A two-wheeler battery pack shipment test system and method

Abstract

The application discloses a two-wheeled vehicle battery package delivery test system and method, and belongs to the technical field of battery manufacturing and testing, which comprises a control terminal, a communication interface module, a bar code identification module and a manufacturing execution system server; wherein the test management software is configured to perform the following: binding the product identification information with the current test task; calling the corresponding preset test parameters according to the product identification information or user selection; controlling the execution of the automatic test process of the battery package based on the preset test parameters; and generating a test record. Thus, the full-process automatic operation from battery package activation, parameter testing, function verification to data uploading can be realized, manual intervention is reduced, the test efficiency and accuracy are improved, and through the integration with the manufacturing execution system, the real-time uploading of test data and the full-life-cycle tracing are realized, so that the quality reliability and consistency of the delivered battery package are ensured.

Description

Technical Field

[0001] This invention relates to a battery pack shipment testing system and method for two-wheeled vehicles, belonging to the field of battery manufacturing and testing technology. Background Technology

[0002] With the popularization of new energy vehicles, the market size of electric two-wheelers continues to expand. As the core power source of electric two-wheelers, the performance, safety, and reliability of the battery pack directly determine the overall user experience and user safety. Therefore, before the battery pack leaves the factory and is shipped, it must undergo rigorous and comprehensive testing to ensure that each battery meets design specifications and safety standards.

[0003] Currently, the industry generally faces the following problems in the shipping testing of battery packs for two-wheeled vehicles:

[0004] Many production processes still rely on manual use of single-function equipment such as multimeters and internal resistance testers to measure and record each item. This method of testing is cumbersome, time-consuming, and requires high skills from operators, making it difficult to adapt to the needs of large-scale, fast-paced production.

[0005] Manual testing and judgment are easily affected by subjective factors. Different testers and at different times may have different understandings and implementations of the same standard, which makes it difficult to guarantee the consistency of test results and leads to large fluctuations in product quality.

[0006] Test data is mostly stored in paper or scattered spreadsheets, making it difficult to effectively bind and systematically manage with product identification information. If problems arise in subsequent stages or in the market, tracing the root cause of the problem is time-consuming and laborious, which is not conducive to quality control and after-sales analysis.

[0007] Modern smart battery packs typically integrate battery management systems and wireless communication modules, enabling remote monitoring and positioning. Traditional testing methods often struggle to automate and integrate the verification of these complex software configurations, communication functions, and data writing.

[0008] Therefore, there is an urgent need for a shipment testing system and method that can achieve full-process automation, standardized test parameters, traceable test data, and comprehensive coverage of battery pack electrical performance, battery management system (BMS) status, and communication functions, in order to improve testing efficiency and ensure the stability and consistency of product quality. Summary of the Invention

[0009] To address the aforementioned technical problems, this invention provides a two-wheeled vehicle battery pack shipment testing system and method, which can automate the entire process from battery pack activation, parameter testing, functional verification to data uploading, reducing manual intervention, improving testing efficiency and accuracy, and through integration with the manufacturing execution system, enabling real-time uploading of test data and full lifecycle traceability, ensuring the quality reliability and consistency of the battery packs leaving the factory.

[0010] The technical solution adopted by this invention to solve its technical problem is:

[0011] A battery pack shipment testing system for two-wheeled vehicles includes:

[0012] Control terminal, run test management software;

[0013] A communication interface module, connected to the control terminal, is used to establish a data communication link with the battery management system of the battery pack under test;

[0014] A barcode recognition module, connected to the control terminal, is used to obtain the product identification information of the battery pack under test;

[0015] An external manufacturing execution system server that is communicatively connected to the control terminal;

[0016] The test management software is configured to execute:

[0017] Bind the product identification information to the current test task;

[0018] Based on the product identification information or user selection, call the corresponding preset test parameters;

[0019] Based on the preset test parameters, an automated test process for the battery pack is controlled and executed. The automated test process includes detecting and comparing at least one of the battery pack's electrical parameters, identification information, and hardware and software configuration information.

[0020] Test records are generated and uploaded to the manufacturing execution system server.

[0021] Preferably, the communication interface module supports the RS485 communication protocol and / or the Controller Area Network (CLAN) protocol.

[0022] Preferably, the test management software is further configured to support loading test parameter configuration files corresponding to different battery pack models in order to adapt to the test standards of different products.

[0023] Preferably, the test management software is configured to, after performing the automated test and determining that it is qualified, control the communication interface module to write traceability information to the non-volatile memory of the battery management system. The traceability information includes the backend server domain name and the product serial number.

