A battery tester dedicated to production safety testing and inspection instruments

Abstract

A battery tester specially used for production safety detection and inspection instruments comprises an instrument housing, and is characterized in that: a cooling channel is arranged in the middle of the instrument housing, a heat sink and a heat dissipation fan are arranged in the cooling channel, an air outlet protective cover and an air inlet protective cover are arranged on both sides of the heat sink, a handle is arranged in the instrument housing, and control and support components are also installed in the instrument housing, including: a single-chip control module, a battery testing system, an energy recovery and heat exchange system; the energy recovery and heat exchange system comprises a water cooling head, and the water cooling head circulates the Seebeck effect sheet and the heat dissipation part of the MOS tube under the drive of a pump.

Description

Technical Field

[0001] The invention relates to the field of detection instruments, and in particular to a battery tester dedicated to production safety detection and inspection instruments. Background Art

[0002] At present, most safety production inspection and testing on-site verification will use test instruments with batteries, such as: loop resistance tester, hoist intelligent tester, anti-fall device tester, ultrasonic flaw detector, gas extraction comprehensive parameter detector, etc. The common feature of these instruments is that the battery power management of their own batteries is often indicated by the battery voltage to indicate the remaining battery power, and there is a lack of precision coulomb meters and other sensors to accurately detect the battery capacity. Combined with the on-site work situation, the inspection and testing personnel lack attention to the instrument battery due to the shortcomings of high instrument use intensity and maintenance omissions. It often seems to be fully charged, but insufficient power supply occurs when it is turned on. Some tests are destructive. For example, the anti-fall device tester often produces loud noises and impacts during the cage unhooking test. The instrument often needs to be tested again due to incomplete data collection due to power supply problems. This situation is difficult for customers to accept and even affects long-term business relationships. The safety production inspection and testing business itself relies on instruments for safety monitoring, but there is a lack of a solution on the market to detect the battery characteristics of such instruments.

[0003] Existing battery capacity testers often use fixed resistors for fixed rate discharge, which generally have low power and cannot perform real-time power closed-loop adjustment. The present invention provides a battery tester for safety production inspection and testing instruments with closed-loop power adjustment and self-supporting capabilities according to the characteristics of safety inspection and testing instruments. Summary of the invention

[0004] The present invention provides a battery tester for production safety detection and inspection instruments with closed-loop power adjustment and self-supporting capability according to the characteristics of safety detection and inspection instruments. In order to achieve the above-mentioned purpose, the technical scheme of the present invention is: a battery tester for production safety detection and inspection instruments, including an instrument housing, characterized in that: a cooling channel is arranged in the middle of the instrument housing, a heat sink and a heat sink fan are arranged in the cooling channel, an air outlet protective cover and an air inlet protective cover are arranged on both sides of the heat sink, and a handle is arranged on the instrument housing.

[0005] The instrument housing also contains control and support components, including: single-chip control module, battery test system, energy recovery and heat exchange system;

[0006] The energy recovery and heat exchange system includes a water cooling head, which circulates the Seebeck effect sheet and the heat dissipation part of the MOS tube under the drive of a pump.

[0007] The energy recovery and heat exchange system includes three water cooling heads. The first water cooling head is installed at the heat dissipation position of the MOS tube. The water heated by the MOS tube heats the Seebeck effect plate through the third water cooling head. The other side of the Seebeck effect plate is connected to a second water cooling head for cooling. The cold water of the first and second water cooling heads directly comes from the water cooled by the radiator. The hot water after heat exchange of the second and third water cooling heads converges to the input end of the radiator. The electric energy output by the Seebeck effect plate is used to charge the built-in battery of the instrument. The water circulation in the pipeline is driven by a pump, and the cooling of the radiator is air-cooled by a fan.

[0008] The DA output port of the single-chip control module controls the gate pin G of the MOS tube, and the drain D of the MOS tube is connected to the current detection module. The other end of the current detection module is connected to the normally open contact of the test relay, and the other end of the test relay is connected to the positive input port of the battery under test. The source S of the MOS tube is connected to the negative input port of the battery, and the signal output ports of the high sampling rate precision voltage module and the high sampling rate precision current module are connected to the single-chip control module. After the external charging interface is connected in series with the normally open contact of the charging relay, it is connected in parallel with the access port of the battery under test.

[0009] The instrument housing is a ladder-shaped structure, with an integrally formed handle on the top of the instrument, an inclined rectangular mounting surface provided at the cut corner below the handle, an air inlet below the mounting surface, a multi-functional compartment provided under the air inlet protective cover, the multi-functional compartment having a reciprocating self-locking cover, a test interface for preventing reverse connection, an instrument emergency charging interface, a main power switch, a charging input interface for the battery being tested, and a test line and an emergency charger for the instrument itself are placed in the compartment.

