above thermal simulation, structural simulation analysis was also performed to verify the structural reliability and safety of the present invention. The structure simulation is divided into two parts of a lithium ion power box for the electric forklift and a lithium ion battery module for the electric forklift.
Statics analysis: statics analysis is mainly used to solve for time-independent or time-effect-negligible load responses. Static load analysis is generally used for evaluating the structural rigidity of the battery system, and the maximum deformation of the battery system cannot exceed 1mm and 3mm under the acceleration of 1g and 3 g. The stress condition of the battery box under the normal vertical bumping condition is the worst. Therefore, in this embodiment, the vertical acceleration of 3g is applied to the entire battery box. As shown in fig. 25, the lithium ion power supply box for an electric forklift has a maximum deformation amount of 0.2mm under a vertical acceleration acting force of 3g, and meets the requirement. As shown in fig. 26, when a vertical acceleration of 3g was applied alone to the lithium ion battery module for an electric forklift, the deformation amounts of examples 1 and 2 were much less than 1mm, and both satisfied the requirements.
And (3) modal analysis: the mode is a natural vibration characteristic of the battery system. The purpose of modal analysis is to obtain the natural frequency of the battery box structure, and if the natural frequency of the structure is close to the frequency of the fixed-frequency vibration test, the structure needs to be improved. The natural frequency of the structure is changed by modifying the structure, so that the main resonance frequency of the structure is prevented from falling within the frequency range of the random vibration high-excitation load. When designing a battery system, the first-order natural frequency and the first-order vibration frequency of the system should be increased as much as possible. The first order frequency requirement of the GM for the battery system is greater than 30 Hz. Table 5 shows the modal analysis results of the lithium ion power supply box for the electric forklift and the lithium ion battery module for the electric forklift, and the first-order natural frequency is higher than 30Hz, so that the requirements are met.
TABLE 5 Battery pack and Module Modal frequency
Random vibration and fatigue analysis: the acceleration spectrum parameters specified by the national standard, namely table 6, are used as the load working conditions to simulate that the battery system undergoes random vibration due to uneven road surfaces when the automobile runs. Based on the lithium ion power supply box for an electric forklift in example 1, random vibration analysis was performed on the Pack model in three directions. Fig. 27 shows the distribution of the 1 σ stress when vibrating in three directions. According to table 7, the maximum 3 σ stress in all three directions does not exceed the material yield strength, meeting the vibration fatigue design requirements. Similarly, the maximum 3 sigma stress values of the lithium ion battery modules for the two electric forklifts in the three directions are less than 60MPa and lower than the yield strength of the material, so that the design requirements of vibration fatigue are met.
TABLE 6 random vibration power spectrum
TABLE 7 maximum stress and maximum displacement under random vibration of lithium ion power supply box for electric forklift
According to the national standard, the testing time of the random vibration test in each direction is 21h, which is equivalent to the quality assurance requirement that the battery system can be ensured for at least 8 years or more than 20 km. And analyzing the fatigue damage value of the battery box at the moment, combining the analysis result of the vibration CAE of the battery pack, the S-N (stress-life curve) of the battery box material and the service life of the battery pack structure under the stress of 1 sigma, 2 sigma and 3 sigma, calculating the fatigue accumulation damage coefficient of the structure according to Miner' S Rule, wherein the damage coefficient is less than 1, which indicates that the structure meets the requirement under the load excitation. The damage coefficient of the lithium ion power supply box for the electric forklift vibrating randomly along the Z axis is shown in fig. 28, except for a fixed point of a main control BMS fixed foot, the damage value of the box body 34 mechanism is less than 1; in addition, the damage value of the lithium ion power supply box for the electric forklift after vibration along the X axis and the Y axis is less than 1.
And (3) simulating collision analysis: with reference to the standard GB/T31467.3-2015-7.5, an acceleration load as specified in table 8 is applied to a lithium ion power supply box for an electric forklift, where the driving direction of the vehicle is defined as the X-axis and the other horizontal direction perpendicular to the driving direction is defined as the Y-axis. The electric fork-lift truck considered in this embodiment weighs between 3.5 and 7 tons. The simulation result is shown in fig. 29, for two groups of pulse width loads ABCD and EFGH, except that the bottom of one fastening long bolt has stress concentration points (229MPa and 396MPa), the stress of other parts in the lithium ion power supply box for the electric forklift is far lower than the yield strength of the material, and the requirements are met.
TABLE 8 simulated Collision parameter Table
Mechanical shock analysis: with reference to the standard GB/T31467.3-2015-7.2, a half-sine impact waveform of 25g and 15ms is applied to a lithium ion power supply box for the electric forklift, and the impact is carried out for 3 times in the Z-axis direction. According to the simulation result, the maximum stress 288MPa appears at one vertex of the fixed foot of the master control BMS, and the stress at other positions in the lithium ion power supply box for the electric forklift is smaller than the yield strength of the material, as shown in FIG. 30, the maximum deformation is 2.76mm, and the requirement is met on the whole.
Drop analysis:
according to the national standard GB/T31485-2015-6.3.5, the lithium ion battery module for the electric forklift freely falls onto the cement ground from the height of 1.2m in a posture that the positive and negative terminals face downwards. As shown in fig. 31, the maximum value of stress of embodiment 1 occurs at the sharp corner of the side plate 10; the maximum stress of example 2 is relatively small, and the maximum deformation amount of both is about 1 mm.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, but rather the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. The utility model provides a lithium ion battery module for electric fork-lift, its characterized in that: the battery pack comprises a housing and a battery pack in the housing, wherein the battery pack comprises battery cells (11), heat insulation sheets (12) between the battery cells (11), bottom surface insulation plates (13) on the periphery of the battery cells (11), side surface insulation plates (15), end surface insulation plates (14) and a busbar support (7) at the top, the battery cells (11) are square lithium iron phosphate batteries, a grouping mode of 1-8 strings is adopted, protruding spacers (18) are arranged on the surfaces of the side surface insulation plates (15) and the bottom surface insulation plates (13), and a connecting bar (4) and an end connecting bar (6) between the battery cells (11) are arranged on the busbar support (7).
