CN107132484B - Comprehensive test system of battery system - Google Patents
Comprehensive test system of battery system Download PDFInfo
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- CN107132484B CN107132484B CN201710326072.9A CN201710326072A CN107132484B CN 107132484 B CN107132484 B CN 107132484B CN 201710326072 A CN201710326072 A CN 201710326072A CN 107132484 B CN107132484 B CN 107132484B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
- G01R31/382—Arrangements for monitoring battery or accumulator variables, e.g. SoC
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
- G01R31/385—Arrangements for measuring battery or accumulator variables
- G01R31/387—Determining ampere-hour charge capacity or SoC
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- Charge And Discharge Circuits For Batteries Or The Like (AREA)
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Abstract
The invention relates to a comprehensive test system of a battery system, which comprises an automatic detection device, a high-voltage control device and a charging and discharging test device, wherein the high-voltage control device is provided with a static test channel and a dynamic test channel, the static test and the dynamic test of the battery system can be realized only by the control of an upper computer under the condition of not changing the test system by controlling the on-off of the dynamic test channel connected between the charging and discharging device and the battery system and controlling the on-off of the static test channel connected between the automatic detection device and the battery system, the test function is comprehensive, the test speed and the test efficiency are ensured, and the test cost is greatly reduced.
Description
Technical Field
The invention belongs to the field of battery system testing, and particularly relates to a comprehensive testing system of a battery system.
Background
In recent years, as the new energy industry is vigorously developed by the nation, the development of electric vehicles is leap forward, and the market share is rising. The continuous expansion of the demand of new energy electric vehicles puts higher demands on the delivery capacity of power battery systems. The production mode of mass supply requires that the power battery system be tested quickly and completely. On the premise of ensuring the comprehensive evaluation of the functions and performances of the battery system, the test time is shortened as much as possible.
The conventional test is a manual test mode, which requires an operator to use a measuring instrument to perform manual measurement. And (3) judging the test result of the evaluation item according to the measurement data displayed by the instrument and in combination with the technical requirements: Pass/Fail. And finally, recording the test result in a test data recording table. And after all the evaluation items are tested item by item and all the evaluation items meet the technical requirements, judging that the battery system is qualified. The manual test operation mode has low production efficiency, and the conditions of missing test and wrong test are easy to occur, so that misjudgment of products is caused, and the safety of the whole vehicle is damaged. In addition, the power battery system has a high voltage platform, the highest voltage can reach six to seven hundred volts and is far higher than the safety voltage of a human body, the personal safety of an operator is threatened by a manual measurement mode, and the potential safety hazard is high.
At present, the automatic test of a power battery system comprises a static test and a dynamic test, wherein the static test refers to a test when the battery system is not connected with a discharging load or a charger and is not charged or discharged. The partial test generally comprises the test verification of the functions of total pressure, insulation resistance, monomer information, relay control and the like of the battery system. The dynamic test refers to the charge and discharge test performed after the battery system is connected with a discharge load or a charger. When the battery system product is off-line for function test, the system for static test and the system for dynamic test are respectively adopted for testing the battery, the testing speed is low, the efficiency is low, the testing function is single, and the method for testing by adopting two sets of testing systems improves the testing cost of the battery system and is not beneficial to saving the testing cost.
Therefore, in the research of the hybrid electric vehicle, it is of great significance to design an economic and effective battery system function verification platform integrating dynamic test and static test.
Disclosure of Invention
The invention aims to provide a comprehensive test system of a battery system, which is used for solving the problem of high test cost caused by respectively carrying out dynamic test and static test on the battery system in the prior art.
In order to solve the technical problem, the invention provides a comprehensive test system of a battery system, which comprises the following solutions:
the first scheme comprises an automatic detection device, a high-voltage control device and charge and discharge testing equipment, wherein the high-voltage control device is provided with a static testing channel and a dynamic testing channel, the charge and discharge testing equipment is connected with one end of the dynamic testing channel, and the other end of the dynamic testing channel is used for being connected with a battery system to be tested;
the automatic detection device is provided with a static test interface and is connected with one end of a static test channel through the static test interface, and the other end of the static test channel is used for connecting a battery system to be detected; the automatic detection device is connected with the high-voltage control device through a high-voltage control interface and used for controlling the on-off of the dynamic test channel and the static test channel, and the automatic detection device is in communication connection with the charging and discharging test equipment through a first communication interface.
