CN111880516A - Automatic detection device and method based on lithium battery controller of electric vehicle - Google Patents
Automatic detection device and method based on lithium battery controller of electric vehicle Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 73
- 238000000034 method Methods 0.000 title claims abstract description 33
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 title claims abstract description 16
- 229910052744 lithium Inorganic materials 0.000 title claims abstract description 16
- 238000004891 communication Methods 0.000 claims abstract description 44
- 239000011159 matrix material Substances 0.000 claims abstract description 35
- 230000007274 generation of a signal involved in cell-cell signaling Effects 0.000 claims abstract description 11
- 238000012360 testing method Methods 0.000 claims description 79
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- 230000001960 triggered effect Effects 0.000 claims description 3
- 230000000977 initiatory effect Effects 0.000 claims description 2
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
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Abstract
The invention belongs to the field of automobiles, in particular to an automatic detection device and method based on a lithium battery controller of an electric automobile, the device controls the closing of an electromagnetic valve and the state acquisition of a proximity switch through a DIO card, the clamping and the loosening of the pneumatic clamp are realized by controlling the electromagnetic valve, whether the tested object is correctly placed to a preset position is judged by the proximity switch, the automatic detection is controlled by the contact type button, the switch matrix is controlled by the network switch to realize the allocation of power signals, the analog load is switched in (out) through the switch matrix, parameters such as current, high and low voltage, impedance and the like of a tested object are measured through the digital multimeter, the signal generation module is used for inputting signals to the tested object, the high-low voltage power supply is used for providing electrical input for the tested object, the port waveform is detected through the digital oscilloscope, and CAN communication is realized by sending and receiving CAN commands through the CAN card. The system has complete control function and detection function and high automation degree.
Description
Technical Field
The invention belongs to the field of automobiles, and particularly relates to an automatic detection device and method based on a lithium battery controller of an electric automobile.
Background
The demand for the research on electric vehicles is high, but in recent years, the development of novel electric vehicles is very slow; power integration is a major factor impeding its development; the management of the battery pack and the real-time monitoring of parameters such as the electric quantity of the single battery are particularly important. The battery controller is a core controller of a battery system, plays an important role in battery charging and discharging and service life estimation, and has great significance in upgrading research thereof.
The current research on battery management in various places mainly focuses on: data acquisition, balance management, thermal management and central processing unit correlation techniques; the technology is hard to upgrade and reform the core algorithm and the physical structure of each part. For the performance evaluation means of the battery management system, a unified judgment standard and a unified verification mode are not formed, the unified standard for the automatic function verification of the battery controller is lacked in China, and related automatic detection technologies are almost blank.
Disclosure of Invention
The invention aims to provide an automatic detection device and method based on a lithium battery controller of an electric vehicle, so that the building difficulty of an automatic test platform is reduced, production data is saved, and the test efficiency is improved.
