Insulation testing device and method for industrial and commercial battery systems

Abstract

This invention proposes an insulation testing device and method for industrial and commercial battery storage systems. The insulation testing device includes a high-voltage connection module, an insulation resistance adjustment module, a polarity switching module, and a human-machine interface module. The high-voltage connection module, the polarity switching module, and the insulation resistance adjustment module are connected sequentially. The human-machine interface module outputs corresponding resistance switching signals and polarity switching signals to the polarity switching module and the insulation resistance adjustment module according to the insulation test operation, so as to connect the positive or negative terminal of the battery module to the corresponding test resistor. At the same time, the human-machine interface module communicates with the battery management system and triggers the battery management system to perform insulation testing, and communicates to obtain the insulation test results. The insulation testing device controls the battery management system to realize insulation testing and verify the test results, thereby improving testing efficiency and safety.

Description

Technical Field

[0001] This invention belongs to the technical field of industrial and commercial battery systems, and particularly relates to an insulation testing device and method for industrial and commercial battery systems. Background Technology

[0002] During the research and development testing phase of commercial and industrial battery systems (such as a 261kWh system using 314Ah cells, with 260 cells connected in series to form a DC high voltage), the insulation detection function of the battery management system needs to be tested. This includes testing the accuracy of detecting the insulation resistance between the positive and negative terminals and ground, as well as the protection function that triggers minor, general, and severe fault alarms when the resistance is lower than different thresholds.

[0003] The existing testing method involves manual testing, where wires are directly connected to the positive and negative terminals of the battery, and the insulation resistance is adjusted by shorting to ground or connecting a 1kΩ~1MΩ resistor in series. The tester must directly contact the high-voltage circuit, which can easily cause electric shock accidents, posing a significant safety hazard, and the testing efficiency is low. Summary of the Invention

[0004] The purpose of this invention is to provide an insulation testing device for industrial and commercial battery storage systems, which aims to solve the problems of low safety and low testing efficiency in traditional methods for testing the insulation function of battery management systems.

[0005] A first aspect of the present invention provides an insulation testing device for an industrial and commercial battery storage system, the industrial and commercial battery storage system including a battery module and a battery management system, the battery module including a plurality of cells connected in series; The insulation testing device includes: A high-voltage connection module is used to connect the positive and negative terminals of the battery module; An insulation resistance adjustment module includes a switching circuit and multiple test resistors with different resistance values. The switching circuit is used to switch the test resistors connected to different resistance values ​​according to a resistance switching signal. A polarity switching module is connected between the high voltage connection module and the insulation resistance adjustment module. The polarity switching module is used to connect the positive terminal or the negative terminal to the corresponding test resistor according to the polarity switching signal. The human-machine interaction module is connected to the insulation resistance adjustment module, the polarity switching module, and the battery management system, respectively. The human-machine interaction module is used for: According to the insulation test operation, output the corresponding resistance value switching signal and the polarity switching signal; The system communicates with the battery management system and triggers the battery management system to perform an insulation test, and then communicates to obtain the insulation test results.

[0006] Optionally, the battery management system is further configured to read the temperature of each of the battery cells and the voltage difference between each of the battery cells; The human-computer interaction module is also used for: The system communicates with the battery management system to obtain the temperature and voltage difference of each cell. When the temperature and voltage difference of the cell are within a preset threshold, the system triggers the output of a corresponding switching signal and triggers the battery management system to perform an insulation test. Otherwise, the system triggers the shutdown of the insulation resistance adjustment module and the polarity switching module and triggers the battery management system to stop the insulation test.

[0007] Optionally, the insulation testing device further includes: A leakage current detection module is connected between the insulation resistance adjustment module and the polarity switching module. The leakage current detection module is also connected to the human-machine interaction module. The leakage current detection module is used to detect the leakage current of the test path between the insulation resistance adjustment module and the polarity switching module. The human-computer interaction module is also used for: The leakage current is acquired during the insulation test of the battery management system; When the leakage current does not exceed the preset leakage current, the insulation test results are obtained via communication. When the leakage current exceeds the preset leakage current, an alarm is triggered and the insulation resistance adjustment module and the polarity switching module are shut down.

[0008] Optionally, the switching circuit includes a plurality of first high-voltage relays, each of which is connected in series with a test resistor to form a resistance loop. The plurality of resistance loops are connected in parallel between the polarity switching module and the grounding terminal, and the plurality of first high-voltage relays are respectively connected to the human-machine interaction module.

[0009] Optionally, the polarity switching module includes: Two second high-voltage relays are provided. The first terminals of the two second high-voltage relays are respectively connected to the positive terminal and the negative terminal through the high-voltage connection module. The second terminals of the two second high-voltage relays are also respectively connected to the insulation resistance adjustment module. The control terminal of the two high-voltage relays is connected to the human-machine interaction module.

[0010] Optionally, the human-computer interaction module is further used for: Upon receiving an insulation test operation, the switching status of the two second high-voltage relays is acquired; If the non-target second high-voltage relay is detected to be on and the target second high-voltage relay is detected to be off, switch the control of the non-target second high-voltage relay to be off and delay for a preset time to obtain the switching state of the control of the non-target second high-voltage relay; When it is determined that the non-target second high-voltage relay is in the off state, the target second high-voltage relay is controlled to be turned on; And when it is detected that both of the second high-voltage relays are in the on state, the control of the two second high-voltage relays is triggered to turn off and an alarm is issued.

[0011] Optionally, the high-voltage connection module includes a first terminal block and a second terminal block, wherein the first terminal block is connected between the positive terminal and one of the second high-voltage relays, and the second terminal block is connected between the negative terminal and the other second high-voltage relay.

[0012] Optionally, the human-computer interaction module is further used for: The corresponding polarity switching signal is output according to the open circuit operation, and the insulation resistance adjustment module is turned off. The system communicates with the battery management system, reads the open-circuit detection status of the battery management system, and records the open-circuit test results.

[0013] Optionally, the insulation testing device further includes: A fuse is connected between the insulation resistance adjustment module and the polarity switching module, and the fuse blows when there is an overcurrent. A short-circuit test interface is used to short-circuit the positive terminal and the negative terminal during a short-circuit test operation.

[0014] A second aspect of this invention provides an insulation testing method for an industrial and commercial battery storage system, applied to the insulation testing device described above, the insulation testing method comprising: Disconnect the battery module from the external connection line, and connect the high voltage connection module and the positive and negative terminals of the battery module with a jumper wire; The output polarity switching signal controls the polarity switching module to be connected to the positive or negative terminal through the high-voltage connection module; The output resistance switching signal is sent to the switching circuit of the insulation resistance adjustment module, and the corresponding test resistor of a certain resistance value is selected and connected to the corresponding positive or negative terminal. The system communicates with the battery management system and triggers the battery management system to perform an insulation test, and then communicates to obtain the insulation test results.