And on the basis of the first scheme, the automatic detection device further comprises an upper computer, and a high-voltage control unit and a low-voltage control unit which are connected with the upper computer respectively, wherein the high-voltage control unit is connected with the high-voltage control interface, the low-voltage control unit is connected with an insulation withstand voltage tester and an ammeter, and the insulation withstand voltage tester or the ammeter is gated to be connected with the static test interface.
According to the third scheme, on the basis of the second scheme, the automatic detection device further comprises a low-voltage power supply module and a low-voltage power supply interface connected with the low-voltage power supply module, the low-voltage power supply module is connected with the upper computer, and the low-voltage power supply module is used for connecting the BMS in the battery system to be detected through the low-voltage power supply interface to supply power to the BMS.
And on the basis of the first scheme, the second scheme and the third scheme, the charge and discharge testing equipment comprises a charge and discharge control unit, and a communication module, an inversion module and a load module which are respectively connected with the charge and discharge control unit, wherein the communication module is connected with a first communication interface of the automatic detection device, and the inversion module and the load module are connected with the dynamic testing channel through gating.
And a seventh scheme, wherein on the basis of the first scheme, the first communication interface is an ethernet communication interface or an RS485 communication interface.
And the automatic detection device is also provided with a plurality of paths of CAN communication interfaces for testing the internal communication, the whole vehicle communication and the charging communication functions of the BMS of the battery system to be tested on the basis of the fourth, fifth and sixth schemes.
And the automatic detection device is also provided with a CC detection interface which is used for connecting a CC charging confirmation interface of the battery system to be detected to perform charging test on the basis of the eighth, ninth and tenth schemes.
The invention has the beneficial effects that: according to the invention, by controlling the on-off of the dynamic test channel connected between the charging and discharging equipment and the battery system and controlling the on-off of the static test channel connected between the automatic detection device and the battery system, the static test and the dynamic test of the battery management system can be realized only by the control of one upper computer under the condition of not changing the test system, the test function is comprehensive, the test speed and efficiency are ensured, and the test cost is greatly reduced.
Drawings
FIG. 1 is a schematic diagram of an automated comprehensive evaluation system of a battery system;
FIG. 2 is a schematic diagram of an automated comprehensive evaluation system for a battery system;
FIG. 3 is an electrical schematic of the charge and discharge test apparatus;
FIG. 4 is an electrical schematic of the high voltage control device;
FIG. 5 is an electrical schematic of the automatic detection device;
FIG. 6 is a connection diagram of an automated comprehensive evaluation system;
FIG. 7 is a test flow diagram of the automated composite evaluation system of the present invention.
Detailed Description
The following further describes embodiments of the present invention with reference to the drawings.
The embodiment one of the comprehensive test system of the battery system of the invention is as follows:
as shown in fig. 1, the integrated test system of the present invention includes an automatic detection device, a high voltage control device, and a charging/discharging test device, wherein the high voltage control device is provided with a static test channel and a dynamic test channel, the charging/discharging test device is connected to one end of the dynamic test channel, and the other end of the dynamic test channel is used for connecting a battery system.
The automatic detection device is provided with a static test interface and is connected with one end of a static test channel through the static test interface, the other end of the static test channel is used for connecting a battery system, the automatic detection device is connected with a high-voltage control device through a high-voltage control interface and is used for controlling the on-off of the dynamic test channel and the static test channel, and the automatic detection device is in communication connection with a charge-discharge test device through a first communication interface and is connected with the battery system through a second communication interface and a low-voltage power supply interface.
When the static test is carried out, the automatic detection device issues a control command to the high-voltage control device through the high-voltage control interface to control the static test channel to be communicated and the dynamic test channel to be disconnected, the static test interface is communicated with the power output interface of the battery management system, and the low-voltage power supply module of the automatic detection device is connected with the 12V/24V power supply interface of the battery system through the low-voltage power supply interface. The static test includes the following:
initialization and BMS power-on: the automatic detection device issues a command, all relays in the test system are opened, a loop of the low-voltage power supply interface is closed, the low-voltage power supply interface outputs DC24V, and a BMS in the battery system is electrified to work.
And (3) total pressure detection of the battery system: and controlling an ammeter in the automatic detection device to be communicated with the static test interface, measuring the total pressure of the battery system by the ammeter, feeding the measured value back to an upper computer of the automatic detection device, and judging by the upper computer according to a voltage qualified standard.
And (3) testing the insulation resistance: after the total pressure of the battery system is detected, the ammeter and the static test interface are disconnected, an insulation withstand voltage tester in the automatic detection device is controlled to be connected with the static test interface, the insulation resistance value is fed back to the upper computer after the insulation resistance test is finished, and the upper computer judges the qualified range of the insulation resistance.