The present invention is achieved in such a way that,
the utility model provides an automatic detection device based on electric automobile lithium battery controller, the device includes:
the industrial personal computer is inserted into the CAN card in a PCI mode to realize communication with the battery controller, is accessed into the DIO card in a PCI mode to realize control of the pneumatic clamp and detection of a proximity switch signal, and controls the program-controlled high-voltage power supply and the code scanning gun to realize an identification code recognition function through USB communication;
the mould is used for placing the tested battery controller;
the pneumatic clamp is used for fixing the tested battery controller into the mold;
the contact button is connected to the input end of the DIO card through a shielding signal line;
the code scanning gun is communicated with the industrial personal computer in a USB mode and is used for identifying the unique identification code of the tested battery controller;
the proximity switch is connected to the DIO card through a shielding signal line;
the light curtain is connected to the DIO card in a signal line shielding mode, so that the safety of testers in the test process is ensured;
the electromagnetic valve is connected to the output control end of the DIO card in a signal wire shielding mode and controls the power-on state of the pneumatic clamp;
the CAN card is used for realizing the communication between the industrial personal computer and the controller of the battery to be detected in a CAN communication mode;
the DIO card is used for collecting the state of the proximity switch and controlling the power-on state of the electromagnetic valve together with the manual switch;
the digital multimeter realizes remote communication with the industrial personal computer through TCP/IP and measures the voltage, current and impedance of the tested battery controller;
the digital oscilloscope realizes remote communication with the industrial personal computer through TCP/IP and mainly realizes voltage waveform capture of the output port of the controller of the battery to be tested;
the program-controlled high-voltage power supply realizes remote communication with the industrial personal computer through a USB and provides high-voltage required by testing for the tested battery controller;
the network switch is arranged among the digital multimeter, the digital oscilloscope and the industrial personal computer and realizes automatic allocation of virtual addresses of the digital multimeter and the digital oscilloscope through the switch;
the switch matrix is in remote communication with the industrial personal computer through TCP/IP, realizes signal transfer, and distributes input resources and measurement resources for test items;
the signal generation module is not programmed and provides waveforms such as square waves with adjustable amplitude, duty ratio and frequency for the battery controller;
the low-voltage power supply module is non-program-controlled and provides proper working voltage for the tested battery controller;
and simulating a load, namely simulating the load of the tested battery controller.
Furthermore, the number of the low-voltage power supply modules is two, the two low-voltage power supply modules are all output to the die through the switch matrix, each low-voltage power supply module is a multi-channel voltage output, one of the multi-channel voltage output modules provides 9-18V voltage to provide a working power supply level for the tested battery controller, the other low-voltage power supply module provides 1-10V low voltage to provide analog voltage for specific test items.
Furthermore, the number of the signal generating modules is two, the two signal generating modules are all output to a tested battery controller of the mold through a switch matrix, one of the two signal generating modules provides square waves with adjustable frequency, amplitude and duty ratio for the tested battery controller, and the other signal generating module provides triangular waves for the tested battery controller.
Furthermore, the independent identification bar code or other identification codes of each tested battery controller are identified by a code scanning gun, and the next operation can be carried out when the identification passes.
Furthermore, the mould contains the probe, and the probe is connected to DB25 adapter through aviation plug and shielding signal line, and switch matrix's port access area is connected with DB25 adapter through the signal line.
Furthermore, after an operator puts in the tested battery controller, the operator detects that all positions are in place through the proximity switch, the pneumatic clamp is tightened, the test is controlled to start by matching with the double-contact button, and meanwhile, the light curtain is in a normal detection state; in the normal detection process, if the light curtain is triggered, the existing test is stopped, the clamp is loosened, and the tested battery controller is popped up.
Furthermore, in the detection process of the battery controller, the industrial personal computer controls whether each power supply is connected to the detected battery controller or not through the switch matrix, controls each measuring device to be connected to the corresponding pin to be detected, and controls the signal generating device to be connected to the corresponding pin to be input;
the industrial personal computer is communicated and controlled with the tested battery controller through the CAN card;
the digital oscilloscope tests a port with a PWM output ground, captures the waveform of the port, and captures the level of a multi-channel communication channel during normal communication and static state;
detecting the current of the battery controller in normal operation, the current in a sleep state, the voltage level of a main power supply port, the voltage level of each input/output port and the ground impedance of the battery controller in a non-operation state by using a digital multimeter;
and in the detection process of the battery controller, if a failure item is detected, continuously setting according to the software of the industrial personal computer, and selecting to continuously carry out the test or immediately stop the test.
Further, after the function detection of the battery controller is finished, if the detection result is qualified, the industrial personal computer sends an instruction to the DIO card, the DIO card is matched with the pneumatic clamp to pop out a detected sample, the system returns to a state to be detected, the code scanning gun is activated to wait for scanning the next battery controller, and an operator puts in the next sample to be detected according to the prompt of the software interface to perform continuous detection.
