CN106886003B - Automatic testing system and method for battery monitoring module of electric vehicle - Google Patents
Automatic testing system and method for battery monitoring module of electric vehicle Download PDFInfo
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- CN106886003B CN106886003B CN201710038703.7A CN201710038703A CN106886003B CN 106886003 B CN106886003 B CN 106886003B CN 201710038703 A CN201710038703 A CN 201710038703A CN 106886003 B CN106886003 B CN 106886003B
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Abstract
The invention relates to an automatic test system and method for a battery monitoring module of an electric vehicle. The control computer is used for sending out a control signal according to the test software setting program, acquiring data output by the to-be-tested battery monitoring module, analyzing the acquired data and outputting an analysis result. The control panel is used for controlling the total pressure analog circuit, the total current analog circuit and the single battery analog circuit to output preset signals according to the control signals so as to simulate power battery modules with various performances. The automatic testing system for the battery monitoring module of the electric vehicle can automatically complete all testing items of the battery monitoring module, has accurate testing results, accelerates the shipment speed of the battery monitoring module product, shortens the production period and saves the labor cost.
Description
Technical Field
The invention relates to an automatic testing system and method for a battery monitoring module of an electric vehicle.
Background
With the enhancement of the environmental protection attention of the country, the electric automobile is a necessary trend of the automobile industry development. The power battery system is used as a power source of the electric automobile, and the safety and the reliability of the power battery system determine the future development prospect of enterprises. In the battery management system, the battery monitoring module plays a role in lifting the weight, and the battery monitoring module is mainly used for detecting and monitoring various parameters of voltage, current, temperature and the like of the battery module. Only if various operation parameters of the power battery are accurately and reliably mastered, corresponding countermeasures can be timely made, and the safe operation of the battery system is ensured.
At present, the test of the battery monitoring module still stays in the manual operation stage. The tester needs to test the test in steps according to the steps of the technical specification. Some self-designed simple tools can be adopted in the test process, so that the test is convenient, for example, a pull switch can be used for pulling back and forth when the 70K resistor and the 30K resistor are required to be switched during the test. And the test data obtained by the test is also checked by utilizing the monitoring upper computer, and then the parameters are manually compared to judge the result. The drawbacks of this test method include: the testing steps are disordered and are easy to lose; manual monitoring judgment is easy to misjudge; data are not stored and cannot be traced back; the testing time is too long, and the efficiency is low.
Disclosure of Invention
The invention aims to provide an automatic testing system and method for an electric vehicle battery monitoring module, which can automatically perform complete testing operation on the battery monitoring module.
An automatic testing system for battery monitoring modules of electric vehicles comprises:
the total voltage simulation circuit is provided with a voltage source and is used for simulating the total voltage of a power battery module;
the total current simulation circuit is provided with a constant current source and is used for simulating the total current of the power battery module;
the single battery simulation circuit is provided with a plurality of virtual batteries and thermistors and is used for simulating a plurality of single batteries and temperature sensors of the power battery module;
the power supply circuit is used for simulating a power supply of the battery monitoring module to be tested and supplying power to each module of the automatic test system;
the control computer is used for sending out a control signal according to a test software setting program, acquiring data output by the to-be-tested battery monitoring module, analyzing the acquired data and outputting an analysis result;
the control board is used for controlling the total pressure analog circuit, the total current analog circuit and the single battery analog circuit to output preset signals according to the control signals so as to simulate the power battery module with various performances; and
the acquisition module is used for acquiring the total voltage, the total current, the single battery temperature and the single battery voltage information of the simulated power battery module and outputting the acquired information to the to-be-tested battery monitoring module;
the control board comprises a control circuit and a relay connected in series in the total pressure analog circuit, the total current analog circuit and the single battery analog circuit.
Preferably, the control computer is connected with the battery monitoring module to be tested through a CAN card interface compatible with a USB interface and a CAN bus interface.
Preferably, the total current analog circuit has a current divider for outputting different current signals.
An automatic testing method for an electric vehicle battery monitoring module comprises the following steps:
accessing the battery monitoring module to be tested into an automatic testing system, and inputting an engineering code corresponding to the battery monitoring module to be tested;
obtaining a preset baud rate, an SX flash file, a configuration file and inspection data according to the engineering code;
detecting the baud rate of the battery monitoring module to be tested;
when the preset baud rate is the same as that of the battery monitoring module to be tested, the obtained SX flash file and configuration file are put into a preset directory for use;
according to the SX flash file, programming in the to-be-tested battery monitoring module so that the to-be-tested battery monitoring module can normally work;
performing insulation test, relay test, external CAN communication test, terminal resistance test and data storage test on the battery monitoring module to be tested; and
and comparing the data output by the battery monitoring module to be tested with the inspection data when the test is executed, and generating and outputting a test result.