[0010] The air outlet protective cover and the air inlet protective cover are flush with the outer surface of the instrument, the angle between the protective cover and the horizontal plane is limited to between 75° and 85°, the inclination angles of the front and rear surfaces of the instrument are symmetrical and the same, the bottom surface of the instrument is flush with the horizontal plane, and the top surface width of the instrument handle is 20mm and chamfered.

[0011] A rectangular installation surface is arranged at the cut corner below the handle, a display screen and a switch setting button are installed on the rectangular installation surface, and an angle range between the rectangular installation surface and a horizontal plane is limited to between 45° and 55°.

[0012] The single-chip microcomputer module has a built-in tilt sensor. When it detects that the instrument is tipping forward or backward, the single-chip microcomputer module terminates the DA output and sounds an alarm.

[0013] The MOS tube uses IRFP460 in TO-247 package.

[0014] When the instrument is testing the battery capacity, the MOS tube is in the non-saturated working area. The working current of the MOS tube is controlled by the single-chip microcomputer module. The single-chip microcomputer detects the working current of the MOS tube through the current sensor and controls the MOS tube to work in the non-saturated area according to the set parameters at all times.

[0015] The advantages of the present invention are that the test power of the test battery can be adjusted in a closed loop, the power can be measured and adjusted in real time, and high-power and overpressure self-protection functions can be supported. The electric energy consumed in the test can also be recovered. The recovered electric energy can drive the instrument to operate in a portable state without additional charging. Measurements in a fixed and precise test mode also support testing after charging the battery under test, and the battery under test is fully charged after the test. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is an exploded schematic diagram of the present invention;

[0017] Figure 2 It is a front structural schematic diagram of the present invention;

[0018] Figure 3 It is a schematic diagram of the back structure of the present invention;

[0019] Figure 4 is a schematic diagram of a heat exchange energy recovery system of the present invention;

[0020] Figure 5 is a schematic diagram of a control and test circuit of the present invention;

[0021] Figure 6 It is a schematic diagram of the charging structure of the present invention.

[0022] In the attached figure, 1. air outlet protective cover; 2. instrument housing; 3. heat sink; 4. fan; 5. air inlet protective cover; 6. tee; 8. hot water; 9. pump; 10. cold water; 11. Seebeck effect plate; 12. temperature sensor signal transmission interface; 13. alarm output port; 14. current sensor signal transmission interface; 15. voltage sensor signal transmission interface; 16. test relay control interface; 17. charging relay control interface; 18. key input bus; 19. screen output bus; 20. fan, water pump PWM control interface; 21. test relay; 22. charging relay; 23. tested battery; 24. first water cooling head; 25. second water cooling head; 26. third water cooling head; 27. instrument emergency charging interface. DETAILED DESCRIPTION

[0023] The following is attached to the instruction manual Figures 1 to 6 The present invention is further described as follows:

[0024] The overall structure of the instrument of the present invention:

[0025] The instrument has an integrated handle on the top, and the overall structure is a ladder. The display screen, switch and setting button are on the cut corner below the handle on the front. The center of the instrument has a heat dissipation inlet and outlet, and a hexagonal hole-shaped protective cover is installed at the outlet. The side with the screen is the front, and the front is equipped with an air inlet, and the side away from the screen is the air outlet. There is a multi-functional compartment below the heat dissipation inlet, and it has a reciprocating self-locking cover. The compartment has: an anti-reverse test interface, an instrument emergency charging interface, a main power switch, and a charging input interface for the battery under test. The compartment is equipped with test wires and an emergency charger for the instrument itself.

[0026] The working method is: use a single-chip microcomputer module with a DA conversion interface, connect the N-channel MOS tube, and adjust the MOS tube to work in the non-saturated area in a closed loop by detecting the deviation from the set current. The single-chip microcomputer module here includes the single-chip microcomputer itself and the peripheral drive circuit, AD conversion circuit, DA conversion circuit, inclination sensor, temperature sensor, etc. It is an integrated module. The single-chip microcomputer module has 10 interfaces, see the attached figure for details. In addition, a high-sampling rate precision voltage module is connected in parallel in the circuit, and a high-sampling rate precision current module is connected in series for measurement. The single-chip module calculates and outputs the measurement results on the display. The single-chip microcomputer module has a built-in inclination sensor. When the instrument is detected to be tilted forward or backward, the single-chip microcomputer module terminates the DA output and alarms.