An automatic detection method based on a lithium battery controller of an electric vehicle comprises the following steps:
the battery control unit with the identification code is placed in a mold and pressed down, a proximity switch is in contact with a sample to be detected, the proximity switch sends confirmation information to a DIO card, an industrial personal computer controls the closing of an electromagnetic valve through the DIO card after information processing, and further controls a pneumatic clamp to be tightened, and the pneumatic clamp, the battery controller to be detected and the mold are tightly attached; scanning an identification code on a controller of the tested battery, and if the format of the identification code is correct, enabling the system to enter a state to be detected;
before the automatic detection of the battery controller, configuring a test category and a test sequence according to test requirements, and configuring a test mode as a continuous test or a word test;
pressing a contact button, automatically detecting and awakening, enabling a light curtain to enter a normal working state, scanning a region to be detected by the light curtain all the time in the working process, and stopping the automatic detection immediately if an operator mistakenly puts a hand or an object into a detection region; if no illegal operation exists, automatic detection based on the lithium battery controller of the electric vehicle is carried out;
initiating an automated testing process of a battery controller, comprising:
performing non-charged routine detection: the method comprises the following steps of detecting earth impedance and static working current of a battery controller, controlling a digital multimeter to be used by an industrial personal computer in a TCP/IP communication mode, automatically distributing virtual physical addresses by adopting a network switch, controlling a normally open end of a relay associated with the digital multimeter in an equipment access area of a switch matrix to be closed by the industrial personal computer in the TCP/IP communication mode, controlling the relay in a pin port area of the switch matrix to act, and enabling earth impedance testing pins of the battery controller and the digital multimeter to form a testing loop;
a four-wire system is adopted for testing the earth impedance;
a static working current detection control switch matrix connects a digital multimeter in series with a power supply circuit of a battery controller;
carrying out electrified conventional detection on the battery controller, controlling a switch matrix by an industrial personal computer, putting a low-voltage power supply module into use, and controlling a digital multimeter to measure pin voltage and rated working current of the battery controller; the industrial personal computer controls the signal generation module to be used for controlling the digital oscilloscope to be put into measurement work so as to verify that the battery controller can normally receive external PWM or other signals and is controlled by the corresponding output pin, and the digital oscilloscope detects the working state and the waveform of the output pin; the industrial personal computer sends a control instruction to the tested battery controller through the CAN card in a CAN communication mode, performs information interaction with the tested battery controller, and the software performs result judgment on the test item according to information fed back by the battery controller;
carrying out high-voltage test, and controlling the program-controlled high-voltage power supply to work by the industrial personal computer;
and carrying out load switching detection, controlling a simulated load switching-in circuit and a simulated load switching-out circuit, and respectively detecting the working states of the battery controller under the load condition and the no-load condition according to the test environment.
Compared with the prior art, the invention has the beneficial effects that: the invention reduces the design cost as much as possible, the measuring equipment uses a digital multimeter and an oscilloscope, the low-voltage power supply module is used for supplying power to the tested object, the signal source uses a high-voltage power supply, a signal generating module and the like, the required equipment and modules are flexibly configured for different testing purposes by combining with the switch matrix, the influence of replacing a certain module on the testing platform is reduced to the minimum, the testing item and the testing sequence are freely configured by controlling the relay matrix through software, the building difficulty of the automatic testing platform is reduced, the production data is saved, and the testing efficiency is improved.