[0015] The beneficial effects of this invention embodiment compared with the prior art are as follows: The above-mentioned insulation testing device includes a high-voltage connection module, an insulation resistance adjustment module, a polarity switching module, and a human-machine interaction module. The high-voltage connection module, the polarity switching module, and the insulation resistance adjustment module are connected in sequence. The human-machine interaction module outputs corresponding resistance switching signals and polarity switching signals to the polarity switching module and the insulation resistance adjustment module according to the insulation test operation, so as to connect the positive or negative terminal of the battery module to the corresponding test resistor. At the same time, the human-machine interaction module communicates with the battery management system and triggers the battery management system to perform insulation testing, and communicates to obtain the insulation test results. The insulation testing device controls the battery management system to realize insulation testing and verify the test results, thereby improving testing efficiency and safety. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the insulation testing device provided in an embodiment of the present invention; Figure 2 A circuit diagram of the insulation testing device provided in an embodiment of the present invention; Figure 3 This is a schematic flowchart of the insulation testing method provided in an embodiment of the present invention. Detailed Implementation

[0017] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0018] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0019] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0020] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0021] The first aspect of this invention proposes an insulation testing device for commercial and industrial battery systems, which aims to solve the technical defects in the insulation detection and testing of battery management systems in existing commercial and industrial battery systems, such as high risk of electric shock to test personnel, lack of effective safety protection, low testing efficiency and poor accuracy.

[0022] like Figure 1 As shown in the figure, in this embodiment, the industrial and commercial battery storage system 100 includes a battery module 110 and a battery management system 120. The battery module 110 includes multiple cells 111 connected in series. The battery management system 120 is used to collect core parameters such as cell temperature, cell voltage difference, and insulation test results in real time, and has functions such as fault alarm and status feedback.

[0023] Insulation testing device 200 includes: High voltage connection module 210 is used to connect the positive terminal B+ and the negative terminal B- of battery module 110; The insulation resistance adjustment module 230 includes a switching circuit 231 and multiple test resistors Rx with different resistance values. The switching circuit 231 is used to switch the test resistors Rx connected to different resistance values ​​according to the resistance switching signal. The polarity switching module 220 is connected between the high voltage connection module 210 and the insulation resistance adjustment module 230. The polarity switching module 220 is used to connect the positive terminal B+ or the negative terminal B- to the corresponding test resistor Rx according to the polarity switching signal. The human-machine interface module 240 is connected to the insulation resistance adjustment module 230, the polarity switching module 220, and the battery management system 120, respectively. The human-machine interface module 240 is used for: According to the insulation test operation, output the corresponding resistance value switching signal and polarity switching signal; The system communicates with the battery management system 120 and triggers the battery management system 120 to perform an insulation test, and then communicates to obtain the insulation test results.

[0024] In this embodiment, the high-voltage connection module 210 is used to connect the positive terminal B+ and the negative terminal B- of the battery module 110. The high-voltage connection module 210 can adopt corresponding copper busbars, interfaces, etc. To adapt to high-voltage transmission, in an optional embodiment, such as... Figure 2As shown, the high-voltage connection module 210 includes a first terminal block 211 and a second terminal block 212, which correspond to the positive terminal B+ and the negative terminal B- of the battery module 110, respectively, to realize the high-voltage interface docking between the test device and the battery module 110.

[0025] Both the first terminal block 211 and the second terminal block 212 are made of copper, and the surface of the terminal blocks is covered with an insulating outer shell. The outer shell is clearly marked with "B+" and "B-" to avoid wiring errors. The terminals of the terminal blocks adopt a crimp-type design to adapt to high-voltage cables, ensuring a firm connection with a contact resistance of ≤5mΩ to prevent overheating and burning under high current.

[0026] To further enhance safety, an insulating pad made of polytetrafluoroethylene (PTFE) is installed between the terminal block and the chassis housing. This pad offers excellent insulation performance and effectively prevents high-voltage leakage from being conducted to the chassis housing. Additionally, the terminal blocks are equipped with insulating protective covers. When not in use, the covers are closed to prevent accidental contact with high-voltage terminals. After wiring is completed, the covers can be securely tightened to prevent cables from loosening.

[0027] The specific connection method of the high-voltage connection module 210 is as follows: one end of the first terminal block 211 is connected to the positive terminal B+ of the battery module 110 through a high-voltage flying wire, and the other end is connected to the first terminal of one of the second high-voltage relays K2 in the polarity switching module 220; one end of the second terminal block 212 is connected to the negative terminal B- of the battery module 110 through a high-voltage flying wire, and the other end is connected to the first terminal of another second high-voltage relay K2 in the polarity switching module 220. The flying wire is made of flame-retardant, high-voltage resistant cable, and the outer layer of the cable is wrapped with a shielding layer to reduce electromagnetic interference. The cable length can be selected according to the requirements of the test site.

[0028] The insulation resistance adjustment module 230 includes a switching circuit 231 and multiple test resistors Rx with different resistance values. The switching circuit 231 is used to switch the test resistors Rx connected to different resistance values ​​according to the resistance switching signal. The switching circuit 231 can be a switching switch or a relay. In an optional embodiment, such as... Figure 2 As shown, the switching circuit 231 includes multiple first high-voltage relays K1. Each first high-voltage relay K1 is connected in series with a test resistor Rx to form a resistance loop. Multiple resistance loops are connected in parallel between the polarity switching module 220 and the grounding terminal. The multiple test resistors Rx include test resistors Rx with different resistance values ​​and zero resistance. The multiple first high-voltage relays K1 are respectively connected to the human-machine interaction module 240. The first high-voltage relays K1 can effectively withstand the voltage and current impact of the high-voltage test environment, ensuring that the switching process is stable and reliable.

[0029] Multiple first high-voltage relays K1 are connected in series with multiple test resistors Rx of different resistance values ​​and a zero resistor, forming multiple independent resistance circuits. All resistance circuits are connected in parallel between the output terminal and the ground terminal of the polarity switching module 220.

[0030] For example Figure 2 As shown, the switching circuit 231 includes eight first high-voltage relays K1. The eight first high-voltage relays K1 are connected in series with seven test resistors Rx of different resistance values ​​and a zero resistor to form eight independent resistance loops.

[0031] Among them, multiple test resistors Rx cover the typical test resistance range of insulation testing for the commercial and industrial battery storage system 100 and battery management system 120. For example, the seven test resistors Rx with different resistance values ​​are 1kΩ, 10kΩ, 100kΩ, 250kΩ, 500kΩ, 750kΩ, and 1MΩ, which can meet the insulation testing requirements under different thresholds. The zero resistance corresponds to the ground short circuit loop and is used to simulate the extreme scenario where the insulation resistance is 0, to verify the serious fault alarm function of the battery management system 120.

[0032] The test resistor Rx is a metal film resistor, which can operate stably for a long time under high voltage conditions without significant resistance drift, ensuring test accuracy. The two ends of the resistor are connected to the contacts of the first high-voltage relay K1 and the grounding terminal respectively via high-voltage wires. The grounding terminal is made of copper and is directly connected to the grounding electrode of the test device to ensure reliable grounding and avoid the risk of leakage.

[0033] The control terminals, i.e. coil pins, of multiple first high-voltage relays K1 are connected to the multi-channel DO interface of the human-machine interface module 240 via wires. Among them, DO0 can be set to correspond to a 1kΩ resistance circuit, DO1 to a 10kΩ resistance circuit, DO2 to a 100kΩ resistance circuit, DO3 to a 250kΩ resistance circuit, DO4 to a 500kΩ resistance circuit, DO5 to a 750kΩ resistance circuit, DO6 to a 1MΩ resistance circuit, and DO7 to a zero-resistance circuit, i.e., a short-circuit circuit to ground.

