Test system and test method of truck battery replacement mechanism

Abstract

The invention discloses a test system and a test method for a truck battery replacing mechanism. The test system comprises a battery replacing bottom support, a charging pile, a discharging tester, a CAN box, a computer and a 24V stabilized voltage supply. The battery replacing bottom support is used for supporting the battery replacing cabinet; the charging pile is used for charging the battery changing cabinet; the discharge tester is electrically connected with the battery replacement bottom support and is used for simulating an automobile load and carrying out controllable discharge on the battery replacement cabinet; the CAN box is electrically connected with the battery changing bottom support through a CAN communication line; the computer is electrically connected with the CAN box, and is used for operating upper computer software, reading signals converted from the CAN box, controlling the battery changing cabinet and reading the signals; and the 24V stabilized voltage supply is electrically connected with the CAN box and supplies power to the CAN box and a starting signal point of the battery changing cabinet. According to the invention, the charging and discharging electrical control of the power conversion cabinet can be detected through the upper computer, so that the functional integrity of the power conversion cabinet can be judged more conveniently and quickly, and whether the power conversion cabinet is a qualified product or not can be judged.

Description

Technical Field

[0001] The present application belongs to the field of battery testing technology, and specifically, is a testing system and testing method for a truck battery replacement mechanism. Background Art

[0002] Heavy-duty truck battery swapping technology refers to the removal and replacement of battery packs on heavy-duty trucks through battery swapping stations to quickly replenish power, thereby improving the vehicle's operating efficiency. Heavy-duty truck battery swapping technology is mainly used for pure electric heavy-duty trucks, which are usually used for short-distance transportation, such as port logistics, mine transportation, and slag removal. The most important component of heavy-duty truck battery swapping is the battery swapping cabinet in the battery swapping mechanism. The battery swapping cabinet includes: battery pack, battery cooling system, charging port, discharge port, battery swapping connector, locking mechanism and communication control system. The factory function detection and quality and safety confirmation of the battery swapping cabinet are the most important processes in the battery swapping mechanism. The present invention detects and confirms the factory function and quality confirmation of the battery swapping cabinet, which greatly improves the efficiency and accuracy of finished product inspection and quality control. Summary of the invention

[0003] Application Contents 1. Technical issues of this application: In order to make up for the deficiencies of the prior art and solve the above-mentioned technical problems, the present application proposes a.

[0004] (II) The specific structure of the technical solution of this application includes: A testing system for a truck battery replacement mechanism, comprising: A battery-swapping base, on which a charging port is provided and which is used to support a battery-swapping cabinet; A charging pile, which is electrically connected to the battery swap base through a DC charging gun and is used to charge the battery swap cabinet; A discharge tester, which is electrically connected to the battery swap base and is used to simulate a car load and perform controllable discharge on the battery swap cabinet; A CAN box, the CAN box being electrically connected to the battery replacement base via a CAN communication line; A computer, which is electrically connected to the CAN box and is used to run the upper computer software, read the signal converted from the CAN box, and control the power exchange cabinet and read the signal; A 24V regulated power supply is electrically connected to the CAN box and supplies power to the start signal points of the CAN box and the power exchange cabinet.

[0005] As the preferred technical solution of the previous step, a locking mechanism is provided on the battery replacement base, and the locking mechanism is connected to the air pump through an air pipe, and the opening and closing of the locking mechanism is controlled by the air pump.

[0006] As the preferred technical solution of the previous step, the battery exchange base includes a support frame, on which a slidingly connected lock column is installed. The lock column is controlled to move by a cylinder. The lock column cooperates with the power exchange cabinet, and the lock column locks and releases the power exchange cabinet.

[0007] As a preferred technical solution in the previous step, the test system also includes a bracket, which is installed under the battery replacement base, and the bracket includes a bottom plate, on which a support plate is fixedly connected, and the support plate is used to support the battery replacement support frame.

[0008] As a preferred technical solution in the previous step, a support groove is provided on the support plate, and the support groove and the support bar provided at the lower end of the support plate cooperate with each other.