Drawings
FIG. 1 is a diagram of an automatic detection device based on a lithium battery controller of an electric vehicle according to an embodiment of the present invention;
fig. 2 is a schematic diagram of installation of each device location provided by an example of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Referring to fig. 1 and fig. 2, an embodiment of the invention relates to an automatic detection device for a lithium battery controller of an electric vehicle. The method comprises the following steps:
the utility model provides an automatic detection device based on electric automobile lithium battery controller, the device includes:
the industrial personal computer 1 is inserted into the CAN card 8 in a PCI mode to realize communication with the battery controller, is accessed into the DIO card 2 in a PCI mode to realize control of the pneumatic clamp and detection of a proximity switch signal, and controls the program-controlled high-voltage power supply and the code scanning gun to realize an identification code recognition function through USB communication;
a mold 17 for placing the battery controller to be tested;
a pneumatic clamp 6 for fixing the battery controller to be tested in the mold;
a contact button 18 which is connected to the input terminal of the DIO card 2 through a shielded signal line;
the code scanning gun 7 is communicated with an industrial personal computer in a USB mode and is used for identifying the unique identification code of the tested battery controller;
the proximity switch 4 is connected to the DIO card through a shielding signal wire;
the light curtain 3 is connected to the DIO card in a signal line shielding mode, so that the safety of testers in the test process is ensured;
the electromagnetic valve 5 is connected to the output control end of the DIO card in a signal shielding wire mode and controls the power-on state of the pneumatic clamp;
the CAN card is used for realizing the communication between the industrial personal computer and the controller of the battery to be detected in a CAN communication mode;
the DIO card is used for collecting the state of the proximity switch and controlling the power-on state of the electromagnetic valve together with the manual switch;
the digital multimeter 10 is in remote communication with an industrial personal computer through TCP/IP and is used for measuring the voltage, the current and the impedance of a battery controller to be measured;
the digital oscilloscope 11 realizes remote communication with an industrial personal computer through TCP/IP and mainly realizes voltage waveform capture of an output port of the controller of the battery to be detected;
the program-controlled high-voltage power supply 12 is in remote communication with an industrial personal computer through a USB (universal serial bus), and provides high-voltage required by testing for a tested battery controller;
the network switch 9 is arranged among the digital multimeter, the digital oscilloscope and the industrial personal computer, and realizes automatic allocation of virtual addresses of the digital multimeter and the digital oscilloscope through the switch;
the switch matrix 15 is in remote communication with the industrial personal computer through TCP/IP, realizes signal transfer, and distributes input resources and measurement resources for test items;
the signal generation module 13 is not programmed and provides waveforms such as square waves with adjustable amplitude, duty ratio and frequency for the battery controller;
the low-voltage power supply module 14 is non-program-controlled and provides proper working voltage for the tested battery controller;
and the simulation load 16 simulates the load of the tested battery controller.
Specifically, a DIO card 2 is inserted into an industrial personal computer 1 in a PCI-E mode, a light curtain 3 is connected into an input port of the DIO card 2 through a signal shielding line, a proximity switch 4 is connected into the input port of the DIO card 2 through the signal shielding line, an electromagnetic valve 5 is connected into an output port of the DIO card 2 through the shielding line, the electromagnetic valve 5 is connected into a positive circuit of a power supply of a pneumatic clamp 6 in series, when the electromagnetic valve 5 is controlled to act and close, the pneumatic clamp works normally, a mould 17 is used for containing a tested battery controller, the mould 17 is matched with the pneumatic clamp 6 to tightly clamp a tested sample, the mould 17 contains a probe, the probe is connected to a DB25 adapter through an aviation plug and a shielding signal line, a port access area of a switch matrix 15 is connected with the DB25 adapter through a signal line, a CAN card 8 is inserted into the industrial personal computer 1 in a PCI mode and is responsible for communication with the tested battery controller, a code scanning gun 7, the digital multimeter 10 and the digital oscilloscope 11 are connected into a network switch 9 through network ports, so that an industrial personal computer 1 controls the digital multimeter 10 and the digital oscilloscope 11 through TCP/IP communication, the industrial personal computer 1 sends a control instruction, the digital multimeter 10 and the digital oscilloscope 11 return response data to the industrial personal computer 1, the program-controlled high-voltage source 12 is connected into the industrial personal computer 1 in a USB mode, the industrial personal computer 1 sends the control instruction to the program-controlled high-voltage source 12 through serial communication, the program-controlled high-voltage source 12 feeds back response data to the industrial personal computer 1, the digital multimeter 10, the digital oscilloscope 11, the program-controlled high-voltage source 12, the signal generation module 13, the low-voltage power supply module 14 and a functional port of an analog load 16 are connected into a device access port area of a switch matrix 15 through a signal shielding line and a power shielding line, the switch matrix 15 is controlled by the industrial personal, And C, automatic software control of development.
