A wireless battery module testing method and system

Abstract

This invention provides a wireless battery module testing method and system in the field of battery testing technology. The method includes: Step S10, configuring a wireless communication module at intervals along a test production line, creating a wireless communication module table and a production line information table, and setting the receiving distance of the wireless communication module; Step S20, updating the wireless communication module table after the test production line is powered on; Step S30, the PLC monitors the position of each battery module on the test production line in real time, and automatically sends a test request to the industrial control computer based on the production line information table when the battery module reaches the designated position on the test production line; Step S40, the industrial control computer matches the wireless communication module based on the test request, through the wireless communication module table, the production line information table, and the receiving distance; Step S50, the test production line establishes a wireless connection with the battery module through the wireless communication module and executes the wireless testing operation of the battery module. The advantages of this invention are: it greatly reduces the battery module testing cost and greatly improves the battery module testing efficiency.

Description

Technical Field

[0001] This invention relates to the field of battery testing technology, and in particular to a method and system for testing wireless battery modules. Background Technology

[0002] Early electric vehicle BMS management systems used a centralized topology, where a single controller was used for battery module testing and management. This required numerous physical wiring harnesses to connect to each battery module. While this structure was simple and low-cost, it resulted in poor flexibility and stability. Because traditional BMS management systems use a serial connection to link the battery modules, a problem with the wiring harness of even one battery module could cause the entire battery pack to crash, and troubleshooting such issues was extremely cumbersome and difficult.

[0003] Replacing traditional wire harness connections with wireless communication technology not only saves space but also solves the vulnerabilities of traditional series-connected battery pack structures, improving the reliability and stability of the battery pack. However, connecting battery modules wirelessly for testing traditionally has the following drawbacks:

[0004] 1. Each testing line is equipped with one wireless communication module. In addition to performing withstand voltage tests and insulation tests on the battery modules, the testing line also requires manual connection operations. The wireless communication module is not needed when performing tests and connection operations, but it is occupied by these tests, resulting in low utilization of the wireless communication module and thus increasing the testing cost of the battery modules. 2. When the wireless communication module fails, the test must be stopped and the wireless communication module replaced. This not only wastes time and affects testing efficiency, but may also lead to the battery module being misjudged as a product defective, or requiring multiple tests, reducing the pass rate of the first test.

[0005] Therefore, how to provide a wireless battery module testing method and system to reduce battery module testing costs and improve battery module testing efficiency has become an urgent technical problem to be solved. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a wireless battery module testing method and system, so as to reduce the testing cost of battery modules and improve the testing efficiency of battery modules.

[0007] In a first aspect, the present invention provides a method for testing a wireless battery module, comprising the following steps:

[0008] Step S10: Configure a wireless communication module at intervals of one test production line, create a wireless communication module table and a production line information table, and set the receiving distance of the wireless communication module.

[0009] Step S20: After powering on the test production line, update the wireless communication module table;

[0010] Step S30: The PLC monitors the position of each battery module on the test production line in real time. When the battery module reaches the designated position on the test production line, it automatically sends a test request to the industrial control computer based on the production line information table.

[0011] Step S40: Based on the received test request, the industrial control computer matches the corresponding wireless communication module through the wireless communication module table, production line information table, and receiving distance, and allocates the wireless communication module through the test middleware.

[0012] Step S50: The test production line establishes a wireless connection with the battery module at the designated location through the allocated wireless communication module, performs wireless test operations on the battery module, and stores the test data in the database through the test middleware.

[0013] Furthermore, in step S10, the wireless communication module table includes at least the module ID, module name, module MAC address, spacing between adjacent wireless communication modules, startup status, and running status.

[0014] The startup status is online or offline; the running status is idle or busy.

[0015] The production line information table includes at least the production line ID, production line name, module ID of this test production line, module IDs of other test production lines within the receiving distance, and the IP address of the industrial control computer.

[0016] Further, step S20 specifically includes:

[0017] After the test production line is powered on and running, the PLC updates the startup status in the wireless communication module table to online.

