Test system and test method of truck battery replacement mechanism

Abstract

The application discloses a test system and a test method for a truck battery replacement mechanism, comprising a battery replacement base, a charging pile, a discharge tester, a CAN box, a computer and a 24V stabilized power supply. The battery replacement base is used for supporting a battery replacement cabinet; the charging pile is used for charging the battery replacement cabinet; the discharge tester is electrically connected with the battery replacement base and is used for simulating a vehicle load to controllably discharge the battery replacement cabinet; the CAN box is electrically connected with the battery replacement base through a CAN communication line; the computer is electrically connected with the CAN box and is used for running host computer software, reading converted signals in the CAN box, and controlling and reading signals of the battery replacement cabinet; and the 24V stabilized power supply is electrically connected with the CAN box and supplies power to starting signal points of the CAN box and the battery replacement cabinet. The application can detect charging and discharging of the battery replacement cabinet through the host computer, more conveniently and quickly judge the functional integrity of the battery replacement cabinet, and judge whether the battery replacement cabinet is a qualified product.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of battery testing, in particular to a testing system and testing method for a truck battery replacement mechanism. BACKGROUND

[0002] Heavy truck battery replacement technology refers to disassembling and replacing battery packs on heavy trucks through a battery replacement station to quickly supplement the power and improve the operation efficiency of the vehicle. Heavy truck battery replacement technology is mainly applied to pure electric heavy trucks, which are usually used for short-distance transportation, such as port logistics, mine transportation, and construction and garbage removal scenes. The most important component of heavy truck battery replacement is the battery replacement cabinet in the battery replacement mechanism, which includes: battery pack, battery cooling system, charging port, discharging port, battery replacement connector, locking mechanism, and communication control system. The factory function detection and quality safety confirmation of the battery replacement cabinet are the most important procedures in the battery replacement mechanism. The application detects and confirms the factory function and quality confirmation of the battery replacement cabinet, greatly improving the efficiency and accuracy of product detection and quality control. SUMMARY

[0003] APPLICATION CONTENT

[0004] (I) Technical problem of the application:

[0005] In order to make up for the shortcomings of the prior art and solve the above technical problems, the application provides a.

[0006] (II) The technical scheme of the application specifically includes:

[0007] A testing system for a truck battery replacement mechanism, comprising:

[0008] A battery replacement base is provided with a charging port and is used to support the battery replacement cabinet;

[0009] A charging pile is electrically connected to the battery replacement base through a direct current charging gun and is used to charge the battery replacement cabinet;

[0010] A discharge tester is electrically connected to the battery replacement base and is used to simulate automobile load and controllably discharge the battery replacement cabinet;

[0011] A CAN box is electrically connected to the battery replacement base through a CAN communication line;

[0012] A computer is electrically connected to the CAN box and is used to run the upper computer software, read the converted signals in the CAN box, and control and read signals of the battery replacement cabinet;

[0013] A 24V stabilized power supply is electrically connected to the CAN box and supplies power to the starting signal points of the CAN box and the battery replacement cabinet.

[0014] As the preferred technical solution of the previous step, the battery replacement bottom support is provided with a locking mechanism, the locking mechanism is communicated with the air pipe and the air pump, and the locking mechanism is controlled to open and close by the air pump.

[0015] As the preferred technical solution of the previous step, the battery replacement bottom support includes a support frame, a slidingly connected lock column is installed on the support frame, the lock column is controlled to move by an air cylinder, the lock column cooperates with the battery replacement cabinet, and the lock column locks and releases the battery replacement cabinet.

[0016] As the preferred technical solution of the previous step, the test system further includes a support, the support is installed below the battery replacement bottom support, the support includes a bottom plate, a support plate is fixedly connected to the bottom plate, and the support plate is used to support the support frame.

[0017] As the preferred technical solution of the previous step, the support plate is provided with a support groove, and the support groove cooperates with a support strip arranged at the lower end of the support plate.

[0018] As the preferred technical solution of the previous step, the test system further includes a fuse, the fuse is installed on the battery replacement cabinet and is used to protect the circuit of the battery replacement cabinet.

[0019] As the preferred technical solution of the previous step, the CAN box and the computer can be replaced by a control cabinet, the control cabinet includes a PLC and an industrial control screen, and the control cabinet is provided with a plurality of interfaces.