The two low-voltage power supply modules are all output to the die through the switch matrix, each low-voltage power supply module is multi-channel voltage output, one of the low-voltage power supply modules provides 9-18V voltage to provide a working power supply level for a tested battery controller, and the other low-voltage power supply module provides 1-10V low voltage to provide analog voltage for a specific test item.
The two signal generation modules are all output to a tested battery controller of the mold through a switch matrix, wherein one of the two signal generation modules provides square waves with adjustable frequency, amplitude and duty ratio for the tested battery controller, and the other signal generation module provides triangular waves for the tested battery controller.
The independent identification bar code or other identification codes of each tested battery controller are identified by a code scanning gun, and the next operation can be carried out when the identification passes.
The mould contains the probe, and the probe is connected to DB25 adapter through aviation plug and shielding signal line, and switch matrix's port access district links to each other with DB25 adapter through the signal line.
After an operator puts in the tested battery controller, the operator detects that all positions are in place through the proximity switch, the pneumatic clamp is tightened, the test is controlled to start by matching with the double-contact button, and meanwhile, the light curtain is in a normal detection state; in the normal detection process, if the light curtain is triggered, the existing test is stopped, the clamp is loosened, and the tested battery controller is popped up.
In the detection process of the battery controller, the industrial personal computer controls whether each power supply is connected to the detected battery controller or not through the switch matrix, controls each measuring device to be connected to the corresponding pin to be detected, and controls the signal generating device to be connected to the corresponding pin to be input;
the industrial personal computer is communicated and controlled with the tested battery controller through the CAN card;
the digital oscilloscope tests a port with a PWM output ground, captures the waveform of the port, and captures the level of a multi-channel communication channel during normal communication and static state;
detecting the current of the battery controller in normal operation, the current in a sleep state, the voltage level of a main power supply port, the voltage level of each input/output port and the ground impedance of the battery controller in a non-operation state by using a digital multimeter;
and in the detection process of the battery controller, if a failure item is detected, continuously setting according to the software of the industrial personal computer, and selecting to continuously carry out the test or immediately stop the test.
After the function detection of the battery controller is finished, if the detection result is qualified, the industrial personal computer sends an instruction to the DIO card, the DIO card is matched with the pneumatic clamp to pop up a sample to be detected, the system returns to a state to be detected, the code scanning gun is activated to wait for scanning the next battery controller, and an operator puts the next sample to be detected according to the prompt of a software interface to perform continuous detection.
The working method of the automatic detection device for the lithium battery controller of the electric automobile comprises the following steps: firstly, a battery control unit with an identification code is placed into a mold 17 and pressed downwards, a proximity switch 4 contacts a tested sample, the proximity switch 4 sends 'confirmation' information to a DIO card 2, an industrial personal computer 1 controls an electromagnetic valve 5 to be closed through the DIO card 2 after information processing, and then a pneumatic clamp 6 is controlled to be tightened, and the pneumatic clamp 6, the tested sample and the mold 17 are tightly attached; and scanning the identification code on the detected sample by an operator, and if the format of the identification code is correct, entering a state to be detected by the system.
Before the automatic detection of the battery controller, technicians need to configure test categories and test sequences according to test requirements, and configure a test mode to be a continuous test or a word test.
The contact button 18 is pressed by an operator, the automatic detection is awakened, the light curtain 3 enters a normal working state, the light curtain 3 can always scan the region to be detected in the working process, and if the operator mistakenly extends a hand or an object into the detection region, the automatic detection stops immediately. And if no illegal operation exists, the system carries out automatic detection based on the lithium battery controller of the electric automobile.