And (3) single body information acquisition and test: and the second communication interface of the automatic detection device is communicated with the internal bus interface of the BMS, receives the internal communication message sent by the BMS, analyzes the voltage and the temperature of the single battery, calculates the whole set of pressure difference and temperature difference, and compares and judges the pressure difference and the temperature difference with a preset qualified standard.
When the dynamic test is carried out, the automatic detection device issues a control command to the high-voltage control device through the high-voltage control interface, the dynamic test channel is controlled to be communicated, the static test channel is controlled to be disconnected, the static test interface is disconnected, and the dynamic test comprises the following contents:
and (3) current acquisition precision testing: after the battery management system is connected with a power loop of the charging and discharging test equipment, the charging and discharging test equipment is controlled to charge and discharge the battery system, and the upper computer calls a current acquisition precision test working condition as shown in table 1. After the test is finished, chargingThe discharge test equipment outputs a charge-discharge current I11、I12Feeding back to the upper computer, receiving the internal communication message sent by the BMS by the upper computer, and analyzing the charging and discharging current I collected by the BMS in the process21、I22. The upper computer calculates charging current error I in sequence11-I21Sum discharge current error I21-I22And comparing and judging with qualified standards.
TABLE 1 Current Collection accuracy test Condition
| Serial number | Name of work step | Electric current | Time of day |
| 1 | Standing still | —— | 5s |
| 2 | Constant current charging | I1 | 5s |
| 3 | Constant current discharge | I2 | 5s |
Testing direct current internal resistance: host computer callingAnd (3) controlling the charging and discharging test equipment to discharge the battery system under the direct current internal resistance test working condition as shown in table 2. The charging and discharging test equipment will U1、U2、I01、I02Feeding back to the upper computer, and calculating the direct current internal resistance DCIR (direct current resistance) of the upper computer to be U1-U2|/|I01-I02And comparing with qualified standard.
TABLE 2 DC INTERNAL RESISTANCE TESTING CONDITION
The contents of the static test and the dynamic test can be set as required, for example, the static test can also be used for performing a direct-current withstand voltage test, a relay control function test and the like, and the dynamic test can also be used for performing a discharge capacity test, a discharge end consistency test and the like.
According to the invention, by controlling the on-off of the dynamic test channel connected between the charging and discharging equipment and the battery system and controlling the on-off of the static test channel connected between the automatic detection device and the battery system, the static test and the dynamic test of the battery management system can be realized only by the control of one upper computer under the condition of not changing the test system, the test function is comprehensive, the test speed and efficiency are ensured, and the test cost is greatly reduced.
The embodiment two of the comprehensive test system of the battery system of the invention:
as shown in fig. 2 and 6, the integrated test system includes an automatic detection device, a high voltage control device, a battery system, and a charging and discharging test device.
An electrical schematic diagram of the charge and discharge testing device is shown in fig. 3, and includes an inverter voltage stabilization module, a load module, a communication module, and a charge and discharge control unit. The inversion voltage stabilizing module is used for converting input 380V alternating current into a stable high-voltage direct current power supply to charge a battery system. The load module is used for discharging the battery system, and the communication module is used for receiving an external instruction and transmitting the external instruction to the charging and discharging control unit. The charging and discharging control unit controls the inversion voltage stabilization module and the load module according to the received external instruction, and realizes the setting of charging and discharging conditions and the control of the charging and discharging process.
The functional interfaces of the charge and discharge test equipment are as follows:
AC380V AC input interface: the testing device is used for connecting 380V three-phase alternating current to supply power for the charging and discharging testing equipment.
The first high-voltage output interface: and the output charge-discharge positive electrode and the charge-discharge negative electrode interface are used for being connected with a first high-voltage output interface of the high-voltage control device. The multi-channel testing device comprises a plurality of channels, and can realize the simultaneous charge and discharge testing of a plurality of battery systems.
RS485 communication, Ethernet communication interface: the RS485 communication interface and the Ethernet communication interface are used for being connected with the automatic detection device. And information interaction between the charging and discharging test equipment and the upper computer is realized. The requirements of charge and discharge test conditions, work steps and the like can be set through upper computer software. And meanwhile, feeding back real-time data of the charging and discharging process to the upper computer, and displaying the real-time data on a software interface in real time.