[0024] Preferably, the test management software is further configured to provide an information input interface for receiving and associating at least one of the following information to the test record: shipping address, tester identifier, test quantity, and work order shipping plan number.

[0025] A method for testing the shipment of a battery pack for a two-wheeled vehicle, applied to the aforementioned two-wheeled vehicle battery pack shipment testing system, includes the following steps:

[0026] Activate the battery pack under test to put its battery management system into working condition;

[0027] Establish a data communication connection between the control terminal and the battery management system;

[0028] The product identification information of the battery pack under test is obtained through the barcode recognition module;

[0029] The test management software matches the test standards based on the product identification information and automatically executes the test process to obtain test data;

[0030] The test data is compared with the matching test standards, and the test results are determined.

[0031] A test record containing the product identification information, test data, and judgment results is generated, and the test record is uploaded to the manufacturing execution system server.

[0032] Preferably, after determining that the test is qualified, the following steps are also included:

[0033] The data communication connection is used to write traceability information, including the backend server domain name and product serial number, into the non-volatile memory of the battery management system.

[0034] Preferably, the step of generating test records further includes:

[0035] Associate at least one of the following information entered through the test management software: shipping address, tester ID, test quantity, and work order shipping plan number, with the test record.

[0036] Preferably, after the test process is completed, the method further includes controlling the battery pack to enter a sleep state.

[0037] Preferably, the automatically executed test process includes at least one of the following: static parameter comparison, barcode information verification, hardware and software information verification, and wireless communication module function testing.

[0038] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0039] It achieves full automation from scanning, testing, judgment to data uploading, replacing traditional cumbersome manual operations, greatly shortening the time of a single test, significantly improving testing efficiency, and meeting the needs of mass production;

[0040] The entire testing process is driven by a pre-set, unified test parameter configuration file, which completely eliminates the differences in human operation and judgment, ensuring a high degree of consistency and reliability of test results from different batches and different operators, and ensuring stable product quality.

[0041] Test data is linked to the product serial number in real time and automatically uploaded to the MES system, forming a complete and searchable electronic quality file. This enables full lifecycle data traceability from production to shipment and even after-sales service, greatly facilitating quality analysis and problem localization.

[0042] It not only covers basic electrical parameters such as voltage and temperature, but also automatically verifies the software and hardware version of the battery management system (BMS), tests the function of the wireless communication module, and automatically writes and verifies traceability information, meeting the comprehensive factory inspection requirements for modern smart battery packs.

[0043] The system adopts a parametric design, which can be adapted to different battery pack models by changing the configuration file. The system has low expansion and maintenance costs, making it easy to promote and apply on the production line. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0045] Figure 1 This is a schematic diagram of the structural connection of the two-wheeled vehicle battery pack shipment testing system provided in an embodiment of the present invention;

[0046] Figure 2 This is a flowchart illustrating the battery pack shipment testing method for two-wheeled vehicles provided in an embodiment of the present invention.

[0047] Figure 3 This is a schematic diagram of the test item list executed by the test management software in an embodiment of the present invention. Detailed Implementation

[0048] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0049] Example 1,

[0050] like Figure 1 As shown, the two-wheeled vehicle battery pack shipment testing system of this invention physically constitutes a complete testing station. Its core components include a control terminal, a communication interface module, a barcode recognition module, the battery pack under test, and a manufacturing execution system server. Its core components and their connections are as follows:

[0051] The control terminal is typically an industrial computer with a stable operating environment and network connectivity. It runs specially developed test management software. This software provides a graphical user interface, serving as the main window for operators to interact with the system and monitor the testing process, and is also the core processing unit for executing test logic, data analysis, and data uploading.

[0052] The communication interface module acts as a communication bridge between the control terminal and the battery pack under test. It can be a standalone RS485-to-USB adapter, a CAN card, or a composite communication card integrating both protocols. One end of the module connects to the control terminal, and the other end connects to the communication interface of the battery pack under test via a standard communication cable. The core of the battery pack consists of the battery management system and battery modules composed of multiple cells. The battery management system manages the battery status and communicates with external devices via RS485 or CAN bus.

[0053] A barcode recognition module is typically a handheld or fixed scanner that connects to a control terminal via USB cable or wirelessly. Its function is to quickly and accurately read the product identification barcode affixed to the casing of the battery pack under test. This barcode usually contains information such as a serial number.