In the automatic detection process of the battery controller, firstly, non-electrified conventional detection is carried out: the method comprises the steps of detecting earth impedance and static working current of a battery controller, controlling a digital multimeter 10 to be used by an industrial personal computer 1 in a TCP/IP communication mode, automatically distributing virtual physical addresses by adopting a network switch 9 in a system due to more network port communication equipment in the system, controlling a normally open end of a relay associated with the digital multimeter 10 in an equipment access area of a switch matrix 15 to be closed by the industrial personal computer 1 in the TCP/IP communication mode, controlling the relay in a pin port area of the switch matrix 15 to act, and enabling earth impedance testing pins of the battery controller to form a testing loop with the digital multimeter 10. And a four-wire system is adopted for testing the earth impedance, so that the detection precision can be improved. Quiescent operating current detection requires control switch matrix 15 to connect digital multimeter 10 in series with a power supply circuit such as a battery controller. And secondly, carrying out electrified conventional detection on the battery controller, controlling a switch matrix 15 by the industrial personal computer 1, enabling a low-voltage power supply module 14 to be put into use, and controlling the digital multimeter 10 to measure pin voltage and rated working current of the battery controller. Detecting the peripheral access function again, controlling the signal generation module 13 to be put into use by the industrial personal computer 1, controlling the digital oscilloscope 11 to be put into measurement work so as to verify that the battery controller can normally receive external PWM or other signals, reasonably controlling the battery controller by the corresponding output pin, and detecting the working state and waveform of the output pin by the digital oscilloscope 11; the industrial personal computer 1 sends a control instruction to the tested battery controller through the CAN card 8 in a CAN communication mode, performs information interaction with the tested battery controller, and the software performs result judgment on the test item according to information fed back by the battery controller. Carrying out high-voltage test again, and controlling the program-controlled high-voltage power supply 12 to work by the industrial personal computer 1; and finally, carrying out load switching detection, controlling a switching-in circuit and a switching-out circuit of the analog load 16, and respectively detecting the working states of the battery controller under the load and the no-load conditions according to the test environment.
In the detection process of the battery controller, an upper computer based on LabView and C language provides a good human-computer interaction interface, and real-time detection data monitoring is provided in the detection process so as to provide an operator to monitor the detection condition in real time. When a failure item occurs in certain detection, an operator can decide whether the system continues to detect or not by himself, and the configuration is convenient, fast and real-time.
After the detection of the battery controller is finished, the software system can count the test results of the independent detection items, automatically give out the whole test result, present the final test result to a human interface, and gather all the test information by the software to form a gathering file and store the gathering file to a corresponding storage disc of the industrial personal computer 1. Industrial computer 1 sends through DIO card 2 to pneumatic fixture 6 and looses the instruction, and light curtain 3 became invalid simultaneously, and pneumatic fixture 6 separates with mould 17, and human-computer interaction interface suggestion operator takes out this tested battery controller sample, and then reminds the operator to put into next sample, sweeps a yard rifle and gets into and treats operating condition to wait for the continuous cycle detection like above-mentioned step.
A good human-computer interaction interface adopts a nested structure plus a 'producer-consumer' cycle, similar test items are written into an independent subprogram, all the independent subprograms can independently run, and can also be coordinately run as a part of the whole system, and the method comprises the following steps: the system comprises a system configuration interface, a monitoring interface and an administrator interface, wherein each interface is attractive and elegant and has complete functions, a human-computer interaction interface is a central pivot for interaction between an experimenter and information, and the interface takes vision as a theme and highlights key factors such as characters, icons and the like; the human-computer interaction interface collects and feeds back signals, processes the signals according to collected data, filters useful information, forms active feedback and transmits the information to a lower computer.