[0034] The human-machine interaction module 240 drives the first high-voltage relay K1 to conduct by outputting a high level and drives the first high-voltage relay K1 to de-conduct by outputting a low level, thereby achieving precise switching of the resistance circuit. At the same time, in order to avoid resistance deviation caused by multiple resistance circuits conducting at the same time, the human-machine interaction module 240 has built-in logic control to ensure that only one resistance circuit is conducted at the same time.

[0035] To improve heat dissipation performance, multiple first high-voltage relays K1 and multiple test resistors Rx are fixed on a metal heat sink bracket. The heat sink bracket is made of aluminum alloy with an anodized surface, resulting in high heat dissipation efficiency. The heat sink bracket corresponds to the cooling fan inside the chassis, and its speed is adjustable. It can automatically adjust the speed according to the component temperature to ensure that the operating temperature of the first high-voltage relays K1 and test resistors Rx is ≤60℃, thus avoiding component damage or performance degradation caused by high temperature.

[0036] The polarity switching module 220 is connected between the high-voltage connection module 210 and the insulation resistance adjustment module 230. It is used to connect the positive terminal B+ or the negative terminal B- to the corresponding test resistor Rx according to the polarity switching signal. The polarity switching module 220 can adopt a relay, switching switch or other structure. In an optional embodiment, the polarity switching module 220 includes two second high-voltage relays K2. The first terminals of the two second high-voltage relays K2 are respectively connected to the positive terminal B+ and the negative terminal B- through the high-voltage connection module 210. The second terminals of the second high-voltage relays K2 are also respectively connected to the insulation resistance adjustment module 230. The control terminal of the second high-voltage relays K2 is connected to the human-machine interaction module 240. The human-machine interaction module 240 is also used to obtain the switching status of the two second high-voltage relays K2 when receiving the insulation test operation, realize the "break first and then close" safety switching logic, and trigger shutdown and alarm when both second high-voltage relays K2 are detected to be on.

[0037] The specific connection method of the two second high-voltage relays K2 is as follows: the first end of the first second high-voltage relay K2 is connected to the first terminal block 211 of the high-voltage connection module 210, and the second end is connected to the input terminal of the parallel resistance circuit of the insulation resistance adjustment module 230; the first end of the second second high-voltage relay K2 is connected to the second terminal block 212 of the high-voltage connection module 210, and the second end is connected to the input terminal of the parallel resistance circuit of the insulation resistance adjustment module 230. That is, after the second ends of the two second high-voltage relays K2 are connected together, they are connected to the input terminal of the insulation resistance adjustment module 230 to achieve selective connection between the positive terminal B+ or the negative terminal B- and the resistance circuit.

[0038] The control terminals, i.e., the coil pins, of the two second high-voltage relays K2 are respectively connected to the DO interface of the human-machine interaction module 240. The human-machine interaction module 240 drives the second high-voltage relays K2 to conduct by outputting a high level and drives the second high-voltage relays K2 to disconnect by outputting a low level, thereby realizing the switching of test polarity.

[0039] The human-machine interaction module 240 is connected to the insulation resistance adjustment module 230, the polarity switching module 220 and the battery management system 120 respectively. It is used to output corresponding resistance switching signals and polarity switching signals according to the insulation test operation; it communicates with the battery management system 120 and triggers it to perform insulation test and obtain insulation test results.

[0040] The human-machine interface module 240 adopts a station control integrated machine, whose hardware configuration has powerful computing and storage capabilities, enabling collaborative control, data acquisition, and storage of multiple modules. The station control integrated machine integrates multiple DO interfaces, multiple DI interfaces, a CAN interface, and an RS485 serial port. The DO interfaces are used to drive the first and second high-voltage relays K2, the DI interfaces are used to detect the relay status, the CAN interface is used to communicate with the battery management system 120, and the RS485 serial port is used to expand other external devices such as printers and data loggers.

[0041] The display terminal of the human-machine interaction module 240 is a capacitive touch screen that supports multi-touch and is easy to operate. The touch screen is embedded in the front of the test device's chassis and its surface is covered with scratch-resistant and oil-resistant tempered glass, making it suitable for industrial testing environments. The touch screen's interface design fits the testing process and is mainly divided into a status display area, an operation control area, and a data query area.

[0042] The status display area displays the test status in real time, including the status parameters of the battery management system 120, such as the average battery temperature, maximum temperature, minimum temperature, maximum voltage difference of cell 111, the currently active test polarity, the currently selected resistance level, the on / off status of each of the first and second high-voltage relays K2, the polarity switching countdown, leakage current value, test progress, alarm information, etc. All parameters are updated in real time to ensure that testers can keep track of the test situation in real time.

[0043] The operation control area features buttons for selecting test modes such as polarity test, resistance test, open circuit test, and short circuit protection verification, as well as setting parameters such as test delay, alarm threshold, leakage current threshold (30A), administrator password, test start / stop, polarity switching, resistance range selection, and open circuit test trigger. The operation logic is clear, making it easy for testers to get started quickly.

[0044] The data query area is used to store and query test data, including historical test records, fault alarm records, battery management system 120 status parameter records, leakage current curves, test time, etc. It supports the export and printing of test data, and also supports the automatic generation of test reports. The reports include test date, test personnel, battery system parameters, test results for each level, alarm records, protection action records, etc., improving the traceability of test data.

[0045] The software system of the human-computer interaction module 240 has built-in core control logic, including the battery management system 120 status pre-verification logic, resistance adjustment logic, fault alarm logic, data storage and report generation logic, etc. All logic is implemented through software programming, and the parameters can be adjusted according to actual test requirements.

[0046] Before the human-computer interaction module 240 starts working, it first disconnects the battery series line of the battery module 110, that is, disconnects the connection between the battery module 110 and the external device, to ensure that the battery module 110 has no high voltage output.

[0047] The operator performs insulation test operations through the operation interface of the human-machine interaction module 240. The human-machine interaction module 240 establishes a communication connection with the battery management system 120 through the CAN interface.

[0048] Meanwhile, the tester selects the polarity to be tested through the test interface, choosing either positive to ground or negative to ground. At the same time, the tester selects the target test resistor Rx range or selects short circuit to ground through the test interface. The human-machine interface outputs resistance switching signals and polarity switching signals, and controls the insulation resistance adjustment module 230 and the polarity switching module 220 to connect the corresponding positive terminal B+ or negative terminal B- to the corresponding test resistor Rx or short circuit to ground.

[0049] Meanwhile, the human-machine interaction module 240 triggers the battery management system 120 to perform insulation testing through the communication connection. At the same time, it reads the insulation test results of the battery management system 120, records the detected insulation resistance value and the corresponding fault alarm level, thereby realizing the test and verification of the insulation test function of the battery management system 120.

[0050] The human-machine interface module 240 can adaptively connect the positive terminal B+ of the battery module 110 to the test resistor Rx of different levels or short-circuit it to ground according to the operation instructions, and adaptively connect the negative terminal B- of the battery module 110 to the test resistor Rx of different levels or short-circuit it to ground, and record different insulation test results.