[0018] Further, step S30 specifically includes:

[0019] The PLC monitors the position of each battery module on the test production line in real time. When a battery module reaches the designated position on the test production line, the PLC obtains the module's MAC address via NFC or a barcode scanner, obtains the IP address of the industrial control computer of this test production line through the production line information table, and automatically sends a test request carrying the module's MAC address to the industrial control computer based on the IP address.

[0020] Further, step S40 specifically includes:

[0021] Step S41: Based on the received test request, the industrial control computer, within the receiving distance, polls the nearest wireless communication module in the wireless communication module table and the production line information table to determine whether the wireless communication module's startup status and running status are online and idle. If so, the idle wireless communication module is directly allocated through the test middleware; otherwise, proceed to step S42.

[0022] Step S42: Determine whether all wireless communication modules within the receiving distance have been polled. If yes, start a new cycle after a preset interval; otherwise, continue polling the next wireless communication module.

[0023] Secondly, the present invention provides a wireless battery module testing system, comprising the following modules:

[0024] The initialization module is used to configure a wireless communication module at intervals of one test production line, create a wireless communication module table and a production line information table, and set the receiving distance of the wireless communication module.

[0025] The wireless communication module table update module is used to update the wireless communication module table after the test production line is powered on and running.

[0026] The test request sending module is used by the PLC to detect the position of each battery module on the test production line in real time. When the battery module reaches the designated position on the test production line, it automatically sends a test request to the industrial control computer based on the production line information table.

[0027] The wireless communication module allocation module is used by the industrial control computer to match the corresponding wireless communication module based on the received test request, through the wireless communication module table, the production line information table, and the receiving distance, and to allocate the wireless communication module through the test middleware.

[0028] The wireless test module is used to test the production line to establish a wireless connection with the battery module at a designated location through the allocated wireless communication module, perform wireless test operations on the battery module, and store the test data in the database through the test middleware.

[0029] Furthermore, in the initialization module, the wireless communication module table includes at least the module ID, module name, module MAC address, spacing between adjacent wireless communication modules, startup status, and running status;

[0030] The startup status is online or offline; the running status is idle or busy.

[0031] The production line information table includes at least the production line ID, production line name, module ID of this test production line, module IDs of other test production lines within the receiving distance, and the IP address of the industrial control computer.

[0032] Furthermore, the wireless communication module table update module is specifically used for:

[0033] After the test production line is powered on and running, the PLC updates the startup status in the wireless communication module table to online.

[0034] Furthermore, the test request sending module is specifically used for:

[0035] The PLC monitors the position of each battery module on the test production line in real time. When a battery module reaches the designated position on the test production line, the PLC obtains the module's MAC address via NFC or a barcode scanner, obtains the IP address of the industrial control computer of this test production line through the production line information table, and automatically sends a test request carrying the module's MAC address to the industrial control computer based on the IP address.

[0036] Furthermore, the wireless communication module allocation module specifically includes:

[0037] The module polling unit is used by the industrial control computer to poll the wireless communication module table and the production line information table within the receiving distance based on the received test request, starting from the nearest wireless communication module, to determine whether the startup status and running status of the wireless communication module are online and idle. If they are, the idle wireless communication module is directly allocated through the test middleware; otherwise, the module repeated polling unit is entered.

[0038] The module repeated polling unit is used to determine whether all wireless communication modules within the receiving distance have been polled. If so, a new cycle begins after a preset interval; otherwise, the next wireless communication module is polled.

[0039] The advantages of this invention are:

[0040] By configuring one wireless communication module per test production line, creating a wireless communication module table and a production line information table, and setting the receiving distance of the wireless communication modules, when a battery module on the test production line triggers a test request, the industrial control computer, within the receiving distance, polls the nearest wireless communication module in the wireless communication module table and the production line information table to determine the startup and running status of the wireless communication modules. It then assigns the nearest available wireless communication module to the battery module and establishes a wireless connection with the battery module to perform wireless testing. Compared to the traditional configuration of one wireless communication module per test production line, this significantly improves the utilization rate of wireless communication modules. When one communication module fails, an available wireless communication module within the receiving distance can be called to take over, without stopping the operation of the test production line, thereby improving the first-pass yield rate. Ultimately, this greatly reduces the battery module testing cost and significantly improves the battery module testing efficiency. Attached Figure Description

[0041] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0042] Figure 1 This is a flowchart of a wireless battery module testing method according to the present invention.