Preferably, the automatic testing method further includes performing a data display test on the battery monitoring module to be tested.
As an embodiment, the automatic testing method further includes performing a historical fault data reading test or a version reading test on the battery monitoring module to be tested.
Preferably, after the step of programming the program in the battery monitoring module to be tested, the following steps are first performed to ensure whether the battery monitoring module to be tested and the automatic test system can work normally:
the battery monitoring module to be tested performs read-write parameter operation according to the configuration file;
correcting data of the automatic test system, wherein the data comprises total current, internal total pressure and external total pressure; and
and monitoring data of the automatic test system, and determining whether each parameter is within a preset range.
The automatic testing system for the battery monitoring module of the electric vehicle can automatically complete all testing items of the battery monitoring module, has accurate testing results, accelerates the shipment speed of the battery monitoring module product, shortens the production period and saves the labor cost.
Drawings
Fig. 1 is a schematic structural diagram of an automatic testing system of an electric vehicle battery monitoring module according to an embodiment.
Detailed Description
The following describes an automatic testing system and method for an electric vehicle battery monitoring module according to the present invention in further detail with reference to the following embodiments and accompanying drawings.
The automatic test system is used for automatically testing the battery monitoring module of the electric automobile. The battery monitoring module to be tested belongs to a Battery Management System (BMS) of an electric vehicle, and is mainly used for detecting the total voltage and the total current of a power battery module connected with the battery monitoring module, the temperature of a plurality of points in the power battery module and the voltage of a single battery in the power battery module and making corresponding feedback according to the detection result.
The automatic testing system is used for simulating the power battery module connected to the to-be-tested battery monitoring module, and comparing the detected data of the simulated power battery module with the actually provided data according to the to-be-tested battery monitoring module to obtain a testing result. In this embodiment, the automatic test system mainly includes a total voltage analog circuit, a total current analog circuit, a single battery analog circuit, a power circuit, a control board, and a control computer, as shown in fig. 1.
The total voltage simulation circuit is used for simulating the total voltage of the power battery module and can output an expected voltage value to the battery monitoring module to be tested under the control of the control board. It will be appreciated that the total voltage simulation circuit includes at least one voltage source to provide a stable high voltage, for example 300V, and a plurality of voltage divider circuits to provide voltages of various values, with a plurality of switching transistors in the circuit to enable the output of the voltage to be controlled by the control board.
The total current simulation circuit is used for simulating the total current of the power battery module and can output an expected current value to the battery monitoring module to be tested under the control of the control board. It will be appreciated that the total current analog circuit includes at least one constant current source to provide a steady current, such as 300A, and a plurality of current dividers to provide various values of current, with a plurality of switching tubes in the circuit such that the output of the current is controlled by the control board.
The single battery simulation circuit is used for simulating a plurality of single batteries and can output a voltage (for example, 3.3V), a current signal (for example, 1000 mA) and a plurality of temperature signals to the battery monitoring module to be tested under the control of the control board. It will be appreciated that the cell simulation circuit may comprise a plurality of virtual batteries and a plurality of thermistors (NTCs), with a plurality of switching tubes in the circuit such that the output of the signals is controlled by the control board.
The power supply circuit is used for simulating a power supply of the battery monitoring module to be tested and supplying power to each module of the automatic test system. In this embodiment, the power supply circuit outputs a stable 12V voltage.
In addition, the battery monitoring module to be tested needs to acquire actual total voltage, total current, single battery temperature and single battery voltage information output by the total voltage analog circuit, the total current analog circuit and the single battery analog circuit through the acquisition module. In this embodiment, the collection modules are respectively distributed in the total voltage analog circuit, the total current analog circuit and the single battery analog circuit.
The control panel is used for controlling the total pressure analog circuit, the total current analog circuit and the single battery analog circuit to output preset signals according to control signals sent by the control computer so as to simulate the performance of the power battery module of the electric automobile. The control panel mainly comprises a relay and a control circuit which are connected in series in the total pressure analog circuit, the total current analog circuit and the single battery analog circuit, and the total pressure analog circuit, the total current analog circuit and the single battery analog circuit are controlled by the relay.