[0027] The setup procedure is: 1. Set the cut-off discharge voltage, set the discharge current, set the battery rated voltage, and the battery full-charge voltage. 2. Portable test mode and charge-discharge integrated test mode 3. If the charge-discharge integrated test mode is selected, this option is available, select external input charging or internal control charging, and input the full-charge voltage of the battery of the instrument under test.

[0028] Preparation before work: Before work, the single-chip microcomputer first detects the voltage of the measured end to see if the voltage exceeds 300V. If it exceeds 300V, it will issue an alarm and stop working. If it does not exceed 300V and is not a negative voltage, the single-chip microcomputer module controls the "test relay" to turn on and start measuring.

[0029] Working stage: 1. If the portable mode is selected, the discharge test will be started directly. 2. If the charging and discharging integrated mode is selected, the single-chip microcomputer controls the "charging relay" to charge the battery under test. After the voltage reaches the full-charge voltage, it will directly enter the discharge mode. After the battery under test is discharged to the set cut-off voltage, the discharge of the battery under test will be stopped, and then the "charging relay" will be turned on to charge the battery under test. After the battery under test is fully charged, the charging relay will be automatically disconnected.

[0030] In the discharge mode, the single chip calculates the discharge time, discharge voltage, and discharge current. The formula is: Displayed measured power W = T (accumulated time, hours) × A (set current, amperes) × V [(pre-test voltage + test cut-off voltage) ÷ 2]. Displayed capacity mAh = W (measured power) ÷ V (rated voltage) × 1000

[0031] During operation, the temperature of the MOS tube is detected by the temperature sensor. When it is greater than 90°C, the machine will shut down and alarm will be sounded. The microcontroller controls the gate of the MOS tube through the DA interface output according to the set current size, and then adjusts the conduction degree of the MOS tube in the non-saturated area, adjusts the current in the circuit to the set value and keeps it stable.

[0032] When the precision voltmeter detects that the voltage reaches the set discharge cut-off voltage, the DA output is stopped to turn off the MOS tube, and the circuit discharge is terminated. The MOS tube is preferably IRFP460 in TO-247 package.

[0033] During operation, the single-chip microcomputer module controls the operation of the micro water pump and the cooling fan at the same time. The micro water pump is connected in parallel with the cooling fan and the speed is adjusted by PWM. The higher the temperature of the MOS tube, the faster the fan / water pump speed. The specific speed is determined by the water discharge flow and the fan air volume. There is no limitation here as long as a sustainable cooling effect can be achieved.

[0034] Circuit Description:

[0035] The single-chip microcomputer has 10 input and output interfaces, among which the DA output port controls the MOS tube. Specifically, the DA output port is connected to a current limiting resistor. The current limiting resistor is selected according to the driving force requirements of the selected MOS tube, and is generally between 5-20Ω. The current limiting resistor is connected to the gate pin G of the MOS tube. The gate pin of the MOS tube is also connected to a 12V / 2W voltage regulator diode for protection and a 100KΩ resistor for shutdown. The other end of the voltage regulator diode and the 100KΩ resistor is connected to the source S of the MOS tube. The drain D of the MOS tube is connected to the current detection module. The other end of the current detection module is connected to the normally open contact of the test relay. The common contact of the test relay is connected to the anti-backflow Schottky diode. The diode can be removed in the precision measurement circuit. The anti-backflow work is judged by the single-chip microcomputer combined with the voltage module. When the negative input voltage under test is detected, the measuring relay does not attract. The voltage module is connected in parallel with the access port of the battery under test. The external charging interface of the special charger used to charge the battery under test is connected in series with the normally open contact of the charging relay to form a circuit, and the formed circuit is then connected in parallel with the access port of the battery under test.

[0036] Energy recovery circuit: The positive output end of the Seebeck effect chip is connected to a Schottky diode, and then connected to the positive input of the lithium battery charging module, and the negative electrode is directly connected to the negative input of the lithium battery charging module. The emergency charging interface used to charge the internal battery of this instrument is directly connected to the input end of the lithium battery charging module. The internal lithium battery of this instrument is connected to the output end of the lithium battery charging module, and its positive and negative electrodes are connected to the power supply end of the single-chip microcomputer module.

[0037] Thermal energy recovery system: Especially when measuring the capacity of lead-acid batteries, a large amount of energy can be recovered for electrical energy to operate the system.

[0038] The heat exchange system is shown in the figure. The system has three water cooling heads. Water cooling head 1 is used to directly cool the MOS tube. The water heated by the MOS tube heats the Seebeck effect plate through water cooling head 3. The other side of the Seebeck effect plate is connected to a water cooling head 2 for cooling. The cold water of water cooling heads 1 and 2 comes directly from the water cooled by the radiator. The hot water after heat exchange of water cooling heads 2 and 3 converges to the input end of the radiator. The water circulation in the pipeline is driven by a pump, and the cooling method of the radiator is air cooling by a fan.