[0020] A test method of a truck battery replacement mechanism includes the following steps:

[0021] 1) Hoist a new battery pack on the battery replacement bottom support;

[0022] 2) Detect the inter-electrode resistance and the ground insulation;

[0023] 3) Connect the low-voltage power supply communication line, plug in the fuse, control the output end voltage to be 460-480V, and the current to be 0.18-0.22mA;

[0024] 4) Power on the 24V stabilized power supply, power on the discharge tester, turn on the discharge tester DC switch, and the current voltage value of the discharge tester will be displayed as 200-220V;

[0025] 5) Control the wake-up signal switch panel to switch to the driving wake-up signal;

[0026] 6) Open the computer software operation interface, click CAN start, and click OK after displaying that the CAN start is successful, if it is displayed that the CAN start fails, check the line connection and then click CAN start again;

[0027] 7) Click to start monitoring, display monitoring data, the current battery box is not in the high voltage state, battery system fault code display 20 and 95 is normal phenomenon, TMS fault code is 5 and 3 level fault is normal phenomenon, after high voltage, fault is eliminated, synchronous observation BMS software version number and water cooling unit software version;

[0028] 8) Send high voltage on command: high voltage on and off command pull-down menu -> high voltage on -> click send -> observe the discharge tester voltage of 580-600V;

[0029] 9) Under the thermal management interface, press the heating load relay in turn: close, open, heating positive relay: close, open, and observe the corresponding text display on the interface;

[0030] 10) Under the thermal management interface, press the water cooling detection mode: self-circulation mode, click the shutdown mode after confirming normal;

[0031] 11) Discharge test: press the discharge tester start button and wait for the discharge to end, the actual setting parameters on site are 1 minute discharge and 10A current;

[0032] 12) After the discharge is completed, switch the wake-up signal switch panel to the charging wake-up signal;

[0033] 13) Plug in the charging gun, observe whether the charging gun is connected on the charging device, connect it in place, and then perform the charging operation, wait for 15-30S to start charging, pull out the charging gun after the charging test is completed;

[0034] 14) Send high voltage interface high voltage off command, and observe whether the voltage display on the discharge tester is 200-220V;

[0035] 15) Disconnect the 24V power supply, disconnect the low voltage power supply communication line, disconnect the fuse, disconnect the discharge tester DC switch, and disconnect the discharge tester AC switch;

[0036] 16) Remove the battery replacement upper frame, complete the charge and discharge test, and record the test items synchronously.

[0037] As the preferred technical solution of the previous step, the method for judging whether the inter-electrode resistance is normal in step 2) is that the resistance value approaches infinity.

[0038] As the preferred technical solution of the previous step, the method for judging whether the self-circulation mode is normal in step 10) is that the water cooling circulation pipe on the battery replacement cabinet is touched, there is water flow feeling, and there is water pump sound at the upper end of the battery replacement cabinet.

[0039] The beneficial effects of the present application at least include the following:

[0040] The application can detect the charging and discharging of the battery swap cabinet through the host computer, more conveniently and quickly judge the functional integrity of the battery swap cabinet, judge whether it is a qualified product, if it is a non-qualified product, the position of the fault and the part of the function loss can be clearly pointed out, which provides a lot of convenience for detection and maintenance, saves labor, and without judging the message one by one, the working condition of the battery swap cabinet can be known, and the fast functional integrity judgment is a big feature of the application. BRIEF DESCRIPTION OF DRAWINGS

[0041] The application will be further described below in combination with the drawings.

[0042] Figure 1 is a schematic diagram of the system structure framework of the application;

[0043] Figure 2 is a schematic diagram of the battery swap bottom support of the application;

[0044] Figure 3 is a schematic diagram of the support of the application.

[0045] In the figure, 10 is a battery swap bottom support, 11 is a support frame, 12 is a support bar, 13 is a lock column, 20 is a support, 21 is a bottom plate, 22 is a support plate, and 23 is a support groove. DETAILED DESCRIPTION

[0046] In order to make the technical means, creative features, purposes and effects realized by the application easy to understand, the application will be further described below in combination with the specific embodiments.