[0009] As a preferred technical solution of the previous step, the test system also includes a fuse, which is installed on the power exchange cabinet and is used to protect the circuit of the power exchange cabinet.

[0010] As a preferred technical solution in the previous step, the CAN box and the computer can be replaced by a control cabinet, which includes a PLC and an industrial control panel, and is provided with multiple interfaces.

[0011] A method for testing a truck battery replacement mechanism comprises the following steps: 1) Hoist the new battery pack onto the battery replacement base; 2) Detect inter-electrode resistance and insulation to ground; 3) Connect the low-voltage power communication line, plug in the fuse, and control the output voltage to 460-480V and the current to 0.18-0.22mA; 4) Power on the 24V regulated power supply and the discharge tester, and close the DC switch of the discharge tester. The current voltage value of the discharge tester will be displayed as 200-220V; 5) Control the wake-up signal switch panel to switch to the driving wake-up signal; 6) Open the computer software operation interface, click CAN start, and click OK after the display shows that CAN start is successful. If it shows that CAN start fails, check the line connection and click CAN start again; 7) Click Start Monitoring to display the monitoring data. The current battery box is not in high voltage state. The battery system fault code 20 and 95 are normal. The TMS fault code is 5 and level 3 fault is normal. The fault is eliminated after high voltage is applied. Simultaneously check the BMS software version number and the water cooling unit software version. 8) Send high voltage command: High voltage power on and off command drop-down menu -> High voltage power on -> Click send -> Observe the discharge tester voltage is 580-600V; 9) In the thermal management interface, press the heating load relay: close, open, heating positive relay: close, open in sequence, and observe the corresponding text displayed on the interface; 10) In the thermal management interface, press the water cooling detection mode: self-circulation mode, and click the shutdown mode after confirming that it is normal; 11) Discharge test: Press the start button of the discharge tester and wait for the discharge to end. The actual setting parameters on site are 1 minute discharge and 10A current; 12) After the discharge is completed, switch the wake-up signal switch panel to the charging wake-up signal; 13) Plug in the charging gun and check whether the charging gun on the charging device is connected in place. After it is connected in place, perform the charging operation and wait for 15-30 seconds to start charging. After the charging test is completed, pull out the charging gun; 14) Send the high voltage power-off command of the high voltage interface, and observe whether the voltage displayed on the discharge tester is 200-220V; 15) Disconnect the 24 V power supply, the low-voltage power supply communication line, the fuse, the DC switch of the discharge tester, and the AC switch of the discharge tester; 16) Remove the upper frame of the battery replacement, complete the charge and discharge test, and record the test items simultaneously.

[0012] As a preferred technical solution of the previous step, the method for judging whether the inter-electrode resistance in step 2) is normal is: the resistance value approaches infinity.

[0013] As the preferred technical solution of the previous step, the method for judging whether the self-circulation mode in step 10) is operating normally is: touch the water-cooling circulation pipe on the power swap cabinet, if there is water flow and the sound of a water pump at the top of the power swap cabinet, it is normal.

[0014] (III) The beneficial effects of this application include at least the following: The present application can detect the charging and discharging industrial control of the battery swap cabinet through the upper computer, and judge the functional integrity of the battery swap cabinet more conveniently and quickly to determine whether it is a qualified product. If it is an unqualified product, the location of the fault and the missing function can be clearly pointed out, which provides a lot of convenience for detection and maintenance, saves manpower, and does not need to judge the messages one by one to know the working condition of the battery swap cabinet. The rapid judgment of functional integrity is a major feature of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present application will be further described below in conjunction with the accompanying drawings.

[0016] Figure 1 It is a schematic diagram of the system structure framework of this application; Figure 2 This is a schematic diagram of the three-dimensional structure of the battery replacement base of the present application; Figure 3 It is a schematic diagram of the three-dimensional structure of the bracket of the present application.

[0017] Among them, in the figure, 10, battery replacement base; 11, support frame; 12, support bar; 13, locking column; 20, bracket; 21, bottom plate; 22, support plate; 23, support groove. DETAILED DESCRIPTION

[0018] In order to make the technical means, creative features, objectives and effects achieved by this application easy to understand, this application is further explained below in conjunction with specific implementation methods.