[0043] Figure 2 This is a schematic diagram of the structure of a wireless battery module testing system according to the present invention.

[0044] Figure 3 This is a hardware architecture diagram of the present invention. Detailed Implementation

[0045] The overall idea of ​​the technical solution in this application embodiment is as follows: By configuring a wireless communication module at intervals of one test production line, a wireless communication module table and a production line information table are created, and the receiving distance of the wireless communication module is set, so as to allocate each wireless communication module. It is not necessary to configure a wireless communication module for each test production line, thereby improving the utilization rate of the wireless communication module, reducing the battery module testing cost, and allowing adjacent wireless communication modules to replace faulty wireless communication modules, thereby improving the battery module testing efficiency.

[0046] Please refer to Figures 1 to 3 As shown, a preferred embodiment of the wireless battery module testing method of the present invention includes the following steps:

[0047] Step S10: Configure a wireless communication module every other test production line, create a wireless communication module table and a production line information table, and set the receiving distance of the wireless communication module; for example, if there are 5 test production lines in the workshop, configure wireless communication modules on the 2nd and 4th test production lines.

[0048] Step S20: After powering on the test production line, update the wireless communication module table;

[0049] Step S30: The PLC monitors the position of each battery module on the test production line in real time. When the battery module reaches the designated position on the test production line, it automatically sends a test request to the industrial control computer based on the production line information table.

[0050] Step S40: Based on the received test request, the industrial control computer matches the corresponding wireless communication module through the wireless communication module table, production line information table, and receiving distance, and allocates the wireless communication module through the test middleware.

[0051] Step S50: The test production line establishes a wireless connection with the battery module at the designated location using the assigned wireless communication module and the module's MAC address, performs wireless testing of the battery module, and stores the test data in the database through the test middleware. During the test, the operating status of the corresponding wireless communication module is updated to busy, and updated to idle after the test is completed. The database uses MongoDB, which has the advantages of high performance, easy deployment, ease of use, and convenient data storage.

[0052] In step S10, the wireless communication module table includes at least the module ID, module name, module MAC address, spacing between adjacent wireless communication modules, startup status, and running status.

[0053] The startup status is online or offline; the running status is idle or busy; testing can only be performed when the startup status is online and the running status is idle.

[0054] The production line information table includes at least the production line ID, production line name, module ID of this test production line, module IDs of other test production lines within the receiving distance, and the IP address of the industrial control computer.

[0055] Step S20 specifically involves:

[0056] After the test production line is powered on and running, the PLC updates the startup status in the wireless communication module table to online.

[0057] Step S30 specifically involves:

[0058] The PLC monitors the position of each battery module on the test production line in real time. When a battery module reaches the designated position on the test production line, the PLC obtains the module's MAC address via NFC or a barcode scanner, obtains the IP address of the industrial control computer of this test production line through the production line information table, and automatically sends a test request carrying the module's MAC address to the industrial control computer based on the IP address.

[0059] Step S40 specifically includes:

[0060] Step S41: Based on the received test request, the industrial control computer, within the receiving distance, polls the nearest wireless communication module in the wireless communication module table and the production line information table to determine whether the wireless communication module's startup status and running status are online and idle. If so, the idle wireless communication module is directly allocated through the test middleware; otherwise, proceed to step S42.

[0061] Step S42: Determine whether all wireless communication modules within the receiving distance have been polled. If yes, start a new cycle after a preset interval; otherwise, continue polling the next wireless communication module.

[0062] For example, if there are 10 test production lines with equal spacing, wireless communication modules are configured on test production lines with even-numbered production line IDs. When the 5th test production line needs to perform a test, the wireless communication modules of the 2nd, 4th, 6th, and 8th test production lines are determined to be within signal coverage by using the wireless communication module table, production line information table, and receiving distance. Then, starting from the wireless communication module of the 4th or 6th test production line, the system polls for online and idle wireless communication modules.