[0047] Embodiment:

[0048] As shown in Figure 1 The test system of the truck battery swap mechanism of the application comprises a battery swap bottom support, a charging pile, a discharge tester, a CAN box, a computer and a 24V stabilized power supply. The battery swap bottom support of the application is used to support the battery swap cabinet, and a charging port is arranged on the battery swap bottom support, which is used to be electrically connected with the battery swap cabinet. The charging pile of the application is electrically connected with the battery swap bottom support through a direct current charging gun, and is used to charge the battery swap cabinet. The discharge tester of the application is electrically connected with the battery swap bottom support, and is used to simulate the automobile load and perform controllable discharge on the battery swap cabinet. Preferably, the discharge tester of the application is a 600V discharge tester. The CAN box of the application is electrically connected with the battery swap bottom support through a CAN communication line, and realizes communication between the computer and the CAN box. The computer of the application is electrically connected with the CAN box, and is used to run the host computer software, read the converted signals in the CAN box, and control and read signals of the battery swap cabinet. The host computer software of the application is named NEWceshiTool. The 24V stabilized power supply of the application is electrically connected with the CAN box, and supplies power to the starting signal points of the CAN box and the battery swap cabinet.

[0049] The application can detect the charging and discharging of the discharging cabinet, more conveniently and quickly judge the functional integrity of the battery replacement cabinet, and judge whether it is a qualified product; if it is a non-qualified product, the position of the fault and the part of the function loss can also be clearly pointed out, which provides a lot of convenience for detection and maintenance.

[0050] As the preferred embodiment of the above step, the battery replacement base 10 of the application is provided with a locking mechanism, which is communicated with the air pipe and the air pump, and the locking mechanism is controlled to open and close by the air pump. By setting the locking mechanism, the battery replacement cabinet can be locked to prevent accidents during detection. Specifically, the battery replacement base of the application comprises a support frame 11, preferably a quadrilateral structure, and a plurality of lock columns 13 are slidably connected to the support frame 11, preferably six lock columns 13, wherein the six lock columns 13 are divided into two groups, each group has three lock columns 13, and each group of lock columns 13 locks and loosens the two ends of the battery replacement cabinet. The lock column 13 of the application is controlled to move by the air cylinder, specifically, each lock column 13 is controlled by an air cylinder, and the air cylinder is supplied with air by the air pump.

[0051] As the preferred embodiment of the above step, the test system of the application further comprises a support 20, wherein the support 20 is installed below the battery replacement base 10 and mainly supports the battery replacement base 10. Specifically, the support comprises a bottom plate 21, preferably a flat plate with a quadrilateral 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 support frame 11. Specifically, the support plate 22 of the application is provided with a support groove 23, and the support groove 23 cooperates with the support bar 12 arranged at the lower end of the support plate. Preferably, the cross section of the support bar 12 is a quadrilateral structure, the support groove 23 is a rectangular structure, and the support bar 12 can be clamped in the support groove 23.

[0052] As the preferred embodiment of the above step, the test system of the application further comprises a fuse, wherein the fuse is installed on the battery replacement cabinet and is used to protect the circuit of the battery replacement cabinet. When a short circuit occurs inside the battery replacement cabinet, the fuse will break the circuit in the first time, thereby protecting the safety of the battery inside the battery replacement cabinet.

[0053] As the preferred embodiment of the above step, the CAN box and the computer of the application can be replaced by a control cabinet, specifically, the control cabinet comprises a PLC and an industrial control screen, and a plurality of interfaces are arranged on the control cabinet. Each operation process is controlled by the industrial control screen, which is simple and clear.

[0054] The application also provides a test method for the truck battery replacement mechanism, comprising the following steps:

[0055] 1) Hoist the new battery pack on the battery replacement bottom support;

[0056] 2) Detect the inter-electrode resistance and ground insulation, wherein the method for determining whether the inter-electrode resistance is normal is that the resistance value approaches infinity;

[0057] 3) Turn on the low-voltage power supply communication line, insert the fuse, control the output voltage 460-480V, the output voltage of the application can be controlled at 460-480V, preferably, the output voltage is 470V, and the output current can be controlled at 0.18-0.22mA, preferably, the output current is 0.2mA;

[0058] 4) Power on the 24V stabilized power supply, power on the discharge tester, turn on the discharge tester DC switch, and the current voltage value of the discharge tester will be displayed as 200-220V, which is a normal value, wherein 210V is better;

[0059] 5) Control the wake-up signal switch panel to switch to the driving wake-up signal;

[0060] 6) Open the computer software operation interface, click CAN start, and click OK after displaying CAN start success, if it displays that CAN start fails, check the line connection and then click CAN start again;