The electrical schematic diagram of the high-voltage control device is shown in fig. 4, and the high-voltage control device comprises a high-voltage on-off unit, an output multi-path high-voltage input interface, a second high-voltage test interface, a second high-voltage output interface and a second high-voltage control interface. The high-voltage input interface is used for being in butt joint with a high-voltage output interface (a power output interface and an auxiliary interface) of the battery system, and the second high-voltage test interface is used for being connected with the first high-voltage test interface of the automatic detection device. Under the control of the upper computer, a test loop of the measuring instrument can be communicated with a high-voltage output loop of the battery system, so that the insulation resistance, the withstand voltage and the open-circuit voltage of the battery system can be tested. The second high-voltage output interface is used for being in butt joint with the charging and discharging test equipment to realize the charging and discharging test of the battery system. The second high-voltage control interface is used for receiving an instruction of the upper computer to complete connection and disconnection of a corresponding loop in the high-voltage on-off loop so as to switch the static test loop and the dynamic test loop (charge and discharge test) of the battery system.
The functional interfaces of the high-voltage control device are as follows:
a high-voltage test interface: the high-voltage testing interface is used for being in butt joint with the high-voltage testing interface of the automatic detection device.
A high-voltage input interface: the interface is used for being in butt joint with a high-voltage output interface of a battery system, comprises a plurality of input interfaces and is used for being in butt joint with a charging interface, a discharging interface, an air conditioner interface, a defrosting interface and other auxiliary interfaces output by the battery system.
A high-voltage output interface: the device is used for being in butt joint with the output anode and the output cathode of the charge and discharge test equipment.
A high-voltage control interface: the high-voltage control interface is used for being butted with a high-voltage control interface of the automatic detection device.
The high-voltage control device receives a command of an upper computer in the automatic detection device through the high-voltage control interface and controls the corresponding loop in the high-voltage on-off unit to be switched on or off. If the static test is carried out, the high-voltage test loop is controlled to be communicated with the positive electrode and the negative electrode of the battery system and is disconnected with the output positive electrode and the output negative electrode of the charge and discharge test equipment, so that the damage to the charge and discharge test equipment during the insulation resistance and voltage withstanding test is avoided. And if the dynamic test is carried out, the battery system is controlled to be disconnected with the positive electrode and the negative electrode of the high-voltage test loop and communicated with the output positive electrode and the output negative electrode of the charge-discharge test equipment, so that the charge and discharge of the battery system are realized.
Fig. 5 shows an electrical schematic diagram of the automatic detection device, which includes:
and the power supply module is used for providing working voltage for an upper computer, an insulation withstand voltage tester, a high-precision multifunctional electric meter, other units and modules in the automatic detection device and outputting a commercial power input interface.
And the upper computer is connected with communication loops of measuring instruments such as an insulation withstand voltage tester and a high-precision multifunctional electric meter through the low-voltage control unit, so that information interaction between the upper computer and different measuring instruments is realized.
The insulation withstand voltage tester and the high-precision multifunctional ammeter are in gating connection with the first high-voltage test interface, the low-voltage control unit receives instructions of the upper computer to complete communication between measurement loops of different measurement instruments and the first high-voltage test interface, and measurement of indexes such as insulation resistance, withstand voltage and open-circuit voltage of the battery system is achieved.
And the low-voltage power supply module is used for outputting 12V and 24V direct current to supply power for the BMS of the battery system. And the upper computer controls the connection and disconnection of a 12V/24V direct current interface output by the low-voltage power supply module according to the power supply requirement of the BMS.
And the variable resistance unit comprises a plurality of resistors with different resistance values according to the requirements of the fast charging/slow charging mode, is connected to the direct current cathode output by the low-voltage power supply module and is used for detecting the wiring correctness of the charging confirmation signal CC. The upper computer can control the variable resistance unit to output a corresponding resistance value according to a charging mode (quick charging or slow charging).
And the communication unit CAN output a plurality of paths of CAN communication interfaces, RS485 communication interfaces and Ethernet communication interfaces. The CAN communication interface is used for connecting the internal CAN communication, the whole vehicle CAN communication and the charging CAN communication interface output by the battery system BMS so as to realize the testing of functions such as the BMS internal communication, the whole vehicle communication and the charging communication. The upper computer CAN send instructions to the BMS or receive messages sent by the BMS through each CAN communication loop. And the RS485 and the Ethernet communication interface are used for realizing information interaction between the upper computer and the charging and discharging test equipment.
The low-voltage acquisition unit is used for outputting a plurality of paths of low-voltage acquisition interfaces and detecting low-voltage signals output by the battery system. The low-voltage acquisition unit is connected with the high-precision multifunctional electric meter, the upper computer controls the connection and disconnection of each acquisition loop and controls the switching of the measurement mode (voltage/resistance/current measurement mode) of the high-precision electric meter.