[0063] A preferred embodiment of the wireless battery module testing system of the present invention includes the following modules:

[0064] The initialization module is used to configure a wireless communication module at intervals of one test production line, create a wireless communication module table and a production line information table, and set the receiving distance of the wireless communication module; for example, when there are 5 test production lines in the workshop, wireless communication modules are configured on the 2nd and 4th test production lines.

[0065] The wireless communication module table update module is used to update the wireless communication module table after the test production line is powered on and running.

[0066] The test request sending module is used by the PLC to detect the position of each battery module on the test production line in real time. When the battery module reaches the designated position on the test production line, it automatically sends a test request to the industrial control computer based on the production line information table.

[0067] The wireless communication module allocation module is used by the industrial control computer to match the corresponding wireless communication module based on the received test request, through the wireless communication module table, the production line information table, and the receiving distance, and to allocate the wireless communication module through the test middleware.

[0068] The wireless testing module is used to test the production line by establishing a wireless connection with the battery module at a designated location using the assigned wireless communication module and the module's MAC address. It then performs wireless testing operations on the battery module and stores the test data in a database via testing middleware. During the test, the operating status of the corresponding wireless communication module is updated to "busy," and updated to "idle" after the test is completed. The database uses MongoDB, which offers advantages such as high performance, ease of deployment, ease of use, and convenient data storage.

[0069] In the initialization module, the wireless communication module table includes at least the module ID, module name, module MAC address, spacing between adjacent wireless communication modules, startup status, and running status.

[0070] The startup status is online or offline; the running status is idle or busy; testing can only be performed when the startup status is online and the running status is idle.

[0071] The production line information table includes at least the production line ID, production line name, module ID of this test production line, module IDs of other test production lines within the receiving distance, and the IP address of the industrial control computer.

[0072] The wireless communication module table update module is specifically used for:

[0073] After the test production line is powered on and running, the PLC updates the startup status in the wireless communication module table to online.

[0074] The test request sending module is specifically used for:

[0075] The PLC monitors the position of each battery module on the test production line in real time. When a battery module reaches the designated position on the test production line, the PLC obtains the module's MAC address via NFC or a barcode scanner, obtains the IP address of the industrial control computer of this test production line through the production line information table, and automatically sends a test request carrying the module's MAC address to the industrial control computer based on the IP address.

[0076] The wireless communication module allocation module specifically includes:

[0077] The module polling unit is used by the industrial control computer to poll the wireless communication module table and the production line information table within the receiving distance based on the received test request, starting from the nearest wireless communication module, to determine whether the startup status and running status of the wireless communication module are online and idle. If they are, the idle wireless communication module is directly allocated through the test middleware; otherwise, the module repeated polling unit is entered.

[0078] The module repeated polling unit is used to determine whether all wireless communication modules within the receiving distance have been polled. If so, a new cycle begins after a preset interval; otherwise, the next wireless communication module is polled.

[0079] For example, if there are 10 test production lines with equal spacing, wireless communication modules are configured on test production lines with even-numbered production line IDs. When the 5th test production line needs to perform a test, the wireless communication modules of the 2nd, 4th, 6th, and 8th test production lines are determined to be within signal coverage by using the wireless communication module table, production line information table, and receiving distance. Then, starting from the wireless communication module of the 4th or 6th test production line, the system polls for online and idle wireless communication modules.

[0080] In summary, the advantages of this invention are as follows:

[0081] By configuring one wireless communication module per test production line, creating a wireless communication module table and a production line information table, and setting the receiving distance of the wireless communication modules, when a battery module on the test production line triggers a test request, the industrial control computer, within the receiving distance, polls the nearest wireless communication module in the wireless communication module table and the production line information table to determine the startup and running status of the wireless communication modules. It then assigns the nearest available wireless communication module to the battery module and establishes a wireless connection with the battery module to perform wireless testing. Compared to the traditional configuration of one wireless communication module per test production line, this significantly improves the utilization rate of wireless communication modules. When one communication module fails, an available wireless communication module within the receiving distance can be called to take over, without stopping the operation of the test production line, thereby improving the first-pass yield rate. Ultimately, this greatly reduces the battery module testing cost and significantly improves the battery module testing efficiency.