In this embodiment, the types of the devices for realizing the above are preferably: an industrial personal computer: hua 610-L; and (3) DIO card: tuhua PCI-1730-U; CAN card: zhou Li Gong PCI-9810I; sweep a yard rifle: Zebra-DS 2208; a contact button: LA 38-11; light curtain: MONCEE GTS 20-16-A; a digital multimeter: is Dekoku 34461A; a digital oscilloscope: RIGOL DS1104 ZPlus; program-controlled high-voltage power supply: HSPY-400-01; the switch matrix consists of 5 32 relays: the electronic DAM3200A board card of gathering is made up; a low-voltage module: the voltage-reducing power supply is based on the LM2596-ADJ chip.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (9)
1. The utility model provides an automatic detection device based on electric automobile lithium battery controller which characterized in that, the device includes:
the industrial personal computer is inserted into the CAN card in a PCI mode to realize communication with the battery controller, is accessed into the DIO card in a PCI mode to realize control of the pneumatic clamp and detection of a proximity switch signal, and controls the program-controlled high-voltage power supply and the code scanning gun to realize an identification code recognition function through USB communication;
the mould is used for placing the tested battery controller;
the pneumatic clamp is used for fixing the tested battery controller into the mold;
the contact button is connected to the input end of the DIO card through a shielding signal line;
the code scanning gun is communicated with the industrial personal computer in a USB mode and is used for identifying the unique identification code of the tested battery controller;
the proximity switch is connected to the DIO card through a shielding signal line;
the light curtain is connected to the DIO card in a signal line shielding mode, so that the safety of testers in the test process is ensured;
the electromagnetic valve is connected to the output control end of the DIO card in a signal wire shielding mode and controls the power-on state of the pneumatic clamp;
the CAN card is used for realizing the communication between the industrial personal computer and the controller of the battery to be detected in a CAN communication mode;
the DIO card is used for collecting the state of the proximity switch and controlling the power-on state of the electromagnetic valve together with the manual switch;
the digital multimeter realizes remote communication with the industrial personal computer through TCP/IP and measures the voltage, current and impedance of the tested battery controller;
the digital oscilloscope realizes remote communication with the industrial personal computer through TCP/IP and mainly realizes voltage waveform capture of the output port of the controller of the battery to be tested;
the program-controlled high-voltage power supply realizes remote communication with the industrial personal computer through a USB and provides high-voltage required by testing for the tested battery controller;
the network switch is arranged among the digital multimeter, the digital oscilloscope and the industrial personal computer and realizes automatic allocation of virtual addresses of the digital multimeter and the digital oscilloscope through the switch;
the switch matrix is in remote communication with the industrial personal computer through TCP/IP, realizes signal transfer, and distributes input resources and measurement resources for test items;
the signal generation module is not programmed and provides waveforms such as square waves with adjustable amplitude, duty ratio and frequency for the battery controller;
the low-voltage power supply module is non-program-controlled and provides proper working voltage for the tested battery controller;
and simulating a load, namely simulating the load of the tested battery controller.
2. The apparatus of claim 1, wherein two of said low voltage power supply modules are provided, each of which is provided with a multi-channel voltage output through a switch matrix, one of which provides a voltage of 9-18V for providing an operating power supply level for the battery controller under test, and the other of which provides a low voltage of 1-10V for providing an analog voltage for a specific test item.
3. The device as claimed in claim 1, wherein the signal generating modules are two, and the two are output to the tested battery controller of the mold through the switch matrix, wherein one of the two is used for providing a square wave with adjustable frequency, amplitude and duty ratio for the tested battery controller, and the other is used for providing a triangular wave for the tested battery controller.
4. The apparatus of claim 1, wherein each battery controller under test is identified by its own identification bar code or other identification code using a code scanning gun, and the identification pass can be followed.
5. The apparatus of claim 1 wherein the mold contains probes that are connected to a DB25 adapter via an air plug and shielded signal line, and the port access area of the switch matrix is connected to a DB25 adapter via a signal line.
6. The device of claim 1, wherein after an operator puts in the tested battery controller, the positions are detected to be in place through the proximity switch, the pneumatic clamp is tightened, the double-contact button is matched to control the test to start, and the light curtain is in a normal detection state; in the normal detection process, if the light curtain is triggered, the existing test is stopped, the clamp is loosened, and the tested battery controller is popped up.
