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Preface: A flaw detector is a portable industrial non-destructive testing instrument that can quickly, conveniently, without damage, and accurately detect, locate, evaluate, and diagnose various internal defects (welds, cracks, inclusions, folds, pores, sand holes, etc.) in workpieces. It can be used not only in laboratories but also in engineering sites. Instruments can be widely used in manufacturing, steel metallurgy, metal processing, chemical industry and other fields that require defect detection and quality control. They are also widely used in in-service safety inspections and life assessments in special aerospace, railway transportation, boilers and pressure vessels, and other fields. They are essential for the non-destructive testing industry. Portable flaw detectors have become an important tool for on-site testing in modern society, and providing efficient, portable, lightweight, and sufficient backup power solutions for portable flaw detectors is an important guarantee for testers to carry out long-term on-site work. The 18650 lithium battery pack has become the preferred backup power solution for such high-tech testing instruments due to its unique advantages.

design requirement

1、 Design requirements for backup lithium batteries for flaw detectors:

Due to the high voltage and long working time of the flaw detector, the quality of the equipment itself and the continuous stability of the power supply are particularly crucial. This requires that its power supply must be achieved through multiple series parallel combinations of large capacity individual lithium batteries; During the operation of the flaw detector, a large amount of valuable data needs to be continuously saved. Therefore, it is necessary to provide an accurate battery level display and alarm system to remind users to save the data in a timely manner, in order to improve the effectiveness of the work. The backup lithium battery solution of this flaw detector adopts an intelligent chip. The host continuously reads the battery level and related important data in the intelligent chip through I2C communication, and monitors the battery at all times to remind users to perform relevant operations in a reasonable and timely manner. The Sanyo battery cells integrated in our company's solution have advantages such as high energy ratio, light weight, small volume, high cycle life, high safety, high voltage, and good consistency. The lithium battery pack is designed to output an overcurrent protection value of 12A, a continuous working current of 7A, and a charging capacity of 5000mAh, fully meeting the electrical needs of the instrument. The specific design requirements parameters are as follows:

1) Design requirements for lithium battery pack models: 18650-3S2P/5000mAh/1.1V.

2) Circuit design requirements:

1. Single section overcharge protection voltage: 4.35± 0.25V

2. Single section overcharge recovery voltage: 4.15± 0.50V

3. Single section over discharge protection voltage: 2.40± 0.08V

4. Single section over discharge recovery voltage: 3.00± 0.10V

5. Combination battery overcurrent protection value (10ms): 30-35A

6. Combination battery over temperature protection value (recoverable): 70± 5 ℃

7. The finished battery also has short-circuit and reverse charging protection.

3) Battery cycle life design requirements: 300-500 cycles (national standard for charging and discharging)

4) Design requirements for battery external dimensions: refer to the battery casing

2、 Design scheme for backup lithium battery of flaw detector:

1) Intelligent Battery Meter Protection Board (PCM): Using the SBS intelligent battery management system, advanced battery calculation principles are used to accurately calculate the battery's power, and the battery's power information is reported to the host through SMBUS. At the same time, functional protection is provided to the rechargeable intelligent battery pack. Due to the chemical characteristics of lithium batteries, they need to provide protection functions such as overcharging, over discharging, short circuit, overcurrent, and over temperature to avoid combustion, explosion, and other hazards.

2) 18650 lithium-ion cell/18650/2500mAh/3.7V lithium-ion cell (SANYO).

3) Temperature switch: mainly designed for temperature protection function. When the temperature of the battery itself reaches 70&plusmn due to other abnormal issues; At a temperature range of 5 ℃, the temperature switch is activated for temperature protection.

4) Field Effect Transistor (MOSFET): A MOSFET transistor that plays a switching role in a protective circuit, always ensuring that the voltage at both ends of the load does not increase or decrease, ensuring voltage stability.

5) Battery pack packaging (shell)

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