[0019] Example: like Figure 1 As shown, a test system for a truck battery swap mechanism of the present application includes: a battery swap base, a charging pile, a discharge tester, a CAN box, a computer, and a 24V regulated power supply. Among them, the battery swap base of the present application is used to support the battery swap cabinet, and a charging port is provided on the battery swap base, which is used to be electrically connected to the battery swap cabinet; the charging pile of the present application is electrically connected to the battery swap base through a DC charging gun, and is used to charge the battery swap cabinet; the discharge tester of the present application is electrically connected to the battery swap base, and is used to simulate the vehicle load and perform controllable discharge on the battery swap cabinet. Preferably, the discharge tester of the present application is a 600V discharge tester; the CAN box of the present application is electrically connected to the battery swap base through a CAN communication line, and the CAN box realizes communication between computers; the computer of the present application is electrically connected to the CAN box, and is used to run the host computer software, read the signal converted from the CAN box, and control the battery swap cabinet and read the signal, wherein the host computer software name of the present application is: NEWceshiTool; the 24V regulated power supply of the present application is electrically connected to the CAN box, and supplies power to the start signal point of the CAN box and the battery swap cabinet.

[0020] The present application can detect the charging and discharging industrial control of the discharge cabinet, and more conveniently and quickly judge the functional integrity of the power exchange cabinet to determine whether it is a qualified product; if it is an unqualified product, it can also clearly point out the location of the fault and the missing function, providing a lot of convenience for detection and maintenance.

[0021] As a preferred implementation of the previous step, a locking mechanism is provided on the battery swap base 10 of the present application, and the locking mechanism is connected to the air pump through an air pipe, and the opening and closing of the locking mechanism is controlled by the air pump. By setting up a locking mechanism, the power swap cabinet can be locked to prevent accidents during the detection process. Specifically, the battery swap base of the present application includes a support frame 11. Preferably, the support frame 11 is a quadrilateral structure, and a plurality of slidingly connected lock columns 13 are installed on the support frame 11. Preferably, the number of lock columns 13 is six, wherein the six lock columns 13 are divided into two groups, each group of three, and each group of lock columns 13 respectively locks and releases the two ends of the power swap cabinet. The lock columns 13 of the present application are controlled to move by cylinders. Specifically, each lock column 13 is respectively controlled by a cylinder, and the cylinder is supplied with air by an air pump.

[0022] As a preferred implementation of the previous step, the test system of the present application also includes a bracket 20, wherein the bracket 20 is installed below the battery swap base 10, and mainly supports the battery swap base 10. Specifically, the bracket includes a bottom plate 21. Preferably, the bottom plate is a flat plate with a square structure, and a support plate 22 is fixedly connected to the bottom plate. Preferably, the support plate 22 and the bottom plate 21 are fixedly connected by welding, and the support plate 22 is used to support the battery swap support frame 11. Specifically, a support groove 23 is provided on the support plate 22 of the present application, and the support groove 23 cooperates with the support bar 12 provided at the lower end of the support plate. Preferably, the cross-section of the support bar 12 of the present application is a four-frame structure, and the support groove 23 is a rectangular structure, and the support bar 12 can be stuck inside the support groove 23.

[0023] As a preferred implementation of the previous step, the test system of the present application also includes a fuse, wherein the fuse is installed on the battery swap cabinet and is used to protect the circuit of the battery swap cabinet. For example, when a short circuit occurs inside the battery swap cabinet, the fuse will be disconnected immediately to protect the safety of the battery inside the battery swap cabinet.

[0024] As a preferred implementation of the previous step, the CAN box and computer of the present application can be replaced by a control cabinet, specifically, the control cabinet includes a PLC and an industrial control screen, and a plurality of interfaces are provided on the control cabinet. Each operation process is controlled by the industrial control screen, which is simple and clear.