7. The device according to claim 1, wherein in the process of detecting the battery controller, the industrial personal computer controls whether each power supply is connected with the detected battery controller or not through the switch matrix, controls each measuring device to be connected with the corresponding pin to be detected, and controls the signal generating device to be connected with the corresponding pin to be input;
the industrial personal computer is communicated and controlled with the tested battery controller through the CAN card;
the digital oscilloscope tests a port with a PWM output ground, captures the waveform of the port, and captures the level of a multi-channel communication channel during normal communication and static state;
detecting the current of the battery controller in normal operation, the current in a sleep state, the voltage level of a main power supply port, the voltage level of each input/output port and the ground impedance of the battery controller in a non-operation state by using a digital multimeter;
and in the detection process of the battery controller, if a failure item is detected, continuously setting according to the software of the industrial personal computer, and selecting to continuously carry out the test or immediately stop the test.
8. The device as claimed in claim 1, wherein after the function detection of the battery controller is finished, if the detection result is qualified, the industrial personal computer sends an instruction to the DIO card, the DIO card is matched with the pneumatic clamp to eject the detected sample, the system returns to the state to be detected, the code scanning gun is activated to wait for scanning the next battery controller, and the operator puts in the next sample to be detected according to the prompt of the software interface to perform continuous detection.
9. An automatic detection method based on a lithium battery controller of an electric vehicle is characterized by comprising the following steps:
the battery control unit with the identification code is placed in a mold and pressed down, a proximity switch is in contact with a sample to be detected, the proximity switch sends confirmation information to a DIO card, an industrial personal computer controls the closing of an electromagnetic valve through the DIO card after information processing, and further controls a pneumatic clamp to be tightened, and the pneumatic clamp, the battery controller to be detected and the mold are tightly attached; scanning an identification code on a controller of the tested battery, and if the format of the identification code is correct, enabling the system to enter a state to be detected;
before the automatic detection of the battery controller, configuring a test category and a test sequence according to test requirements, and configuring a test mode as a continuous test or a word test;
pressing a contact button, automatically detecting and awakening, enabling a light curtain to enter a normal working state, scanning a region to be detected by the light curtain all the time in the working process, and stopping the automatic detection immediately if an operator mistakenly puts a hand or an object into a detection region; if no illegal operation exists, automatic detection based on the lithium battery controller of the electric vehicle is carried out;
initiating an automated testing process of a battery controller, comprising:
performing non-charged routine detection: the method comprises the following steps of detecting earth impedance and static working current of a battery controller, controlling a digital multimeter to be used by an industrial personal computer in a TCP/IP communication mode, automatically distributing virtual physical addresses by adopting a network switch, controlling a normally open end of a relay associated with the digital multimeter in an equipment access area of a switch matrix to be closed by the industrial personal computer in the TCP/IP communication mode, controlling the relay in a pin port area of the switch matrix to act, and enabling earth impedance testing pins of the battery controller and the digital multimeter to form a testing loop;
a four-wire system is adopted for testing the earth impedance;
a static working current detection control switch matrix connects a digital multimeter in series with a power supply circuit of a battery controller;
carrying out electrified conventional detection on the battery controller, controlling a switch matrix by an industrial personal computer, putting a low-voltage power supply module into use, and controlling a digital multimeter to measure pin voltage and rated working current of the battery controller; the industrial personal computer controls the signal generation module to be used for controlling the digital oscilloscope to be put into measurement work so as to verify that the battery controller can normally receive external PWM or other signals and is controlled by the corresponding output pin, and the digital oscilloscope detects the working state and the waveform of the output pin; the industrial personal computer sends a control instruction to the tested battery controller through the CAN card in a CAN communication mode, performs information interaction with the tested battery controller, and the software performs result judgment on the test item according to information fed back by the battery controller;
carrying out high-voltage test, and controlling the program-controlled high-voltage power supply to work by the industrial personal computer;
and carrying out load switching detection, controlling a simulated load switching-in circuit and a simulated load switching-out circuit, and respectively detecting the working states of the battery controller under the load condition and the no-load condition according to the test environment.
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Application publication date: 20201103 |