[0051] Furthermore, to improve testing safety, in an optional embodiment, the battery management system 120 is also used to read the temperature of each cell 111 and the voltage difference of each cell 111. At the same time, the human-machine interaction module 240 also reads the temperature of each cell 111 and the maximum voltage difference of each cell 111 uploaded by the battery management system 120 in real time. The temperature may include average temperature, maximum temperature and minimum temperature.

[0052] The human-computer interaction module 240 is also used for: The communication connection to the battery management system 120 is used to obtain the temperature and voltage difference of each cell 111. When the temperature and voltage difference of the cell 111 are within the preset threshold, the corresponding switching signal is triggered and the battery management system 120 is triggered to perform an insulation test. Otherwise, the insulation resistance adjustment module 230 and the polarity switching module 220 are turned off and the battery management system 120 is triggered to stop the insulation test.

[0053] In this embodiment, the human-computer interaction module 240 reads the temperature of each cell 111 and the maximum voltage difference of each cell 111 uploaded by the battery management system 120 in real time, and compares the temperature and voltage difference values ​​with the corresponding preset thresholds. The preset temperature thresholds can be 20-50℃ and the maximum voltage difference <400mV.

[0054] When the temperature of cell 111 is detected to be between 20-50℃ and the maximum voltage difference of cell 111 is less than 400mV, the verification is passed, and the human-machine interaction module 240 is allowed to output resistance switching signal and polarity switching signal, triggering the battery management system 120 to perform insulation test.

[0055] When the temperature of cell 111 is detected to be <20℃ or >50℃, or the maximum voltage difference of cell 111 is ≥400mV, the verification fails. The human-machine interaction module 240 immediately triggers the shutdown of all first high-voltage relays K1 of the insulation resistance adjustment module 230 and all second high-voltage relays K2 of the polarity switching module 220. At the same time, the battery management system 120 is triggered to stop the insulation test and displays an alarm message such as "Battery management system 120 status abnormal: temperature XX℃ / voltage difference XXmV, test prohibited" on the touch screen, locking the test function. The battery system status needs to be checked and the verification is performed again.

[0056] In an optional embodiment, to improve test safety, the insulation test apparatus 200 further includes: The leakage current detection module 250 is connected between the insulation resistance adjustment module 230 and the polarity switching module 220. The leakage current detection module 250 is also connected to the human-machine interaction module 240. The leakage current detection module 250 is used to detect the leakage current of the test path between the insulation resistance adjustment module 230 and the polarity switching module 220. The human-computer interaction module 240 is also used for: During insulation testing of the battery management system 120, leakage current is measured; When the leakage current does not exceed the preset leakage current, the insulation test results are obtained via communication. When the leakage current exceeds the preset leakage current, an alarm is triggered and the insulation resistance adjustment module 230 and the polarity switching module 220 are shut down.

[0057] In this embodiment, the leakage current detection module 250 is also connected to the human-machine interaction module 240, and transmits the detected leakage current data to the human-machine interaction module 240 for leakage protection control.

[0058] The human-machine interaction module 240 acquires leakage current data transmitted by the leakage current detection module 250 in real time; the preset leakage current threshold can be set according to requirements, such as 30A. When the battery management system 120 performs insulation testing, the human-machine interaction module 240 judges the leakage current magnitude in real time: if the leakage current does not exceed the preset leakage current, the test is carried out normally, the insulation test result of the battery management system 120 is obtained through the CAN interface, and the result and the corresponding leakage current value are recorded.

[0059] If the leakage current exceeds the preset leakage current, the human-machine interface module 240 immediately triggers a "leakage alarm" and displays an alarm message such as "leakage alarm: current XX A (>30A)" on the touch screen. At the same time, it drives all first high-voltage relays K1 and second high-voltage relays K2 to disconnect, cut off the test circuit, and lock the operation interface. After troubleshooting the leakage fault, the administrator password must be entered to unlock the interface before the test can be performed again.

[0060] The leakage current detection module 250 can use a Hall current sensor, such as the Xici STB-CAB500-22C Hall current sensor. This sensor is based on active closed-loop technology, has high measurement accuracy, strong anti-electromagnetic interference capability, and is suitable for complex working conditions in high-voltage testing environments. Its rated measurement range is -500A to 500A, with high measurement accuracy (error of only ±0.2A within ±30A range). It has CANBUS digital output function, communication protocol compatibility with CAN 2.0A / B, data update cycle of 10ms, and can transmit leakage current data to the human-machine interface module 240 in real time. Its operating temperature range is -40℃ to +85℃, insulation resistance is ≥500MΩ, dielectric withstand voltage is 3000VAC / 1min, and it can work stably in high-voltage and high / low temperature environments.

[0061] The leakage current detection module 250 is connected in series in the main circuit between the output terminal of the polarity switching module 220 (the common terminal of the two second high-voltage relays K2) and the input terminal of the insulation resistance adjustment module 230. It adopts a through-hole installation method, with the main circuit high-voltage cable passing through the sensor's detection hole. Leakage current detection can be achieved without disconnecting the cable, making installation convenient and not affecting the continuity of the main circuit. The sensor's power supply voltage is provided by the power interface of the human-machine interface module 240, ensuring stable power supply.

[0062] The CAN interface of the leakage current detection module 250 is connected to the CAN interface of the human-machine interface module 240 through a shielded cable. Both ends of the shielded cable are grounded to reduce electromagnetic interference and ensure the accuracy of leakage current data transmission.

[0063] The sensor collects leakage current data of the main circuit in real time and sends the data to the human-machine interaction module 240. After receiving the data, the human-machine interaction module 240 analyzes and processes it to determine whether the leakage current exceeds the preset threshold and executes the corresponding protection logic.

[0064] In order to prevent test failure caused by the simultaneous conduction of both second high-voltage relays K2, in an optional embodiment, the human-machine interaction module 240 is further used for: Upon receiving an insulation test operation, the switching status of the two second high-voltage relays K2 is obtained; If the non-target second high-voltage relay K2 is detected to be on and the target second high-voltage relay K2 is detected to be off, switch the control of the non-target second high-voltage relay K2 to be off and delay for a preset time to obtain the switching state of the control of the non-target second high-voltage relay K2; When it is determined that the non-target second high-voltage relay K2 is in the off state, the target second high-voltage relay K2 is turned on. And when it is detected that both second high-voltage relays K2 are in the on state, the control of the two second high-voltage relays K2 is triggered to turn off and an alarm is triggered.

[0065] In this embodiment, to completely avoid the risk of short circuit caused by simultaneous conduction of positive and negative terminals, the human-computer interaction module 240 incorporates a "break first, then make" polarity switching logic, which is implemented as follows: When a user inputs a polarity switching operation through the human-machine interaction module 240, such as switching from positive to negative testing, the human-machine interaction module 240 first reads the switching status of the two second high-voltage relays K2 through the DI interface, confirms that the non-target second high-voltage relay K2 is currently conducting, and the target second high-voltage relay K2 is turned off, such as the positive switching relay being on and the negative switching relay being off.