[0061] 7) Click start monitoring, display monitoring data, the current battery box is not in high-voltage state, the battery system fault code display 20 and 95 are normal phenomena, the TMS fault code is 5 and the 3-level fault is normal, the fault is eliminated after high voltage, and the BMS software version number and water cooling unit software version are observed synchronously;

[0062] 8) Send high-voltage power-on instruction: high-voltage power-on instruction pull-down menu -> high-voltage power-on -> click send -> observe that the discharge tester voltage is 580-600V, which is normal, and 590V is better;

[0063] 9) Under the thermal management interface, press the heating load relay in turn: close, open, heating positive relay: close, open, and observe the display of the corresponding text on the interface;

[0064] 10) Under the thermal management interface, press the water cooling detection mode: self-circulation mode, confirm normal and click shutdown mode, the judgment method of normal operation of the self-circulation mode is that there is water flow feeling when touching the water cooling circulation pipe on the battery replacement cabinet, and there is water pump sound at the upper end of the battery replacement cabinet, which is normal;

[0065] 11) Discharge test: press the discharge tester start button and wait for the discharge to end, the actual setting parameters on site are discharge 1 minute and current 10A;

[0066] 12) After the discharge is completed, switch the wake-up signal switch panel to the charging wake-up signal;

[0067] 13) Plug in the charging gun and check whether the charging gun on the charging device is connected properly. After it is connected, start charging. Wait for 15-30 seconds to start charging. Preferably, wait for 20 seconds to start charging. After the charging test is completed, unplug the charging gun;

[0068] 14) Send the high voltage power-off command on the high voltage interface and observe whether the voltage displayed on the discharge tester is 200-220V;

[0069] 15) Disconnect the 24 V power supply, disconnect the low-voltage power supply communication line, disconnect the fuse, disconnect the DC switch of the discharge tester, and disconnect the AC switch of the discharge tester;

[0070] 16) Remove the battery replacement frame, complete the charge and discharge test, and record the test items simultaneously.

[0071] 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 this 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 this 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.

[0072] 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 to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present application. Various changes and improvements may be made to the present application without departing from the spirit and scope of the present application. These changes and improvements are intended to fall within the scope of the present application. The scope of protection claimed in this application is defined by the appended claims and their equivalents.

Claims

1. A test system for a truck battery swap mechanism, characterized in that: The test system comprises: A battery swap base, which is provided with a charging port and is used to support the battery swap cabinet; 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; CAN box, the CAN box is electrically connected to the battery replacement base through a CAN communication line; A computer, which is electrically connected to the CAN box and is used to run the host computer software, read the signals converted from the CAN box, and control the power exchange cabinet and read the signals; 24V regulated power supply, which is electrically connected to the CAN box and supplies power to the start signal point of the CAN box and the power exchange cabinet; The testing method of the testing system 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, turn on the DC switch of the discharge tester, and 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 it displays that CAN start is successful. If it displays that CAN start fails, check the line connection and click CAN start again; 7) Click Start Monitoring to display the monitoring data. The battery box is currently not in high voltage state. Battery system fault codes 20 and 95 are normal. TMS fault codes 5 and level 3 faults are normal. The faults are 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 discharge for 1 minute and current of 10A; 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, start charging 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 on the high voltage interface and observe whether the voltage displayed on the discharge tester is 200-220V; 15) Disconnect the 24 V power supply, disconnect the low-voltage power supply communication line, disconnect the fuse, disconnect the DC switch of the discharge tester, and disconnect the AC switch of the discharge tester; 16) Remove the battery replacement frame, complete the charge and discharge test, and record the test items simultaneously.

2. A test system for a truck battery swap mechanism according to claim 1, characterized in that: A locking mechanism is provided on the battery replacement base, which 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 swap 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 battery exchange cabinet, and the lock column locks and releases the battery exchange cabinet.

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

7. The test system for a truck battery swap 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 multiple interfaces.

8. The test system for a truck battery swap mechanism according to claim 1, characterized in that: The method for judging whether the inter-electrode resistance in step 2) is normal is: the resistance value approaches infinity.

9. The test system for a truck battery swap mechanism according to claim 1, characterized in that: 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 exchange cabinet. If there is water flow and the sound of a water pump at the top of the power exchange cabinet, it is normal.

Images