[0025] The present application also provides a method for testing a truck battery replacement mechanism, comprising the following steps: 1) Hoist the new battery pack onto the battery replacement base; 2) Detect the inter-electrode resistance and insulation to the ground. The method for judging whether the inter-electrode resistance is normal is: the resistance value approaches infinity; 3) Connect the low-voltage power communication line, plug in the fuse, and control the output voltage to 460-480V. In this application, the output voltage can be controlled at 460-480V. Preferably, the output voltage is 470V. The output current can be controlled at 0.18-0.22mA. Preferably, the output current is 0.2mA. 4) Turn on the 24V regulated power supply and the discharge tester, and close the DC switch of the discharge tester. The current voltage value of the discharge tester will be displayed as 200-220V, which are all normal values. Among them, 210V is better. 5) Control the wake-up signal switch panel to switch to the driving wake-up signal; 6) Open the computer software operation interface, click CAN start, and click OK after the display shows that CAN start is successful. If it shows that CAN start fails, check the line connection and click CAN start again; 7) Click Start Monitoring to display the monitoring data. The current battery box is not in high voltage state. The battery system fault code 20 and 95 are normal. The TMS fault code is 5 and level 3 fault is normal. The fault is eliminated after high voltage is applied. Simultaneously check the BMS software version number and the water cooling unit software version. 8) Send high voltage command: High voltage power on and off command drop-down menu -> High voltage power on -> Click send -> Observe the discharge tester voltage is 580-600V is normal, among which 590V is better; 9) In the thermal management interface, press the heating load relay: close, open, heating positive relay: close, open in sequence, and observe the corresponding text displayed on the interface; 10) In the thermal management interface, press the water cooling detection mode: self-circulation mode, confirm that it is normal, and then click the shutdown mode. The method to judge whether the self-circulation mode is operating normally is: touch the water cooling circulation pipe on the power exchange cabinet, if there is water flow, and there is a water pump sound at the top of the power exchange cabinet, it is normal; 11) Discharge test: Press the start button of the discharge tester and wait for the discharge to end. The actual setting parameters on site are 1 minute discharge and 10A current; 12) After the discharge is completed, switch the wake-up signal switch panel to the charging wake-up signal; 13) Plug in the charging gun and check whether the charging gun on the charging device is connected in place. After it is connected in place, perform the charging operation and wait for 15-30 seconds to start charging. Preferably, wait for 20 seconds to start charging. After the charging test is completed, pull out the charging gun; 14) Send the high voltage power-off command of the high voltage interface, and observe whether the voltage displayed on the discharge tester is 200-220V; 15) Disconnect the 24 V power supply, the low-voltage power supply communication line, the fuse, the DC switch of the discharge tester, and the AC switch of the discharge tester; 16) Remove the upper frame of the battery replacement, complete the charge and discharge test, and record the test items simultaneously.

[0026] In the description of this application, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate directions or positional relationships based on the attached Figure 1 The orientation or positional relationship shown is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it cannot be understood as limiting the scope of protection of the present application. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0027] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited by the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present application. Without departing from the spirit and scope of the present application, the present application may have various changes and improvements, which fall within the scope of the present application to be protected. The scope of protection claimed in the present application is defined by the attached claims and their equivalents.

Claims

1. A test system for a truck battery replacement mechanism, characterized in that: include: A battery-swapping base, on which a charging port is provided and which is used to support a battery-swapping cabinet; A charging pile, which is electrically connected to the battery swap base through a DC charging gun and is used to charge the battery swap cabinet; A discharge tester, which is electrically connected to the battery swap base and is used to simulate a car load and perform controllable discharge on the battery swap cabinet; A CAN box, the CAN box being electrically connected to the battery replacement base via a CAN communication line; A computer, which is electrically connected to the CAN box and is used to run the upper computer software, read the signal converted from the CAN box, and control the power exchange cabinet and read the signal; A 24V regulated power supply is electrically connected to the CAN box and supplies power to the start signal points of the CAN box and the power exchange cabinet.