[0066] The human-machine interaction module 240 immediately outputs a low level to the control terminal of the non-target second high-voltage relay K2, driving it to disconnect, and displays "Polarity switching countdown preset duration" on the touch screen, starting the countdown; the preset duration delay is designed based on the release time of the second high-voltage relay K2, leaving sufficient safety redundancy to ensure that the non-target circuit is completely disconnected and to avoid residual high voltage causing a short circuit.

[0067] After the countdown ends, the human-machine interface module 240 checks the switching status of the non-target second high-voltage relay K2 again through the DI interface to confirm that it has been completely disconnected.

[0068] The human-machine interaction module 240 outputs a high level to the control terminal of the target second high-voltage relay K2 to drive it to conduct. At the same time, the current conduction test polarity (such as "current polarity: negative to ground") is displayed in real time on the touch screen. If the human-machine interface module 240 detects at any time that both second high-voltage relays K2 are in the on state, it will immediately output a low level to the control terminals of the two second high-voltage relays K2 to drive them to disconnect and trigger a "polarity short circuit alarm". The alarm information will be displayed on the touch screen, such as "polarity short circuit alarm: positive and negative poles are conducting at the same time, please check the fault". At the same time, the operation interface will be locked and can only be unlocked by entering the administrator password to avoid accidental operation that could lead to the expansion of the fault.

[0069] In addition, both second high-voltage relays K2 are equipped with status feedback pins, which are connected to the DI interface of the human-machine interface module 240 to transmit the switching status of the relays to the human-machine interface module 240 in real time. This ensures that the human-machine interface module 240 can accurately obtain the actual status of polarity switching and avoid abnormal switching caused by relay failure.

[0070] In an optional embodiment, the insulation testing device 200 can also perform open-circuit testing. Correspondingly, the human-machine interaction module 240 is also used for: The corresponding polarity switching signal is output according to the open circuit operation, and the insulation resistance adjustment module 230 is turned off. The communication connection is established with the battery management system 120 to read the open circuit detection status of the battery management system 120 and record the open circuit test results.

[0071] In this embodiment, when the operator inputs the "open circuit test" operation via the touch screen, the human-machine interaction module 240 outputs a corresponding polarity switching signal, turns on the corresponding second high-voltage relay K2, and simultaneously outputs a low level to all first high-voltage relays K1, controlling the insulation resistance adjustment module 230 to turn off, thus disconnecting all corresponding resistance circuits and forming an open circuit between the insulation resistance adjustment module 230 and ground. Subsequently, the human-machine interaction module 240 connects to the battery management system 120 via the CAN interface, reads the open circuit detection status of the battery management system 120, records the open circuit test results, including test polarity, battery management system 120 detection status, test time, etc., and stores them locally for easy subsequent query and export.

[0072] In addition, the human-machine interaction module 240 also has a fault self-diagnosis function, which can detect its own and the working status of each module in real time. If a DO / DI interface fault, CAN communication fault, touch screen fault, relay fault, etc. are detected, an alarm will be triggered immediately and the cause of the fault will be displayed on the touch screen, which will facilitate testers to quickly troubleshoot the fault.

[0073] In an optional embodiment, to achieve short-circuit fault protection, the insulation testing device 200 may be equipped with a corresponding short-circuit protection module, and to ensure reliable switching of the short-circuit protection module, a corresponding short-circuit testing module is also required. In an optional embodiment, the insulation testing device 200 further includes: The fuse FU is connected between the insulation resistance adjustment module 230 and the polarity switching module 220. The fuse FU blows when there is an overcurrent. The short-circuit test interface is used to short-circuit the positive terminal B+ and the negative terminal B- during short-circuit test operations.

[0074] In this embodiment, the fuse FU is connected between the insulation resistance adjustment module 230 and the polarity switching module 220 for overcurrent melting, serving as the ultimate hardware protection against short-circuit faults; the short-circuit test interface is used to short-circuit the positive terminal B+ and the negative terminal B- during short-circuit test operations to verify the short-circuit protection function of the fuse FU.

[0075] The fuse FU can be an A3710 series fast-acting fuse FU, model A3710-150. This fuse FU is suitable for high-voltage, high-current scenarios. Its core parameters are as follows: rated voltage 1000VDC, rated current 150A, fast-acting characteristic, fusing time ≤5ms (when the current reaches 1.2 times the rated current), it can fuse in milliseconds, forcibly cutting off the main circuit and preventing the escalation of faults caused by control module response delays. The fuse FU is installed in series between the output terminal of the leakage current detection module 250 and the input terminal of the insulation resistance adjustment module 230. That is, the current path of the main circuit is: high-voltage connection module 210, polarity switching module 220, leakage current detection module 250, fuse FU, insulation resistance adjustment module 230, grounding terminal, ensuring that the fuse FU can detect all currents in the main circuit and achieve comprehensive short-circuit protection.

[0076] The short-circuit test interface is located on the side of the test device's chassis. It uses a dedicated high-voltage interface and is equipped with an insulating protective cover. When not in use, the cover should be closed to prevent accidental contact. An internal high-voltage switch is installed; the switch only activates when a dedicated short-circuit test tool is connected, preventing accidental short circuits. The two terminals of the short-circuit test interface are connected to the first terminal block 211 and the second terminal block 212 of the high-voltage connection module 210 via high-voltage wires. During short-circuit testing, the positive terminal B+ and the negative terminal B- are short-circuited using a dedicated tool to simulate a positive and negative short-circuit scenario, verifying the fast-blow function of the fuse FU and the short-circuit protection logic of the control module.

[0077] The fuse FU is a disposable component. After it blows, it must be replaced with a new fuse FU before testing can continue. The test device's chassis has a spare installation position for the fuse FU, which can be quickly replaced on site. At the same time, the human-machine interface module 240 detects the status of the fuse FU through the DI interface. If the fuse FU blows, it immediately triggers a "fuse FU blown alarm" and displays alarm information on the touch screen, such as "Fuse FU blown: main circuit short circuit, please replace fuse FU and troubleshoot the fault," and locks the operation interface. After replacing the fuse FU and troubleshooting the fault, the administrator password must be entered to unlock it.

[0078] The human-computer interaction module 240 includes a corresponding communication module, a display screen, and a processor. The display screen is used for human-computer interaction, the communication module is used to realize communication between the battery management system 120 and the processor, and the processor performs communication, control, and signal processing tasks of the human-computer interaction module 240.

[0079] The communication module can perform tasks such as data reading, status feedback, and test triggering. It reads the core battery status parameters uploaded by the battery management system 120 in real time via the CAN bus, including the average temperature of the battery pack, the highest temperature, the lowest temperature, the voltage value of each cell 111, the maximum voltage difference between each cell 111, the insulation test results of the battery management system 120, and the fault alarm level of the battery management system 120. All data is transmitted to the human-machine interaction module 240, which analyzes, processes, displays, and stores the data.

[0080] The operating status of the testing device is fed back to the battery management system 120, including the test start / stop status, current test polarity, currently selected resistance level, and test fault alarm information such as leakage alarm, polarity short circuit alarm, and fuse FU blown alarm information, so as to realize two-way interaction between the testing device and the battery management system 120 and ensure that the battery management system 120 can keep track of the test progress and status in real time.