The control computer is a brain of the automatic testing system of the battery monitoring module of the electric automobile and is used for sending a control signal to the control panel according to a program set by built-in testing software, acquiring detection data output by the battery monitoring module to be tested from the battery monitoring module to be tested, analyzing the acquired detection data and outputting an analysis result. And when the acquired detection data are analyzed, comparing the detection data with the inspection data, and if the detection data are the same as the inspection data or within a certain range of the inspection data, determining that the battery monitoring module is qualified, otherwise, determining that the battery monitoring module is unqualified. The control computer is connected with the battery monitoring module to be tested through a CAN card interface compatible with a USB interface and a CAN bus interface, such as the CAN card interface with the model number of CAN _2E _ U, so as to obtain the detection data of the battery monitoring module. Specifically, the control computer is connected with a CAN card interface through a USB data line, and the CAN card interface is connected with a battery monitoring module to be tested through a CAN bus.
The automatic test system for the battery monitoring module of the electric automobile is in standard configuration and can test various types of battery monitoring modules. The battery monitoring module is typically formed as an independent circuit board that needs to be clamped to the mechanical console of the test system during the testing process. Each type of battery monitoring module has a unique engineering code.
The testing method of the automatic testing system of the battery monitoring module of the electric automobile comprises the following steps:
step 101, a battery monitoring module to be tested is accessed into an automatic testing system, and a corresponding engineering code is input into a control computer.
102, acquiring a preset baud rate, an SX flash file, a configuration file and inspection data which are pre-stored in a control computer according to the engineering code; the SX flash file is an application layer program of the battery monitoring module to be tested, and the battery monitoring module to be tested can be normally used only by flashing the SX flash file to the application layer of the battery monitoring module chip to be tested according to the bottom layer protocol. The configuration file records product parameters of the battery monitoring module to be tested, such as but not limited to, working temperature range, voltage measurement accuracy and the like. The test data is data which is actually provided for the simulated power battery module by the control computer and is used for comparing with the output data of the battery monitoring module to be tested so as to test the battery monitoring module to be tested.
And 103, detecting whether the bottom layer baud rate of the battery monitoring module to be tested is the same as the preset baud rate obtained in the step 102, if so, executing the next step, otherwise, outputting warning or prompt information.
And step 104, placing the obtained SX flash file and configuration file (ini file) into a specified directory under the control computer for use. After the step is executed, an operator can find the ini file, the SX flash file and the corresponding software and hardware version information under the appointed mainboard directory.
And 105, calling an SX flash file from the specified directory, and flashing the SX flash file in the battery monitoring module to be tested so that the battery monitoring module to be tested can be started normally.
And 106, calling the configuration file, reading the corresponding parameters by the battery monitoring module to be tested, and writing the parameters into the configuration file. Specifically, a configuration file (ini file) corresponding to the engineering code number is searched under the specified directory, parameters are read out to be written and read, the writing and reading are confirmed to be correct, and if the parameters are incorrect, a warning or prompting signal is output.
And step 107, performing data correction on the automatic test system. Specifically, the total current, the inner total pressure, and the outer total pressure are subjected to data correction, for example: 1000mA is input, only 998mA is output due to intermediate loss, the output is corrected to 1000mA, in addition, the type of a shunt of the total current analog circuit is written and distinguished, and the zero point and the full scale of a voltage source and a constant current source are corrected.
And 108, monitoring data and a balance function of the automatic test system, and determining whether each parameter is within a preset range and whether the balance function of the system is intact. Specifically, the method can be used for testing and judging the part of fault information, DI/AI, time, year, month, day, total current, internal total pressure, external total pressure, CC CC2, zero drift, CP, cell voltage, cell temperature and the like, and comprises the following steps:
opening a control computer and monitoring various parameters;
opening a high-voltage source program of the total-pressure analog circuit, setting the program to be an upper limit value (for example, 300V), and judging whether the total pressure inside the monitoring is within the range (plus or minus 1 percent);
opening a constant current source program of the total current analog circuit, setting the program as an upper limit value (for example 300A), and checking whether the total current is within the range (plus or minus 0.5%); closing the constant current source, looking at the fluctuation range of the value of the total current at the moment, looking at whether the value is in the range (0 +/-0.3A), and determining whether the zero drift is in the range at the moment;
checking the monitoring data, determining that the values of CC (alternating current charging signal) and CC2 (direct current charging signal) are within the range (12 +/-0.5V), connecting 1K resistors at the ends of CC and CC2, checking the values of CC and CC2 at the moment, and judging whether the values are within the range (6 +/-0.5V);
turn on the signal generator program, set the signal generator (waveform selection: SQU; FREQ: 1K; AMPL: 10; DUTY: 10), look at the CP value at that time to see if it is within range (10% + -1%);
opening the virtual battery program, setting all the cells to a preset voltage, such as 3.3V, checking the cell voltage monitored at the moment to see whether the cell voltage is within the range (+/-10 mV); the automatic machine set temperature is resistance, the fixed value is 25 degrees for example, and the monomer temperature at this time is checked to see whether the temperature is within the range (plus or minus 2 degrees).
