The portable juice cup's industrial control circuit board implements intelligent overcharge and over-discharge protection through the coordinated control of hardware circuit design and software algorithms. This multi-layered protection system combines a lithium battery protection chip, a voltage detection module, and a power management unit. Its core logic monitors battery voltage in real time and quickly shuts off the charge and discharge circuits in abnormal conditions. A delay mechanism prevents false triggering, ensuring battery life and device safety.
At the hardware level, the circuit board, centered around a lithium battery protection chip, integrates triple protection features for overcharge, over-discharge, and overcurrent. During charging, the protection chip continuously monitors the voltage. If the voltage exceeds a threshold (e.g., 4.25V), it immediately controls the power MOSFET to disconnect the charging circuit, preventing overcharge-induced battery expansion or electrolyte decomposition. During discharge, if the voltage falls below a safe level (e.g., 2.3V), the chip similarly disconnects the discharge circuit to prevent over-discharge-induced battery capacity degradation. Furthermore, the circuit board is equipped with an independent voltage detection module that collects battery voltage in real time via a voltage divider resistor network and transmits the data to the main control MCU, creating dual redundancy for hardware protection and software monitoring.
The software algorithm dynamically manages battery status through the main control MCU. The MCU periodically reads data from the voltage detection module and, combined with the charge status flag, determines the current operating condition. If overcharge or over-discharge conditions are detected, the MCU not only triggers the hardware protection circuitry but also issues an alarm via an LED indicator or buzzer, prompting the user to take prompt action. Furthermore, the software algorithm incorporates a delay mechanism; for example, overcharge detection requires a certain period of time before triggering the protection function to prevent false triggering due to voltage fluctuations. After the protection function is activated, the MCU continuously monitors the battery voltage and automatically releases the protection function when it returns to a safe range, resuming normal device operation.
The design of the power management unit is crucial to the stability of the protection function. The circuit board uses a low-dropout linear regulator (LDO) to power the MCU, ensuring a stable 3.3V operating voltage even when the battery voltage fluctuates, preventing protection logic failure due to power supply anomalies. Furthermore, the charging circuit utilizes a constant-current-constant-voltage (CC-CV) charging mode, initially charging rapidly with a constant current. Once the voltage approaches the threshold, it switches to constant-voltage mode to prevent overcharging caused by excessive voltage. Some high-end solutions also integrate temperature sensors, using NTC thermistors to monitor battery temperature and suspend charging in the event of overheating, further enhancing safety.
For the unique use case of portable juice cups, the circuit board also requires optimized low-power design. In standby mode, the MCU enters a low-power mode, disabling non-essential peripheral clocks and retaining only the periodic wake-up function of the voltage detection module, significantly reducing quiescent current consumption. Furthermore, the battery voltage detection utilizes high-impedance voltage divider resistors to reduce current leakage during standby mode, preventing battery over-discharge due to prolonged inactivity. These designs extend battery life while reducing the risk of false triggering of the protection circuitry.
During actual testing, the circuit board undergoes rigorous charge-discharge cycle testing to verify the reliability of the protection functions. These tests cover a variety of abnormal operating conditions, including overcharge, over-discharge, short circuit, and reverse connection, ensuring that both the hardware protection chip and the software algorithm can respond promptly. For example, during overcharge testing, when the battery voltage is forced above a threshold, the protection chip must disconnect the circuit within microseconds, while the MCU records the event and triggers an alarm. Overdischarge testing simulates a gradual drop in battery voltage below a safe value to verify whether the protection circuit can stop discharge before the voltage reaches the critical point.
The overcharge and overdischarge protection functions of the portable juice cup's industrial control circuit board require a coordinated implementation of precise hardware monitoring and rapid response, intelligent software algorithm decision-making and redundant design, and a stable power supply and low-power strategy from the power management unit. This system not only effectively extends battery life but also enhances device safety in complex operating environments, providing users with a reliable portable juice-making experience.