[0081] The human-machine interaction module 240 sends an insulation test trigger signal to the battery management system 120 through the battery management system 120 communication interaction module, triggering the battery management system 120 to start the insulation detection function, perform insulation resistance detection between the positive terminal and ground or between the negative terminal and ground, and feed back the detection result to the human-machine interaction module 240; at the same time, when the battery management system 120 is in an abnormal state, the human-machine interaction module 240 sends a stop test signal to the battery management system 120 through this module, triggering the battery management system 120 to stop the insulation detection.

[0082] To ensure stable communication, the communication interaction module of the battery management system 120 also has a communication fault detection function. If a communication interruption with the battery management system 120 is detected, such as a CAN bus disconnection or a fault in the battery management system 120, a communication fault signal is immediately sent to the human-machine interaction module 240. The human-machine interaction module 240 triggers a "communication fault alarm", displays the alarm information on the touch screen, and simultaneously controls all high-voltage relays to disconnect and stop the test to avoid battery damage caused by blind testing.

[0083] The beneficial effects of this invention embodiment compared with the prior art are as follows: The above-mentioned insulation testing device 200 includes a high-voltage connection module 210, an insulation resistance adjustment module 230, a polarity switching module 220, and a human-machine interaction module 240. The high-voltage connection module 210, the polarity switching module 220, and the insulation resistance adjustment module 230 are connected in sequence. The human-machine interaction module 240 outputs corresponding resistance switching signals and polarity switching signals to the polarity switching module 220 and the insulation resistance adjustment module 230 according to the insulation test operation, so as to connect the positive terminal B+ or the negative terminal B- of the battery module 110 to the corresponding test resistor Rx. At the same time, the human-machine interaction module 240 communicates with the battery management system 120 and triggers the battery management system 120 to perform insulation testing, and communicates to obtain the insulation test results. The insulation testing device 200 controls the battery management system 120 to realize insulation testing and verify the test results, thereby improving testing efficiency and safety.

[0084] Corresponding to the insulation testing device 200 described above, a second aspect of this invention provides an insulation testing method for an industrial and commercial battery storage system 100, the insulation testing method comprising: Disconnect the battery module 110 from the external connection line, and connect the positive terminal B+ and the negative terminal B- of the high voltage connection module 210 and the battery module 110 with a jumper wire; The output polarity switching signal controls the polarity switching module 220 to be connected to the positive terminal B+ or the negative terminal B- through the high voltage connection module 210; The output resistance switching signal is sent to the switching circuit 231 of the insulation resistance adjustment module 230, and the test resistor Rx with a corresponding resistance value is selected and connected to the corresponding positive terminal B+ or negative terminal B-. The system communicates with the battery management system 120 and triggers the battery management system 120 to perform an insulation test, and then communicates to obtain the insulation test results.

[0085] In this embodiment, before testing, disconnect the battery module 110 of the industrial and commercial battery storage system 100 from the external load and charger to ensure that the battery module 110 has no high voltage output; use a multimeter to measure the voltage between the positive terminal B+ (B+) and the negative terminal B- (B-) of the battery module 110 to confirm that the voltage is 0V (or within the safe voltage range) to avoid live operation; at the same time, check the appearance of the battery module 110 to confirm that there are no abnormalities such as leakage, damage, or bulging, and troubleshoot the basic faults of the battery system.

[0086] Inspect the appearance of the test device to ensure that the chassis is undamaged, the cables are secure, and the insulation covers are intact. Turn on the power switch of the test device, start the human-machine interface module 240, and wait for the system initialization to complete. After initialization, enter the "Parameter Setting" interface of the test device, confirm that all parameters are set correctly, and adjust and save if the parameters are incorrect.

[0087] Prepare two high-voltage jumper wires and check that the insulation layer of the jumper wires is undamaged and broken, and that the terminals are free from oxidation and looseness. Crimp one end of the jumper wires to the terminals of the first terminal block 211 and the second terminal block 212 of the high-voltage connection module 210, and tighten the fixing screws to ensure a secure connection. Mark the other end of the jumper wires for easy connection to the battery module 110.

[0088] After disconnecting the battery module 110 from the external connection, connect the high-voltage jumper wire of the test device to the positive terminal B+ of the battery module 110 and the jumper wire to the negative terminal B- of the battery module 110. When connecting, ensure that the terminals are tightened and there is no looseness or loose connection. After the connection is completed, use a multimeter to measure the voltage between the first terminal block 211 and the second terminal block 212 of the high-voltage connection module 210 again to confirm that it is consistent with the rated voltage of the battery module 110 and to ensure that the connection is correct.

[0089] At the same time, check the internal circuit connections of the test device to confirm that the leakage current detection module 250, fuse FU, polarity switching module 220, and insulation resistance adjustment module 230 are firmly connected without looseness or short circuit; check that the connection lines (DO / DI interface, CAN interface) between the human-machine interface module 240 and each module are correctly connected without being disconnected; check the grounding condition of the grounding terminal to ensure reliable grounding (grounding resistance ≤ 4Ω).

[0090] Start the "Insulation Detection Test" interface of the human-machine interaction module 240, click the "Connect to Battery Management System 120" button, and the human-machine interaction module 240 establishes a CAN communication connection with the battery management system 120 through the communication interaction module of the battery management system 120. After the communication is successfully established, the status display area of ​​the touch screen will display "Battery Management System 120 Communication Normal", and update the battery status parameters uploaded by the battery management system 120 in real time, such as the average temperature, maximum temperature, minimum temperature of cell 111, and maximum voltage difference of cell 111.

[0091] The human-computer interaction module 240 automatically executes the status verification logic of the battery management system 120, comparing the collected battery status parameters with preset thresholds.

[0092] If the average battery temperature is between 20-50℃ and the maximum voltage difference of cell 111 is <400mV, the verification is successful. The touch screen will display "Battery Management System 120 is in normal condition, test allowed", and the test function will be unlocked, allowing subsequent test operations to be performed.

[0093] If the average battery temperature is <20℃ or >50℃, or the maximum voltage difference of cell 111 is ≥400mV, the verification fails. The touch screen displays "Battery Management System 120 Status Abnormal: Temperature XX℃ / Voltage Difference XXmV, Test Prohibited". At the same time, the human-machine interface module 240 outputs a low level to all first high-voltage relays K1 and second high-voltage relays K2, controlling them to disconnect and locking the test function. The tester needs to troubleshoot the battery system. If the temperature is abnormal, the test environment temperature needs to be adjusted. If the voltage difference exceeds the standard, the status of cell 111 needs to be checked. After the troubleshooting is completed, click the "Verify Battery Management System 120" button again until the verification passes.

[0094] After the verification is passed, check the status of all high-voltage relays to ensure that all first high-voltage relays K1 and second high-voltage relays K2 are in the open state, the leakage current value displayed by the leakage current detection module 250 is 0A, and all resistance circuits of the insulation resistance adjustment module 230 are in the open circuit state. After confirming that there are no errors, proceed to the next step of testing.

[0095] Users can select the polarity to be tested in the "Operation Control Area" through the touch screen of the human-computer interaction module 240. They can choose "positive to ground" or "negative to ground". This embodiment will take the example of testing positive to ground first and then switching to negative to ground.