[0054] The Manufacturing Execution System (MES) server is deployed in the factory network environment and communicates with the control terminals via the network. It is responsible for receiving, storing, and managing test records uploaded from various test stations, providing data support for production management and quality traceability.

[0055] Furthermore, such as Figure 2 As shown, the test management software is configured to perform the following core functions:

[0056] Receive product identification information from the barcode recognition module and uniquely bind it to the currently initiated test task to ensure that all subsequent test data can be accurately associated with the specific battery pack.

[0057] The system automatically identifies the battery pack model based on the bound product identification information, or receives the operator's selection instructions through the user interface and calls the preset test parameter configuration file corresponding to the model from the configuration library. The configuration file defines the pass threshold, verification rules, communication instruction format, etc. for all test items.

[0058] Based on the preset test parameters, the software automatically generates and sequentially sends a series of test commands, which are then sent to the battery management system of the battery pack through the communication interface module, and the software receives the response data. The entire process does not require manual operation step by step.

[0059] The software records the instructions, response data, and timestamps of each test step in real time, and automatically compares and judges each test result according to preset rules, generates a structured and complete test record, and automatically uploads it to the manufacturing execution system server.

[0060] Specifically, the automated testing process covers multiple dimensions of battery pack testing, mainly including:

[0061] Electrical parameter testing, such as static parameters like total battery pack voltage, state of charge, cell temperature, ambient temperature, power transistor temperature, and cell voltage balance;

[0062] Identity and configuration information verification, such as verifying whether the format, length, and fixed characters of the serial number read from the barcode conform to the rules, and reading and verifying whether the hardware version number, software version number, design capacity, cell constant, cell model, and other information read from the battery management system are consistent with the preset standards;

[0063] For smart battery packs with integrated wireless communication modules, functional module tests are conducted, including wireless signal strength, module model identification, GPS positioning status, and network connectivity status.

[0064] In one embodiment, the test management software supports modular and parameterized design. For different models and specifications of battery packs, only the corresponding test parameter configuration files need to be prepared or updated, without modifying the core code of the software itself, greatly enhancing the system's versatility and scalability.

[0065] Furthermore, after the automated testing process determines that the battery pack is qualified, the test management software is also configured to control the communication interface module to write key traceability and configuration information into the non-volatile memory of the battery management system. This information typically includes the domain name of the backend server that needs to be connected after the product leaves the factory, the complete product serial number, etc., and is read back for verification after the writing is completed.

[0066] Furthermore, the test management software also provides an information input interface for receiving additional information related to the current production batch input by the operator during or after the test, such as the shipping destination address, the operator's work ID, the number of tests for this batch, the associated production work order or shipping plan number, etc. This information will be associated with the core test record and uploaded to the manufacturing execution system server together.

[0067] Embodiment 2

[0068] This embodiment provides a two-wheeler battery pack shipping test method applied to the above system, and this method includes the following steps:

[0069] Equipment preparation and battery pack activation to make the battery management system enter the working state;

[0070] Establish a data communication connection between the control terminal and the battery management system;

[0071] Obtain the product identification information of the battery pack to be tested through the barcode identification module;

[0072] The test management software matches the test standard according to the product identification information and automatically executes the test process to obtain test data;

[0073] Compare the test data with the matched test standard and determine the test result;

[0074] Generate a test record including product identification information, test data and determination result, and upload the test record to the manufacturing execution system server.

[0075] Furthermore, after determining that the test is qualified, it also includes the step of writing traceability information including the background server domain name and product serial number into the non-volatile memory of the battery management system through the data communication connection.

[0076] Furthermore, in the step of generating the test record, it also includes associating at least one piece of information such as the shipping address, test personnel identification, test quantity, and work order shipping plan number input through the test management software with the test record.

[0077] Furthermore, after the test process ends, it also includes the step of controlling the battery pack to enter the sleep state.

[0078] Specifically, in one embodiment, taking the lithium-ion two-wheeler battery pack of model EP-4816 as an example,

[0079] The operator powers on a battery pack with a serial number of "EP4816-240401-0001" and connects it to the CAN interface card of the test station computer through the CAN bus.

[0080] After scanning the serial number, the software identifies the model "EP-4816" and automatically loads the corresponding configuration file. This file defines parameters such as the total voltage acceptable range, state of charge range, maximum permissible temperature difference, maximum permissible cell voltage difference, expected battery management system hardware and software version, wireless module model, and minimum signal strength.