And the high-voltage control unit is connected with the high-voltage control device through a high-voltage control interface. The upper computer controls a high-voltage on-off unit in the high-voltage control device through the high-voltage control unit.
The functional interfaces of the automatic detection device are as follows:
the commercial power input interface: the device is used for connecting AC220V commercial power and providing a power supply for an upper computer, an insulation withstand voltage tester, a high-precision multifunctional electric meter and the like in the automatic detection device. Meanwhile, the power supply module converts the voltage of the power supply into low-voltage direct current to provide power supply for each internal unit and module.
A first high-voltage control interface: and the high-voltage control unit receives an instruction sent by an upper computer in the automatic detection device and outputs a control signal through the second high-voltage control interface.
Low-voltage power supply interface: the BMS power supply interface is used for connecting a battery system and can output multi-path 12V and 24V direct currents. The upper computer realizes the connection and disconnection of each low-voltage power supply loop through the low-voltage power supply module.
And (3) a CC detection interface: a CC2 charging connection confirmation signal line for connecting the battery system. According to the charging mode (fast charging/slow charging), the upper computer controls the variable resistance unit to output different resistance values (1K omega/680 omega) and is connected to the negative pole of a 12V/24V direct current power supply, and meanwhile, the multifunctional electric meter is called to measure the voltage of the CC detection interface to judge the wiring correctness of the CC2 charging confirmation signal line in the battery system.
A CAN communication interface: and the CAN communication interface is used for connecting the charging CAN communication, the whole vehicle CAN communication and the internal CAN communication interface output by the battery system. The upper computer controls the communication and the cut-off of different CAN communication loops through the communication module, and the communication function of the battery system is tested.
RS485, Ethernet communication interface: and the RS485 and the Ethernet communication interface are used for connecting the charge and discharge test equipment, so that information interaction between the upper computer and the charge and discharge test equipment is realized. Such as setting charge and discharge conditions, controlling the start/end of charge and discharge test working conditions, calling charge and discharge test working conditions, returning charge and discharge test information and the like.
The low-voltage acquisition interface comprises: and a relay control signal line for connecting the battery system, such as a fan relay +, an air conditioner relay +, a defrosting relay +, and the like. The upper computer controls the communication of the corresponding test loop through the low-voltage acquisition unit, and simultaneously calls the multifunctional electric meter to measure the voltage of the detection interface and judges whether the voltage of the detection interface meets the requirements.
A high-voltage test interface: and the high-voltage test interface is used for connecting the high-voltage control device. The upper computer is connected with the insulation withstand voltage tester and a communication loop of the high-precision multifunctional electric meter through the low-voltage control unit, and information interaction between the upper computer and different measuring instruments is realized. If the insulation resistance test is carried out, the upper computer sends an instruction to control the high-voltage test interface to be communicated with a measurement loop of the insulation voltage tester and send parameter settings (the setting of an IR/DC voltage-withstand/AC voltage-withstand mode, the setting of test voltage, the setting of test time and the like) to the insulation voltage tester. And after the test is finished, the upper computer reads the measured value of the insulation withstand voltage tester and judges the result. When the open-circuit voltage test is carried out, the upper computer issues a command to control the high-voltage test interface to be connected with a measurement loop of the high-precision multifunctional electric meter.
Fig. 7 shows an automatic testing process of the battery system, which includes performing a static test and then performing a dynamic test. The number of the static test evaluation items is 11, and the number of the dynamic test evaluation items is 7. The specific automatic evaluation process is as follows:
1) the automatic evaluation system is connected: and connecting corresponding interfaces of the automatic detection device, the high-voltage control device, the battery system and the charge and discharge test equipment, and completing the butt joint of the corresponding interfaces according to the table 3.
TABLE 3 automatic evaluation system interface docking
2) Initialization and BMS power-on: firstly, an upper computer of the automatic detection device issues a command, and all relays in the evaluation system are disconnected; and the upper computer issues a command, an output loop of the low-voltage power supply module is closed, the low-voltage power supply interface outputs DC24V, and a BMS in the battery system is electrified to work.
3) And (3) total pressure detection of the battery system: the upper computer issues a command to communicate the measurement loop of the high-precision multifunctional electric meter with the first high-voltage test interface. The upper computer issues a command, the high-voltage control interface receives the command and communicates the second high-voltage testing interface with the high-voltage input interface 1. And the upper computer issues a command to set the high-precision multifunctional electric meter into a voltage measurement mode. The ammeter measures the total pressure of the battery system and feeds the measured value back to the upper computer. And the upper computer judges whether the total pressure value is qualified according to the total pressure qualified standard, if so, the upper computer issues a command to control the second high-voltage test interface to be disconnected from the high-voltage input interface 1, and then the next test is carried out, otherwise, the abnormal analysis and processing are carried out.