[0096] After selecting "positive to ground", the human-machine interaction module 240 outputs a polarity switching signal to the control terminal of the first second high-voltage relay K2 to drive it to conduct. At the same time, it outputs a low level to the second second high-voltage relay K2 to ensure that it is in the off state. After conduction, the status display area of ​​the touch screen is updated to "current polarity: positive to ground", and the status of the positive switching relay is displayed as "conducting" and the status of the negative switching relay is "disconnected".

[0097] To switch to the "negative to ground" test, click the "Switch to negative" button on the touchscreen. The human-computer interaction module 240 will then execute the "disconnect first, then connect" logic. Immediately output a low level to the control terminal of the positive switching relay to drive it to disconnect; The touchscreen displays "Polarity Switching Countdown: Preset Duration" and starts the countdown. During the countdown, the human-machine interface module 240 monitors the status of the positive switching relay in real time through the DI interface to ensure that it gradually disconnects. After the preset countdown ends, the human-machine interaction module 240 detects that the positive switching relay has been completely disconnected and outputs a 24V high level to the control terminal of the negative switching relay to drive it to conduct. The touchscreen updates to display "Current polarity: Negative to ground," and simultaneously shows the status of the negative polarity switching relay as "On" and the status of the positive polarity switching relay as "Off," completing the polarity switch.

[0098] If, during polarity switching, the human-machine interface module 240 detects that both second high-voltage relays K2 are in the conducting state, it immediately drives both relays to disconnect, triggering a "polarity short circuit alarm," locking the operation interface, and the tester needs to troubleshoot the relay fault. After troubleshooting, the tester enters the administrator password to unlock the interface and performs polarity switching again.

[0099] After the polarity switch is completed, the user can select the target resistance level through the "Operation Control Area" of the touch screen. The user can select any level from 1kΩ, 10kΩ, 100kΩ, 250kΩ, 500kΩ, 750kΩ, and 1MΩ, or select "Short circuit to ground". This embodiment will use the 250kΩ level as an example for explanation.

[0100] After selecting the 250kΩ range, the human-machine interface module 240 outputs a resistance value switching signal to the control terminal of the corresponding first high-voltage relay K1, driving the relay to conduct. At the same time, it outputs a low level to all other first high-voltage relays K1 to ensure that other resistor circuits are in the open state, avoiding resistance value deviation caused by multiple resistors in parallel. After the relay conducts, the status display area of ​​the touch screen is updated to "Current resistance value: 250kΩ", and the status of the first high-voltage relay K1 is displayed as "conducting", while the status of the other first high-voltage relays K1 is "disconnected".

[0101] Wait for the relay to conduct stably (delay 50ms, refer to the ≤30ms action time of HFE82P-100B relay) to ensure that the resistance circuit conducts stably and there is no poor contact; at this time, the leakage current detection module 250 collects the leakage current data of the main circuit in real time and sends the data to the human-machine interaction module 240 every 10ms, and the touch screen displays the current leakage current value synchronously.

[0102] If the leakage current is ≤30A, the test proceeds normally. The human-machine interaction module 240 sends an "insulation test trigger" signal to the battery management system 120 through the battery management system 120 communication interaction module, triggering the battery management system 120 to start the insulation detection function of the positive terminal to ground (or the negative terminal to ground). After completing the insulation test, the battery management system 120 feeds back the detected insulation resistance value and fault alarm level (if the resistance value is lower than the corresponding threshold, a minor, general or serious fault alarm is triggered) to the human-machine interaction module 240 via the CAN bus. The human-machine interaction module 240 receives and stores the detection results of the battery management system 120, and displays "Test normal: Battery management system 120 detected resistance value XX kΩ, no alarm / alarm level: XXX" on the touch screen. At the same time, it records data such as test time, current polarity, current resistance value, and leakage current value.

[0103] If the leakage current is greater than 30A, the human-machine interface module 240 will immediately trigger a "leakage alarm" and display "leakage alarm" on the touch screen. At the same time, it will output a low level to all first high-voltage relays K1 and second high-voltage relays K2, driving them to disconnect and cut off the test circuit. The operation interface will be locked, and the tester needs to check for leakage faults (such as broken insulation of flying wires, short circuits in module connections, etc.). After the check is completed, the administrator password will be entered to unlock the device and the test will be repeated.

[0104] Repeat the above steps, selecting all resistance levels (1kΩ, 10kΩ, 100kΩ, 500kΩ, 750kΩ, 1MΩ) and "short circuit to ground" in sequence to complete all insulation tests for the corresponding polarity. After each level of test is completed, the human-machine interface module 240 automatically stores the test data to ensure data traceability.

[0105] After completing the open circuit test for all resistance levels, the user can click the "Open Circuit Test" button in the "Operation Control Area" of the touchscreen and select the polarity to be tested (positive to ground or negative to ground). This embodiment takes positive to ground as an example.

[0106] The human-machine interaction module 240 outputs a corresponding polarity switching signal to drive the positive pole switching relay to turn on and the negative pole switching relay to turn off. At the same time, it outputs a low level to all the first high voltage relays K1 to control the insulation resistance adjustment module 230 to turn off, so that the insulation resistance adjustment module 230 and ground are open.

[0107] The leakage current detection module 250 monitors the leakage current of the main circuit. After confirming that the leakage current is 0A, the human-machine interaction module 240 sends an "open circuit test trigger" signal to the battery management system 120 through the battery management system 120 communication interaction module, triggering the battery management system 120 to perform open circuit detection.

[0108] After the battery management system 120 completes the open circuit test, it feeds back the test status to the human-machine interaction module 240. The human-machine interaction module 240 records the open circuit test results (including test polarity, battery management system 120 test status, test time, leakage current value, etc.) and displays "Open circuit test completed: Battery management system 120 test status XXX" on the touch screen.

[0109] Repeat the above steps to complete the open circuit test for the other polarity, ensuring that the battery management system 120 can correctly identify the open circuit state, and the test data is automatically stored in the human-machine interaction module 240.

[0110] Short-circuit emergency protection verification is used to verify the fast-blow function of the fuse FU and the short-circuit protection logic of the test device. It is only performed when it is necessary to verify the short-circuit protection performance.

[0111] After completing the open circuit test, switch the test device to the "short circuit protection verification" mode, click the "short circuit verification preparation" button on the touch screen, and the human-machine interaction module 240 will drive all the first high-voltage relays K1 and the second high-voltage relays K2 to disconnect, cutting off the test circuit. At the same time, the touch screen will display "Short circuit verification preparation complete, please confirm that the test environment is safe".

[0112] Testers confirm that the test environment is safe, such as being away from high-voltage components and wearing complete insulating protective equipment. They then connect the dedicated short-circuit test tool to the short-circuit test interface of the test device, ensuring that the tool is securely connected.

[0113] Clicking the "Start Short Circuit Verification" button on the touchscreen activates the human-machine interface module 240, which simultaneously turns on the positive and negative switching relays. At this time, the dedicated short circuit test tool short-circuites the positive terminal B+ and the negative terminal B- of the battery module 110, causing the main circuit current to rise instantaneously, exceeding the rated current of the fuse FU.

[0114] If the human-machine interaction module 240 fails to respond in time, the main circuit current continues to rise, the fuse FU blows quickly, and the main circuit is forcibly cut off to prevent the fault from spreading. At this time, the human-machine interaction module 240 detects the blown fuse FU through the DI interface, triggers the "Fuse FU Blown Alarm", displays "Fuse FU Blown: Main circuit short circuit, please replace fuse FU and troubleshoot the fault" on the touch screen, and locks the operation interface.