Monitoring whether the equalization function is intact, whether the monomer power consumption is within a range of values (e.g. <1mA), etc. The above monitored data is only partial content, and the content of other monitored data is not necessarily set forth.
Finally, when it is confirmed that the test system and each item of the battery monitoring module to be tested are ready, the formal test can be started.
Step 109, performing insulation test on the battery monitoring module to be tested, mainly testing the insulation state of the total positive and the total negative to the ground, so as to determine whether the battery monitoring module to be tested can normally report a fault, wherein the specific method includes, but is not limited to:
opening the total voltage, setting the total voltage to be 300V, and opening a total positive switch;
when the resistor is not connected, no insulation fault exists (including the first level, the second level and the third level do not exist);
connecting a 70K resistor, checking insulation faults and checking whether a secondary insulation fault exists;
switching in a 30K resistor, and checking whether a three-level insulation fault exists;
closing the main positive switch and opening the main negative switch;
and repeating the two steps and outputting a result.
And step 110, carrying out relay test on the battery monitoring module to be tested to test whether the relay on the hardware can normally work or not, wherein the relay comprises a total positive relay, a total negative relay, a pre-charging relay, a heating relay and a fan relay. The test method can be as follows: opening a main positive relay to see whether the main positive relay is normally opened or not, and closing other relays; closing the main positive relay to see whether the main positive relay is normally closed or not, wherein other relays are closed; and by analogy, testing the opening and closing of other relays and outputting results.
And step 111, carrying out external CAN communication test on the battery monitoring module to be tested, mainly testing whether the data sent by the whole vehicle CAN and the charging CAN are normal or not without testing the correctness of the data sent by the whole vehicle CAN and the charging CAN. The test method can include; opening the CAN of the whole vehicle, adjusting the Baud rate to be consistent, confirming that the data CAN be received, and outputting a result; opening a charging CAN, adjusting the baud rate, confirming that data CAN be received, and outputting a result;
and step 112, performing historical fault data reading test on the battery monitoring module to be tested, wherein the test fault data can be normally read, and the historical fault data can be normally cleared. The test method can be as follows: reading fault data, and restarting a hardware power supply after confirming that the data can be read; and starting to clear the historical data and the fault data, and outputting a result after the historical data and the fault data are successfully cleared.
And 113, performing version reading test on the battery monitoring module to be tested, wherein the version reading test is mainly used for reading a platform software version, a project software version and a hardware version. The method comprises the following steps: and automatically reading the three versions of information, comparing the three versions of information with preset versions of information, and outputting a result.
And step 114, carrying out terminal resistance test on the battery monitoring module to be tested, mainly carrying out terminal resistance test on an internal CAN, a charging CAN and a whole CAN, checking the monitored resistance value, and determining whether a terminal resistor is connected. The test method can include; automatically testing the current resistance value, and judging and displaying; turning off the power supply, printing the CAN in the power supply, and comparing the resistance value displayed on the resistance value ammeter with the automatically read resistance value to output a result; by analogy, the terminal resistance test of the whole CAN and the charging CAN is completed, and the result is output.
And step 115, performing data storage test on the battery monitoring module to be tested, wherein the data storage test is mainly used for storing a plurality of test data, and providing data support for a subsequent shipment inspection system and a subsequent traceability system. The test method can comprise the following steps: and confirming whether the latest saved file exists under the preset folder under the preset directory, confirming the content of the saved file, ensuring that the content of the file is automatically generated at this time, and outputting a result.
And step 116, performing data display test on the battery monitoring module to be tested, and performing partial test data and result display on the interface, so that the purpose of analyzing the fault by only looking at the interface can be achieved. The method specifically comprises the following steps: after the operation is finished, whether display conditions such as a display interface, mainboard information, slave board information and qualification rate information are the same as preset or not is confirmed, then a hardware mainboard (slave board) is replaced for testing (when the battery monitoring module to be tested is divided into the mainboard and the slave board), whether test data are different from a previous picture or not is seen, and a result is output.
The advantages of the test system and method of the present invention include:
1) the specification file is input once, and all subsequent automatic judgment is carried out, so that the error probability and the judgment accuracy are reduced;
2) the test sequence is normalized, the test items are fixed, and the probability of missing the test items is reduced;
3) each piece of test data is stored, and the product data can be traced and checked;
4) several processes are combined, so that the multi-process testing time is reduced; (for example, measuring the equilibrium state, measuring the power consumption of the cell, etc.)