4) Auxiliary interface voltage detection: the upper computer issues a command, the high-voltage control interface receives the command and controls the high-voltage input interface 2 to be communicated with the second high-voltage testing interface. The electric meter measures the output voltage of the auxiliary interface of the battery system and feeds the voltage value back to the upper computer. The upper computer judges according to the voltage qualified standard, if the upper computer is qualified, the upper computer issues a command to disconnect the high-voltage input interface 2 from the second high-voltage test interface, and the high-voltage input interface 1 and the second high-voltage test interface are closed again, otherwise, abnormal analysis and processing are performed.
5) And (3) testing the insulation resistance: the upper computer issues a command to control a measurement loop of the insulation withstand voltage tester to be communicated with the first high-voltage test interface. And setting the insulation withstand voltage tester to be in an insulation resistance measurement mode. After the insulation resistance test is finished, the insulation resistance value is fed back to the upper computer, the upper computer judges according to the qualified range of the insulation resistance, if the insulation resistance value is qualified, the next step of test is carried out, and if the insulation resistance value is not qualified, the abnormality analysis and processing are carried out.
6) And D, direct-current voltage withstand test: and the upper computer issues a command, and the insulation withstand voltage tester is set to be in a DC withstand voltage measurement mode. After the test is finished, the insulation withstand voltage tester feeds the measured leakage current back to the upper computer, the upper computer judges according to the qualified standard of the leakage current, if the leakage current is qualified, a measuring loop of the insulation withstand voltage tester is disconnected, the next step of test is carried out, and if the leakage current is not qualified, the abnormal analysis and processing are carried out.
7) Testing the relay control function: the host computer sends the relay closure order to the BMS through inside CAN, and the host computer sends the measurement return circuit and the low pressure collection interface intercommunication of order control high accuracy multifunctional electric meter down, sets up high accuracy multifunctional electric meter and is the voltage measurement mode, measures battery system's relay control signal output's voltage to feed back the voltage value who records to the host computer, the host computer is judged according to the qualified standard of this voltage, if qualified, tests on next step, otherwise carries out abnormal analysis and processing.
8) And (3) testing the communication function of the whole vehicle: and the upper computer receives and analyzes the message sent by the CAN interface of the whole vehicle to obtain the total pressure of the battery system. And judging according to the qualified standard of the total pressure, if the total pressure is qualified, carrying out the next step of testing, and otherwise, carrying out abnormal analysis and processing.
9) And (3) testing a charging communication function: and the upper computer issues a command, and the DC 24V-of the low-voltage power supply module is communicated with the 1K omega resistor output by the variable resistance unit and is communicated to the CC detection interface. The charge confirmation signal line for battery system CC2 was implemented to be connected to DC 24V-through a 1K Ω resistor. The upper computer sends messages through the CAN interface and receives feedback messages of the BMS. And the upper computer judges the correctness of the received message according to a preset qualified standard, if the message is correct, the next step of testing is carried out, and if the message is not correct, the abnormal analysis and processing are carried out.
10) Acquiring monomer information: and the upper computer receives an internal communication message sent by the BMS through an internal CAN communication interface, analyzes the voltage and the temperature of the single battery, calculates the whole set of pressure difference and temperature difference, compares the whole set of pressure difference and temperature difference with a preset qualified standard, tests the next step if the whole set of pressure difference and temperature difference are qualified, and otherwise, performs abnormal analysis and processing.
11) And (3) total pressure acquisition precision test: and (3) the upper computer calculates the accumulated value of the single voltage, compares the accumulated value with the total pressure value (measured in the step 8) analyzed by the CAN message of the whole vehicle and the total pressure actual measurement value (measured in the step 3) of the battery system respectively, calculates an acquisition error, performs the next test if the acquired error meets the qualified standard, and otherwise performs the abnormal analysis and processing.
12) And (3) current acquisition precision testing: the upper computer issues a command to control the disconnection of the high-voltage input interface 1 and the second high-voltage test interface; and the high-voltage input interface 1 is controlled to be communicated with the second high-voltage output interface, so that the battery system is connected with a power loop of the charge and discharge test equipment. Similarly, the upper computer calls the current acquisition precision test working condition shown in the table 2 to control the charging and discharging test equipment to charge and discharge the battery system, and the upper computer sequentially calculates the charging current error | I11-I21Sum discharge current error I21-I22And comparing with qualified standard, both satisfying the qualified standardAnd if not, carrying out exception analysis and processing.