[0115] The tester disconnects the power switch of the test device, removes the short-circuit test tool, replaces the fuse FU with a new one, investigates the cause of the short circuit, ensures that the short-circuit test tool has been removed and there are no other potential short-circuit hazards, and after the investigation is completed, enters the administrator password to unlock the operation interface and exits the "short-circuit protection verification" mode.

[0116] After all test steps are completed, the user clicks the "Test End" button in the "Operation Control Area" of the touch screen. The human-machine interaction module 240 outputs a low level to all the first high-voltage relays K1 and the second high-voltage relays K2, driving them to disconnect and cut off all test circuits. At the same time, the "Test End" feedback signal is sent to the battery management system 120 through the communication interaction module, triggering the battery management system 120 to stop insulation detection and return to normal operation.

[0117] Disconnect the power switch of the test device and wait for the high voltage inside the test device to completely discharge. After confirming that there is no high voltage residue, remove the high voltage jumper wire between the test device and the battery module 110, tidy up the terminals of the jumper wire, and cover them with the insulating protective cover. At the same time, restore the connection wires between the battery module 110 and the external load and charger, and ensure that the connection is firm.

[0118] Turn the power switch of the test device back on, enter the "Data Query" interface, view all test data, and confirm that the test data is complete and without abnormalities; click the "Export Data" button to export the test data to a USB flash drive via the USB interface, and generate a test report containing test date, test personnel, battery system parameters, test results for each gear, alarm records, protection action records, etc. The test report can be connected to a printer to print and archive for future reference.

[0119] Turn off the power switch of the testing equipment, tidy up the testing site, and put the testing tools, spare fuses, and other items back in their places to complete the entire testing process.

[0120] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. An insulation testing device for an industrial and commercial battery storage system, the industrial and commercial battery storage system including a battery module and a battery management system, the battery module including multiple cells connected in series; Its features are, The insulation testing device includes: A high-voltage connection module is used to connect the positive and negative terminals of the battery module; An insulation resistance adjustment module includes a switching circuit and multiple test resistors with different resistance values. The switching circuit is used to switch the test resistors connected to different resistance values ​​according to a resistance switching signal. A polarity switching module is connected between the high voltage connection module and the insulation resistance adjustment module. The polarity switching module is used to connect the positive terminal or the negative terminal to the corresponding test resistor according to the polarity switching signal. The human-machine interaction module is connected to the insulation resistance adjustment module, the polarity switching module, and the battery management system, respectively. The human-machine interaction module is used for: According to the insulation test operation, output the corresponding resistance value switching signal and the polarity switching signal; The system communicates with the battery management system and triggers the battery management system to perform an insulation test, and then communicates to obtain the insulation test results.

2. The insulation testing device for an industrial and commercial battery system as described in claim 1, characterized in that, The battery management system is also used to read the temperature of each of the cells and the voltage difference between each of the cells; The human-computer interaction module is also used for: The system communicates with the battery management system to obtain the temperature and voltage difference of each cell. When the temperature and voltage difference of the cell are within a preset threshold, the system triggers the output of a corresponding switching signal and triggers the battery management system to perform an insulation test. Otherwise, the system triggers the shutdown of the insulation resistance adjustment module and the polarity switching module and triggers the battery management system to stop the insulation test.

3. The insulation testing device for industrial and commercial battery systems as described in claim 2, characterized in that, The insulation testing device also includes: A leakage current detection module is connected between the insulation resistance adjustment module and the polarity switching module. The leakage current detection module is also connected to the human-machine interaction module. The leakage current detection module is used to detect the leakage current of the test path between the insulation resistance adjustment module and the polarity switching module. The human-computer interaction module is also used for: The leakage current is acquired during the insulation test of the battery management system; When the leakage current does not exceed the preset leakage current, the insulation test results are obtained via communication. When the leakage current exceeds the preset leakage current, an alarm is triggered and the insulation resistance adjustment module and the polarity switching module are shut down.

4. The insulation testing device for an industrial and commercial battery system as described in claim 1, characterized in that, The switching circuit includes multiple first high-voltage relays. Each first high-voltage relay is connected in series with a test resistor to form a resistance loop. The multiple resistance loops are connected in parallel between the polarity switching module and the grounding terminal. The multiple first high-voltage relays are respectively connected to the human-machine interaction module.

5. The insulation testing device for an industrial and commercial battery system as described in claim 1, characterized in that, The polarity switching module includes: Two second high-voltage relays are provided. The first terminals of the two second high-voltage relays are respectively connected to the positive terminal and the negative terminal through the high-voltage connection module. The second terminals of the two second high-voltage relays are also respectively connected to the insulation resistance adjustment module. The control terminal of the two high-voltage relays is connected to the human-machine interaction module.

6. The insulation testing device for an industrial and commercial battery system as described in claim 5, characterized in that, The human-computer interaction module is also used for: Upon receiving an insulation test operation, the switching status of the two second high-voltage relays is acquired; If the non-target second high-voltage relay is detected to be on and the target second high-voltage relay is detected to be off, switch the control of the non-target second high-voltage relay to be off and delay for a preset time to obtain the switching state of the control of the non-target second high-voltage relay; When it is determined that the non-target second high-voltage relay is in the off state, the target second high-voltage relay is controlled to be turned on; And when it is detected that both of the second high-voltage relays are in the on state, the control of the two second high-voltage relays is triggered to turn off and an alarm is issued.

7. The insulation testing device for an industrial and commercial battery system as described in claim 5, characterized in that, The high-voltage connection module includes a first terminal block and a second terminal block. The first terminal block is connected between the positive terminal and one of the second high-voltage relays, and the second terminal block is connected between the negative terminal and the other second high-voltage relay.

8. The insulation testing apparatus for an industrial and commercial battery system as described in any one of claims 1 to 7, characterized in that, The human-computer interaction module is also used for: The corresponding polarity switching signal is output according to the open circuit operation, and the insulation resistance adjustment module is turned off. Read the open-circuit detection status of the battery management system and record the open-circuit test results.

9. The insulation testing apparatus for an industrial and commercial battery system as described in any one of claims 1 to 7, characterized in that, The insulation testing device also includes: A fuse is connected between the insulation resistance adjustment module and the polarity switching module, and the fuse blows when there is an overcurrent. A short-circuit test interface is used to short-circuit the positive terminal and the negative terminal during a short-circuit test operation.

10. An insulation testing method for an industrial and commercial battery storage system, applied to the insulation testing device as described in any one of claims 1 to 9, characterized in that, The insulation test method includes: Disconnect the battery module from the external connection line, and connect the high voltage connection module and the positive and negative terminals of the battery module with a jumper wire; The output polarity switching signal controls the polarity switching module to be connected to the positive or negative terminal through the high-voltage connection module; The output resistance switching signal is sent to the switching circuit of the insulation resistance adjustment module, and the corresponding test resistor of a certain resistance value is selected and connected to the corresponding positive or negative terminal. The system communicates with the battery management system and triggers the battery management system to perform an insulation test, and then communicates to obtain the insulation test results.

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