[0082] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A wireless battery module testing method, characterized by: The method comprises the following steps: Step S10, configuring a wireless communication module for each test production line, creating a wireless communication module table and a production line information table, and setting the receiving distance of the wireless communication module; the wireless communication module table at least comprises module ID, module name, module mac address, distance between adjacent wireless communication modules, start state and running state; The start state is online or offline; the running state is idle or busy; The production line information table at least comprises production line ID, production line name, module ID of the test production line, module ID of the remaining test production lines within the receiving distance, and IP address of the industrial computer; Step S20, after the test production line is powered on and operated, the PLC updates the start state in the wireless communication module table to online; Step S30, the PLC detects the position of each battery module on the test production line in real time, obtains the module mac address of the battery module through NFC or a code scanning gun when the battery module reaches the specified position on the test production line, obtains the IP address of the industrial computer of the test production line based on the production line information table, and automatically sends a test request carrying the module mac address to the industrial computer based on the IP address; Step S40, the industrial computer matches the corresponding wireless communication module based on the received test request through the wireless communication module table, the production line information table and the receiving distance, and distributes the wireless communication module through the test middleware; Step S50, the test production line establishes a wireless connection with the battery module at the specified position through the distributed wireless communication module, performs a wireless test operation on the battery module, and stores the test data in the database through the test middleware.

2. The method of claim 1, wherein: The step S40 specifically comprises: Step S41, the industrial computer, based on the received test request, polls the start state and the running state of the wireless communication module from the nearest wireless communication module within the receiving distance through the wireless communication module table and the production line information table to determine whether the start state and the running state are online and idle, and if so, directly distributes the idle wireless communication module through the test middleware; if not, step S42 is entered; Step S42, whether all wireless communication modules within the receiving distance are polled, if so, a new cycle is started after a preset time interval; if not, the next wireless communication module is continuously polled.

3. A wireless battery module test system, comprising: The method comprises the following modules: An initialization module is configured for each test production line to configure a wireless communication module, create a wireless communication module table and a production line information table, and set the receiving distance of the wireless communication module; the wireless communication module table at least comprises module ID, module name, module mac address, distance between adjacent wireless communication modules, start state and running state; The start state is online or offline; the running state is idle or busy; The production line information table at least comprises production line ID, production line name, module ID of the test production line, module ID of the remaining test production lines within the receiving distance, and IP address of the industrial computer; A wireless communication module table updating module is configured for the PLC to update the start state in the wireless communication module table to online after the test production line is powered on and operated; The test request sending module is configured to detect the positions of the battery modules on the test production line in real time, acquire the module MAC address of the battery module through NFC or a code scanning gun when the battery module reaches a specified position on the test production line, acquire the IP address of the industrial computer of the test production line through the production line information table, and automatically send a test request carrying the module MAC address to the industrial computer based on the IP address. The wireless communication module distribution module is configured to match a corresponding wireless communication module through the wireless communication module table, the production line information table and the receiving distance based on the received test request, and distribute the wireless communication module through the test middleware. The wireless test module is configured to establish a wireless connection between the test production line and the battery module at the specified position through the distributed wireless communication module, perform a wireless test operation on the battery module, and store test data in a database through the test middleware.

4. A wireless battery module test system as claimed in claim 3, wherein: The wireless communication module distribution module specifically includes: The module polling unit is configured to poll the start state and the running state of the wireless communication module to determine whether the start state and the running state are online and idle based on the received test request, and directly distribute the idle wireless communication module through the test middleware if the start state and the running state are online and idle; otherwise, the module repeated polling unit is entered. The module repeated polling unit is configured to determine whether all the wireless communication modules in the receiving distance have been polled, and start a new cycle after a preset time interval if all the wireless communication modules in the receiving distance have been polled; otherwise, the next wireless communication module is continuously polled.

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