Intelligent Battery Solution for Rail Transit Inspection Instruments

Due to the rapid development of lithium batteries in recent years, many portable products utilize voltage measurements to estimate the remaining battery charge, but the relationship between battery voltage and remaining charge changes with discharge rate, temperature, and battery aging, and the error rate can be up to 50% using this method. As the market demand for products that last longer continues to grow, more accurate solutions are needed in design. The use of intelligent power detection meter IC to measure the amount of power charged or consumed by the battery will be able to provide a more accurate estimate of battery capacity over a wide range of application power levels.

I. Design Requirements for Testing Instrument Smart Battery:
According to the customer's requirements and specifications, the design of intelligent battery packs with the host, the intelligent power meter with communication protocol (SBS communication protocol) and battery safety and protection performance integrated into your solution can be achieved with the battery pack and the host information sharing, to achieve a reasonable, efficient and safe battery management program.

Specific design parameters required under:

1) Cell modeling requirements: using imported Sanyo cell combination (18650-4S4P/8.8Ah/14.8V).
2) Structure design requirements: exquisite appearance, the overall battery to achieve waterproof, shockproof requirements. In terms of appearance design, it adopts high-grade aluminum alloy shell + aviation waterproof plug.
3) Circuit design requirements: precise power management + precise LED power display. Adopt SBS intelligent battery management system design program to effectively manage the remaining battery power at all times. Accurate LED power display, the battery's remaining power at all times effectively according to the precise percentage of the LED light to show the user, in order to achieve efficient and intuitive purpose.

Second, the testing instrument intelligent battery design program:

(1) Aluminum alloy shell and aluminum parts bracket: according to customer requirements to design exquisite aluminum alloy shell, and to meet the waterproof and shockproof requirements, as well as a good heat dissipation requirements under high-current operation.
(2) Intelligent power meter protection board (PCM): SBS intelligent battery management system, the use of advanced power calculation principle of accurate time to time calculation of the battery's power, and through the SMBUS time to time to report the battery power information to the host computer, and at the same time to the rechargeable intelligent battery pack (generally referred to as lithium batteries) to protect the function of the lithium batteries themselves due to the chemical characteristics of lithium batteries, the need to provide over-charging, over-discharging, short-circuit, Over-current and over-temperature protection functions, in order to avoid causing combustion, explosion and other dangers.
(3) LED power display board: LED power display lamp according to the 20% power ratio, the intelligent power meter protection board will calculate the battery capacity intuitively displayed, in order to efficiently and intuitively convenient for customers to use.
(4) overcurrent protection chip (PTC): mainly for the secondary protection function design. ptc restorable fuse with overcurrent protection, automatic recovery dual function. The PTC in battery products can prevent the battery from high temperature discharge and unsafe high current.
5) UR18650-4S4P/10Ah/14.8V lithium cell battery pack (SANYO).
6) Specialized vacuum waterproof aviation plug: the battery is connected externally with vacuum waterproof to meet the waterproof requirement of customers.