2. The lithium ion battery module for an electric forklift according to claim 1, characterized in that: the heat insulation sheet (12) is soft polyethylene foam, and the bottom surface insulation plate (13), the side surface insulation plate (15) and the end surface insulation plate (14) are made of PC-ABS plastic plates.
3. The lithium ion battery module for an electric forklift according to claim 1, characterized in that: the shell comprises an end plate (8), a bottom plate (9), a side plate (10) and an upper outer cover (2), wherein the upper edge and the lower edge of the side plate (10) are provided with bending structures (19), and the front end and the rear end of the side plate (10) are provided with bending parts (20); a fixed groove (21) is formed in the edge of the busbar support (7), a clamping groove (22) matched with the fixed groove (21) is formed in the upper edge of the side plate (10), outer clamping grooves (23) are formed in two sides of the upper outer cover (2), and an outer buckle (24) matched with the outer clamping grooves (23) is formed in the upper edge of the side plate (10); the busbar support (7) is also provided with a wire clip (25) and an annular structure (26).
4. The lithium ion battery module for an electric forklift according to claim 1, characterized in that: four corners of the connecting row (4) between the electric cores (11) and the end connecting row (6) are fillets (27).
5. The lithium ion battery module for an electric forklift according to claim 3, characterized in that: the front surface of the end plate (8) is provided with a heat dissipation groove (32), the side plate (10) is provided with an oval groove (33), the end plate (8) is made of carbon fiber composite materials, and the bottom surface insulating plate (13), the side surface insulating plate (15) and the end surface insulating plate (14) are made of thermoplastic heat-conducting insulating plastics TCP 200-30-6A.
6. The lithium ion battery module for an electric forklift according to claim 3, characterized in that: go up to be provided with total positive enclosing cover (1) and total negative enclosing cover (3) on enclosing cover (2), end run-on (6) are located total positive enclosing cover (1) and total negative enclosing cover (3) below respectively including total positive terminal run-on and total negative terminal run-on.
7. The utility model provides a lithium ion power supply box for electric fork-lift, its characterized in that: the lithium ion battery module comprises a box body (34), wherein a high-pressure box (35), a BMS and the lithium ion battery module (38) for the electric forklift as claimed in any one of claims 1 to 5 are arranged in the box body (34), a box cover (39) is arranged on the box body (34), and an exhaust valve (50) is arranged on the box cover (39).
8. The lithium ion power supply box for an electric forklift according to claim 8, characterized in that: the lithium ion battery modules (38) for the electric forklift are arranged into 6 groups, and the two sides of the lithium ion battery modules are symmetrically arranged; the connection mode is 2-to-3 series, the modules on the same side are connected in series, and the modules on two sides are connected in parallel.
9. The lithium ion power supply box for an electric forklift according to claim 9, characterized in that: a first relay (42), a second relay (43), a third relay (44), a pre-charging relay (45), a pre-charging resistor (46), a first fuse (47), a second fuse (48) and a current sensor (49) are arranged in the high-voltage box (35), one path of the first fuse (47) is connected with the first relay (42), the other end of the first relay (42) is connected with the anode of the battery module (38), the other path of the first fuse (47) is connected with the pre-charging relay (45), the other end of the pre-charging relay (45) is connected with the pre-charging resistor (46), and the other end of the pre-charging resistor (46) is connected with the anode of the battery module (38); the second fuse (48) is connected with the second relay (43), and the other end of the second relay (43) is connected with the positive electrode of the battery module (38); the current sensor (49) is connected with the third relay (44), and the third relay (44) is connected with the negative electrode of the battery module (38).
10. The lithium ion power supply box for an electric forklift according to claim 9, characterized in that: the left side and the right side of the middle part in the box body (34) are respectively provided with a partition plate (41), the battery module (38) is placed on the lower layer of the partition plate (41), the high-voltage box (35) and the BMS are placed on the upper layer of the partition plate, a cavity is arranged at the bottom of the box body (34), the thickness of the bottom of the box body (34) is larger than 10 times of the thickness of a side plate, and the thickness of the bottom of the box body (.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/CN2019/111812 WO2021072726A1 (en) | 2019-10-18 | 2019-10-18 | Lithium ion battery module for electric forklift truck, and power supply box |
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| CN112585807A true CN112585807A (en) | 2021-03-30 |
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| WO (1) | WO2021072726A1 (en) |
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| CN114436174A (en) * | 2022-04-11 | 2022-05-06 | 杭叉集团股份有限公司 | Framework forward-moving type forklift special for lithium battery |
| WO2022227774A1 (en) * | 2021-04-30 | 2022-11-03 | 宁德时代新能源科技股份有限公司 | Battery and electric device |
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| CN113471589A (en) * | 2021-06-30 | 2021-10-01 | 东莞新能安科技有限公司 | Battery package and consumer |
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| WO2024032641A1 (en) * | 2022-08-09 | 2024-02-15 | 天津市捷威动力工业有限公司 | Battery module and battery pack |
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| CN117525756A (en) * | 2024-01-04 | 2024-02-06 | 上海聚信海聚新能源科技有限公司 | Busbar welding support and battery pack with same |
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| WO2021072726A1 (en) | 2021-04-22 |
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