5) The production efficiency is improved by more than 3 times; for example, actually measuring a mainboard with the model EV05, the original manual test is carried out for 20 minutes/block, and the actual test is improved to 3 minutes/block; the original 3 minutes per block of the slave plate with the model number of EV05 is increased to 1 minute per block;
6) the stability of the test is improved, the test results of each time are similar, and the deviation is extremely small.
Therefore, the product delivery speed is accelerated, the production period is shortened, the reject ratio is reduced, and the customer complaint rate is reduced.
While the invention has been described in conjunction with the specific embodiments set forth above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims.
Claims (6)
1. The utility model provides an electric automobile battery monitoring module automatic test system which characterized in that includes:
the total voltage simulation circuit is provided with a voltage source and is used for simulating the total voltage of a power battery module;
the total current simulation circuit is provided with a constant current source and is used for simulating the total current of the power battery module;
the single battery simulation circuit is provided with a plurality of virtual batteries and thermistors and is used for simulating a plurality of single batteries and temperature sensors of the power battery module;
the power supply circuit is used for simulating a power supply of the battery monitoring module to be tested and supplying power to each module of the automatic test system;
the control computer is used for sending out a control signal according to a test software setting program, acquiring data output by the to-be-tested battery monitoring module, analyzing the acquired data and outputting an analysis result;
the control board is used for controlling the total pressure analog circuit, the total current analog circuit and the single battery analog circuit to output preset signals according to the control signals so as to simulate the power battery module with various performances; and
the acquisition module is used for acquiring the total voltage, the total current, the single battery temperature and the single battery voltage information of the simulated power battery module and outputting the acquired information to the to-be-tested battery monitoring module;
the control board comprises a control circuit and relays connected in series in the total pressure analog circuit, the total current analog circuit and the single battery analog circuit;
during testing, the battery monitoring module to be tested is accessed into an automatic testing system, and a corresponding engineering code is input into the control computer;
the control computer obtains a preset baud rate, an SX flash file, a configuration file and inspection data according to the engineering code;
detecting the baud rate of the battery monitoring module to be tested; when the preset baud rate is the same as that of the battery monitoring module to be tested, the obtained SX flash file and configuration file are put into a preset directory of the control computer for standby use;
according to the SX flash file, programming in the to-be-tested battery monitoring module so that the to-be-tested battery monitoring module can normally work;
the battery monitoring module to be tested is subjected to insulation test, relay test, external CAN communication test, terminal resistance test and data storage test through a control board; and comparing the data output by the battery monitoring module to be tested with the inspection data when the test is executed, and generating and outputting a test result.
2. The automatic testing system of the battery monitoring module of the electric vehicle as claimed in claim 1, wherein the control computer is connected to the battery monitoring module to be tested through a CAN card interface compatible with a USB interface and a CAN bus interface.
3. The automatic test system of claim 2, wherein the total current analog circuit has a shunt for outputting different current signals.
4. The automatic test system of claim 1, further comprising performing a data display test on the battery monitoring module under test.
5. The automatic test system of claim 4, further comprising performing a historical fault data read test or a version read test on the battery monitoring module under test.
6. The automatic test system of claim 4, wherein the step of programming the battery monitoring module to be tested is followed by the following steps to ensure that the battery monitoring module to be tested and the automatic test system can work properly:
the battery monitoring module to be tested performs read-write parameter operation according to the configuration file;
correcting data of the automatic test system, wherein the data comprises total current, internal total pressure and external total pressure;
and monitoring data of the automatic test system, and determining whether each parameter is within a preset range.
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| CN109143072A (en) * | 2017-06-28 | 2019-01-04 | 东软集团股份有限公司 | A kind of test method of battery management system, device and equipment |
| CN109878334A (en) * | 2017-12-05 | 2019-06-14 | 王波 | A kind of dual pressure controller |
| CN108376803A (en) * | 2017-12-29 | 2018-08-07 | 北京智行鸿远汽车有限公司 | A kind of battery TT＆C system and method based on Labview |
| CN110596627B (en) * | 2019-08-22 | 2021-09-03 | 深圳市鹏巨术信息技术有限公司 | Detection method and device for vehicle diagnosis box |
| US11474160B2 (en) | 2020-08-18 | 2022-10-18 | Rohde & Schwarz Gmbh & Co. Kg | Battery emulation apparatus |
| CN113093034A (en) * | 2021-04-07 | 2021-07-09 | 阳光三星(合肥)储能电源有限公司 | Automatic testing method, device and system for battery management system |
| CN113960948A (en) * | 2021-11-23 | 2022-01-21 | 深圳市太美亚电子科技有限公司 | Automatic test system and method for simulating battery charging |
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