13) Testing direct current internal resistance: the same as the test process in the first embodiment, the upper computer still calls the direct current internal resistance test working condition shown in table 3, and controls the charge and discharge test equipment to discharge the battery system.
14) And (3) testing discharge capacity: and calling a discharge capacity test working condition by the upper computer software, and controlling the charge and discharge test equipment to discharge the battery system according to the working condition requirement. And after the discharge is finished, the discharge capacity recorded by the charge and discharge testing equipment is fed back to the upper computer. And the upper computer judges according to the discharge capacity qualification standard, if the discharge capacity qualification standard is qualified, the next step of testing is carried out, and if the discharge capacity qualification standard is not qualified, the abnormal analysis and processing are carried out.
15) Discharge end consistency test: the upper computer obtains the message through an internal CAN communication interface, analyzes the voltage of the single battery at the discharging end moment, calculates the maximum value and the minimum value of the voltage of the single battery, and further calculates the pressure difference of the whole group. If the pressure difference meets the qualified standard, the next step of testing is carried out, otherwise, the abnormity analysis and processing are carried out.
16) And (3) testing an over-discharge alarm function: and the upper computer acquires the message through an internal CAN communication interface, analyzes the fault code at the moment of finishing the discharge, performs the next test if the fault code is consistent with the preset code, and performs exception analysis and processing if the fault code is not consistent with the preset code.
17) Factory SOC setting: after the charging and discharging test is finished, the upper computer sends an SOC setting command through the internal CAN communication interface, after the setting is finished, the upper computer receives a message through the whole vehicle CAN communication interface, analyzes the SOC and judges the SOC and the set value, if the SOC is consistent with the set value, the next step of test is carried out, and if the SOC is not consistent with the set value, the abnormal analysis and processing are carried out.
18) BMS power down, battery system power down: the upper computer issues a command to control the low-voltage power supply module to be disconnected with the low-voltage power supply interface, and the BMS is powered off at the moment. And disconnecting the battery system from the automatic detection device and the high-voltage control device.
The operation steps of the comprehensive test system of the invention are as follows:
(1) the method comprises the following steps of compiling an evaluation scheme of a project to be tested in automatic evaluation software of the battery system, wherein the evaluation scheme comprises a static test evaluation project, a dynamic test evaluation project and a qualification standard of each evaluation project. And compiling the charging and discharging working conditions and requirements of the dynamic evaluation project on the operation software of the charging and discharging test equipment. The evaluation scheme requires a tuning test when first used.
(2) System connection: and connecting the automatic detection device, the high-voltage control device, the battery system and the charge and discharge test equipment in a wiring manner.
(3) And selecting an evaluation scheme in an upper computer software operation interface of the automatic detection device, scanning the bar code number of the battery system to be tested, and clicking to start testing.
(4) And monitoring the test result of each evaluation item, and judging that the battery system is qualified after all the evaluation items are qualified. Otherwise, judging the product to be unqualified, performing abnormal analysis processing according to the test result, and uploading the test report to the main server after the product is tested to be qualified.
The invention is used for automatically evaluating the comprehensive performance of the battery system. The evaluation content relates to evaluation items of the electrical function, the communication function, the protection function, the battery pack performance and the like of the battery system. The automatic detection device is used for automatically testing static evaluation items of the battery system, such as insulation resistance, voltage resistance, low-voltage signal detection, total voltage, communication function, control function and the like; the automatic detection device can realize control and information interaction of the charging and discharging test equipment, and is used for automatically testing dynamic evaluation items such as direct current internal resistance, charging and discharging capacity, charging and discharging consistency, an alarm function, factory SOC (system on chip) setting and the like of the battery system; the automatic detection device can also realize the control of the high-voltage control device and realize the switching of the static test loop and the dynamic test loop of the battery system. When the battery system is comprehensively evaluated, the automatic comprehensive evaluation system is connected, and an evaluation scheme is selected from the automatic detection device, so that the automatic test can be performed. And after the test of each evaluation item is finished, automatically displaying the test result OK/NG and the test data in sequence. And after the evaluation scheme is tested, automatically forming a test report. And when the test results of all the evaluation items are OK, judging the battery system to be qualified. The automatic comprehensive evaluation system can realize comprehensive evaluation of the battery system, manual intervention is not needed in the test process, and the test efficiency, the safety and the accuracy of the test result are greatly improved.