2. A test system for a truck battery replacement mechanism according to claim 1, characterized in that: A locking mechanism is provided on the battery replacement base, and the locking mechanism is connected to the air pump through an air pipe, and the opening and closing of the locking mechanism is controlled by the air pump.

3. A test system for a truck battery replacement mechanism according to claim 2, characterized in that: The battery exchange base includes a support frame, on which a slidingly connected lock column is installed. The lock column is controlled to move by a cylinder. The lock column cooperates with the power exchange cabinet, and the lock column locks and releases the power exchange cabinet.

4. A test system for a truck battery replacement mechanism according to claim 3, characterized in that: The test system also includes a bracket, which is installed under the battery replacement base. The bracket includes a bottom plate, and a support plate is fixedly connected to the bottom plate, and the support plate is used to support the battery replacement support frame.

5. A test system for a truck battery replacement mechanism according to claim 4, characterized in that: The support plate is provided with a support groove, and the support groove and the support bar provided at the lower end of the support plate cooperate with each other.

6. A test system for a truck battery replacement mechanism according to claim 1, characterized in that: The test system also includes a fuse, which is installed on the power exchange cabinet and is used to protect the circuit of the power exchange cabinet.

7. A test system for a truck battery replacement mechanism according to claim 1, characterized in that: The CAN box and the computer can be replaced by a control cabinet, which includes a PLC and an industrial control screen, and is provided with a plurality of interfaces.

8. A method for testing a truck battery replacement mechanism, characterized in that: The steps include: 1) Hoist the new battery pack onto the battery replacement base; 2) Detect inter-electrode resistance and insulation to ground; 3) Connect the low-voltage power communication line, plug in the fuse, and control the output voltage to 460-480V and the current to 0.18-0.22mA; 4) Power on the 24V regulated power supply and the discharge tester, and close the DC switch of the discharge tester. The current voltage value of the discharge tester will be displayed as 200-220V; 5) Control the wake-up signal switch panel to switch to the driving wake-up signal; 6) Open the computer software operation interface, click CAN start, and click OK after the display shows that CAN start is successful. If it shows that CAN start fails, check the line connection and click CAN start again; 7) Click Start Monitoring to display the monitoring data. The current battery box is not in high voltage state. The battery system fault code 20 and 95 are normal. The TMS fault code is 5 and level 3 fault is normal. The fault is eliminated after high voltage is applied. Simultaneously check the BMS software version number and the water cooling unit software version. 8) Send high voltage command: High voltage power on and off command drop-down menu -> High voltage power on -> Click send -> Observe the discharge tester voltage is 580-600V; 9) In the thermal management interface, press the heating load relay: close, open, heating positive relay: close, open in sequence, and observe the corresponding text displayed on the interface; 10) In the thermal management interface, press the water cooling detection mode: self-circulation mode, and click the shutdown mode after confirming that it is normal; 11) Discharge test: Press the start button of the discharge tester and wait for the discharge to end. The actual setting parameters on site are 1 minute discharge and 10A current; 12) After the discharge is completed, switch the wake-up signal switch panel to the charging wake-up signal; 13) Plug in the charging gun and check whether the charging gun on the charging device is connected in place. After it is connected in place, perform the charging operation and wait for 15-30 seconds to start charging. After the charging test is completed, pull out the charging gun; 14) Send the high voltage power-off command of the high voltage interface, and observe whether the voltage displayed on the discharge tester is 200-220V; 15) Disconnect the 24 V power supply, the low-voltage power supply communication line, the fuse, the DC switch of the discharge tester, and the AC switch of the discharge tester; 16) Remove the upper frame of the battery replacement, complete the charge and discharge test, and record the test items simultaneously.

9. A method for testing a truck battery replacement mechanism according to claim 8, characterized in that: The method for judging whether the inter-electrode resistance in the step 2) is normal is: the resistance value approaches infinity.

10. A method for testing a truck battery replacement mechanism according to claim 8, characterized in that: The method for judging whether the self-circulation mode in step 10) is operating normally is as follows: touch the water-cooling circulation pipe on the power-swap cabinet, if there is water flow and the sound of a water pump at the top of the power-swap cabinet, it is normal.

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