[0081] The software automatically executes preset test items. Specifically, it reads the total voltage as 52.1V and determines whether it falls within the preset range of 48.0V to 54.6V; it reads the battery management system software version and determines whether it matches the preset "1.2.3"; it reads the wireless module signal strength and determines whether it exceeds the preset -95dBm threshold; it reads the voltage of all battery cells and calculates the maximum voltage difference, determining whether it is less than the preset 50mV threshold. All items are tested and compared one by one.

[0082] All items passed, and the software indicated success. The backend server domain name and complete serial number were then written to the battery management system and verified successfully. The operator entered the relevant work order number. The software then put the battery pack into sleep mode and uploaded a complete test record containing all the above data to the manufacturing execution system server.

[0083] By applying this system and methodology, the following significant results were achieved on the customer's production line: Testing efficiency was greatly improved, with the testing time for a single battery pack reduced from approximately 8-10 minutes using traditional methods to 2-3 minutes. Testing consistency was extremely high, eliminating human error and operational discrepancies; test results from different shifts and personnel were completely consistent. Comprehensive electronic traceability was achieved; each shipped battery pack has a complete test file in the Manufacturing Execution System, significantly reducing the average time for identifying quality issues. The professional skills required of operators and training costs were reduced; operators only need to perform simple actions such as placing the battery, scanning the barcode, and clicking start. A reliable quality assurance foundation was provided for intelligent product upgrades, ensuring the reliability of automated verification and configuration of the battery management system software version and wireless communication functions.

[0084] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A battery pack shipment testing system for two-wheeled vehicles, characterized in that, include: Control terminal, run test management software; A communication interface module, connected to the control terminal, is used to establish a data communication link with the battery management system of the battery pack under test; A barcode recognition module, connected to the control terminal, is used to obtain the product identification information of the battery pack under test; An external manufacturing execution system server that is communicatively connected to the control terminal; The test management software is configured to execute: Bind the product identification information to the current test task; Based on the product identification information or user selection, call the corresponding preset test parameters; Based on the preset test parameters, an automated test process for the battery pack is controlled and executed. The automated test process includes detecting and comparing at least one of the battery pack's electrical parameters, identification information, and hardware and software configuration information. Test records are generated and uploaded to the manufacturing execution system server.

2. The two-wheeled vehicle battery pack shipment testing system according to claim 1, characterized in that, The communication interface module supports RS485 communication protocol and / or controller area network protocol.

3. The two-wheeled vehicle battery pack shipment testing system according to claim 1, characterized in that, The test management software is also configured to support loading test parameter configuration files corresponding to different battery pack models in order to adapt to the test standards of different products.

4. The two-wheeled vehicle battery pack shipment testing system according to claim 3, characterized in that, The test management software is configured to, after executing the automated test and determining that it is qualified, control the communication interface module to write traceability information to the non-volatile memory of the battery management system. The traceability information includes the backend server domain name and the product serial number.

5. The two-wheeled vehicle battery pack shipment testing system according to claim 1, characterized in that, The test management software is also configured to provide an information input interface for receiving and associating at least one of the following information to the test record: shipping address, tester identifier, test quantity, and work order shipping plan number.

6. A method for testing the shipment of a two-wheeled vehicle battery pack, applied to the two-wheeled vehicle battery pack shipment testing system as described in any one of claims 1 to 5, characterized in that, Includes the following steps: Activate the battery pack under test to put its battery management system into working condition; Establish a data communication connection between the control terminal and the battery management system; The product identification information of the battery pack under test is obtained through the barcode recognition module; The test management software matches the test standards based on the product identification information and automatically executes the test process to obtain test data; The test data is compared with the matching test standards, and the test results are determined. A test record containing the product identification information, test data, and judgment results is generated, and the test record is uploaded to the manufacturing execution system server.

7. The method for testing the shipment of a two-wheeled vehicle battery pack according to claim 6, characterized in that, After determining that the test is passed, the following is also included: The data communication connection is used to write traceability information, including the backend server domain name and product serial number, into the non-volatile memory of the battery management system.

8. The method for testing the shipment of a two-wheeled vehicle battery pack according to claim 6, characterized in that, The steps for generating test records also include: Associate at least one of the following information entered through the test management software: shipping address, tester ID, test quantity, and work order shipping plan number, with the test record.

9. The method for testing the shipment of a two-wheeled vehicle battery pack according to claim 6, characterized in that, After the test process is completed, the method also includes: controlling the battery pack to enter a sleep state.

10. The method for testing the shipment of a two-wheeled vehicle battery pack according to claim 6, characterized in that, The automatically executed test process includes at least one of the following: static parameter comparison, barcode information verification, hardware and software information verification, and wireless communication module function testing.

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