[0039] Self-charging after testing: When the instrument battery is connected to an external charger, if the charging and discharging integrated mode is selected, after the discharge program is completed, the microcontroller controls the "charging relay" to be turned on for charging, and the "charging relay" is disconnected to end charging after the voltage reaches the full charge voltage.

Claims

1. A battery tester for production safety inspection and testing instruments, comprising an instrument housing (2), characterized in that: A cooling channel is provided in the middle of the instrument housing (2), a heat sink (3) and a heat sink fan (4) are provided in the cooling channel, an air outlet protective cover (1) and an air inlet protective cover (5) are provided on both sides of the heat sink (3), the instrument housing (2) is provided with a handle, and control and support components are also installed in the instrument housing (2), including: a single-chip control module, a battery test system, and an energy recovery and heat exchange system; the energy recovery and heat exchange system includes a water cooling head, and the water cooling head circulates the Seebeck effect plate (11) and the MOS tube heat dissipation part under the drive of a pump (9); The energy recovery and heat exchange system comprises three water cooling heads, wherein the first water cooling head (24) is installed at the heat dissipation position of the MOS tube, the water heated by the MOS tube heats the Seebeck effect plate (11) through the third water cooling head (26), the other side of the Seebeck effect plate (11) is connected to a second water cooling head (25) for cooling, the cold water of the first water cooling head and the second water cooling head directly comes from the water cooled by the heat sink, the hot water after the heat exchange between the second water cooling head and the third water cooling head is gathered at the input end of the heat sink, the electric energy output by the Seebeck effect plate (11) is used to charge the built-in battery of the instrument, the water circulation in the pipeline is driven by the pump (9), and the air cooling of the heat dissipation fan (4) is used to cool the heat sink (3); The DA output port of the single-chip control module controls the gate pin G of the MOS tube, the drain D of the MOS tube is connected to the current detection module, the other end of the current detection module is connected to the normally open contact of the test relay, the other end of the test relay is connected to the positive input port of the battery under test, the source S of the MOS tube is connected to the negative input port of the battery, the signal output ports of the high sampling rate precision voltage module and the high sampling rate precision current module are connected to the single-chip control module, and the external charging interface is connected in series with the normally open contact of the charging relay and then connected in parallel with the access port of the battery under test.

2. The battery tester for production safety detection and inspection instruments according to claim 1 is characterized in that: The instrument housing (2) is a ladder-shaped structure, with an integrally formed handle on the top of the instrument, an inclined rectangular mounting surface is provided at the cut corner below the handle, the air outlet below the mounting surface is an air inlet, a multifunctional compartment is provided under the air inlet protective cover (5), the multifunctional compartment has a reciprocating self-locking cover, the compartment has an anti-reverse connection test interface, an instrument emergency charging interface, a main power switch, and a charging input interface for a tested battery, and a test line and an emergency charger for the instrument itself are placed in the compartment.

3. The battery tester for production safety detection and inspection instruments according to claim 1 is characterized in that: The air outlet protective cover (1) and the air inlet protective cover (5) are flush with the outer surface of the instrument, the angle between the protective cover and the horizontal plane is limited to between 75° and 85°, the inclination angles of the front and rear surfaces of the instrument are symmetrical and the same, the bottom surface of the instrument is flush with the horizontal plane, and the top surface of the instrument handle is 20 mm wide and chamfered.

4. The battery tester for production safety detection and inspection instruments according to claim 1 is characterized in that: A rectangular installation surface is arranged at the cut corner below the handle, a display screen and a switch setting button are installed on the rectangular installation surface, and an angle range between the rectangular installation surface and a horizontal plane is limited to between 45° and 55°.

5. The battery tester for production safety detection and inspection instruments according to claim 1 is characterized in that: The single-chip microcomputer module has a built-in tilt sensor. When it detects that the instrument is tipping forward or backward, the single-chip microcomputer module terminates the DA output and sounds an alarm.

6. The battery tester for production safety detection and inspection instrument according to claim 1 is characterized in that: The MOS tube uses IRFP460 in TO-247 package.

7. The battery tester for production safety detection and inspection instruments according to claim 1 is characterized by: When the instrument is testing the battery capacity, the MOS tube is in the non-saturated working area. The working current of the MOS tube is controlled by the single-chip microcomputer module. The single-chip microcomputer detects the working current of the MOS tube through the current sensor and controls the MOS tube to work in the non-saturated area according to the set parameters at all times.

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