In the high-voltage control device, the set dynamic test channel is a branch for communicating the charging and discharging test equipment and the battery system to be tested, and the set static test channel is a branch for communicating the battery system to be tested and the automatic monitoring device, wherein the dynamic test channel and the static test channel are both multiple channels and can be set according to test requirements.
The automatic detection device, such as an alternating current internal resistance tester and the like, can correspondingly increase the automatic realization of the alternating current internal resistance test function. The upper computer in the automatic detection device is provided with automatic evaluation software of the battery system and operation software of the charging and discharging test equipment, the automatic evaluation software of the battery system is used for compiling an automatic evaluation program and controlling each unit and module in the automatic detection device, and each unit and module of the high-voltage control device work according to instructions. The automatic evaluation software of the battery system can also call the charge and discharge test process step. And operating software of the charge and discharge testing equipment is used for setting the charge and discharge testing work steps and requirements and controlling the charge and discharge testing equipment to carry out charge and discharge step by step according to the specified testing work steps.
Before testing, the battery system, the high-voltage control device, the automatic detection device and the charging and discharging test equipment need to be connected in a wiring way; during testing, an evaluation scheme is selected, after the test is started by clicking, each evaluation item is automatically tested one by one, and a test result is automatically displayed: Pass/Fail, while displaying critical test data (e.g., insulation resistance, leakage current, open circuit voltage, etc.). After the whole evaluation scheme is tested, the final test result of the battery system is automatically displayed: and (5) passing/Fail, and generating a test report. Human intervention is not needed in the whole testing process.
The invention can realize the automatic test of the power battery system, only needs to carry out the wiring connection of the comprehensive evaluation system before the test, and does not need to carry out the human intervention on the battery system again in the whole test process. Because the high-voltage live operation of operators is avoided, the safety is greatly improved. Each test item is automatically tested according to the evaluation scheme, so that the situations of test omission, test error and the like are avoided. In addition, after the battery system is tested, a corresponding test report is automatically generated, the accuracy and the traceability are greatly improved, and the problems of low manual test operation efficiency, high error probability and high potential safety hazard are solved. Compared with the existing single dynamic test system or static test system, the invention can realize the static test and the dynamic test of the battery management system by controlling the on-off of the dynamic test channel and the static test channel under the condition of not changing the test system, thereby ensuring the test items, speed and efficiency and reducing the test cost.
Claims (4)
1. The integrated test system of the battery system is characterized by comprising an automatic detection device, a high-voltage control device and a charging and discharging test device, wherein the high-voltage control device is provided with a static test channel and a dynamic test channel;
the automatic detection device is provided with a static test interface and is connected with one end of a static test channel through the static test interface, and the other end of the static test channel is used for connecting a battery system to be detected; the automatic detection device is connected with the high-voltage control device through a high-voltage control interface and used for controlling the on-off of the dynamic test channel and the static test channel, and the automatic detection device is in communication connection with the charge and discharge test equipment through a first communication interface;
the automatic detection device also comprises an upper computer, a low-voltage power supply module and a low-voltage power supply interface connected with the low-voltage power supply module, wherein the low-voltage power supply module is connected with the upper computer and is used for connecting a BMS in a battery system to be detected through the low-voltage power supply interface to supply power to the BMS;
the automatic detection device is also provided with a plurality of paths of CAN communication interfaces for testing the internal communication, the whole vehicle communication and the charging communication functions of the BMS of the battery system to be tested;
the automatic detection device is also provided with a CC detection interface for connecting a CC charging confirmation interface of the battery system to be detected to carry out charging test; the automatic detection device also comprises a variable resistance unit, and the CC detection interface is connected with the negative electrode of the low-voltage power supply module through the variable resistance unit.
2. The integrated testing system of the battery system according to claim 1, wherein the automatic detection device further comprises a high voltage control unit and a low voltage control unit respectively connected with the upper computer, the high voltage control unit is connected with the high voltage control interface, the low voltage control unit is connected with the insulation withstand voltage tester and the electric meter, and the insulation withstand voltage tester or the electric meter is selected to be connected with the static testing interface.
3. The system of any one of claims 1-2, wherein the charge and discharge testing device comprises a charge and discharge control unit, and a communication module, an inverter module and a load module respectively connected to the charge and discharge control unit, wherein the communication module is connected to the first communication interface of the automatic detection device, and the inverter module and the load module are connected to the dynamic testing channel through a gate.
4. The integrated test system for battery systems according to claim 1, wherein the first communication interface is an ethernet communication interface or an RS485 communication interface.
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