Ice water shock test system

Abstract

This invention relates to the field of battery testing technology and discloses an ice-water impact testing system, comprising: a temperature control unit for regulating the temperature of the testing environment, the temperature control unit including a liquid nitrogen cooling device and an electric heating device, and using a PID algorithm to regulate temperature fluctuations within ±0.5℃; an impact unit for simulating water flow impact and mechanical vibration of battery samples during testing, the impact unit including a high-pressure water pump and a mechanical vibration device, capable of adjusting water flow pressure and vibration acceleration; and a data acquisition and analysis module for real-time acquisition of temperature, humidity, pressure, and battery voltage data during the testing process, and evaluating battery performance through intelligent analysis algorithms. By combining the liquid nitrogen cooling device and the electric heating device, and employing a PID control algorithm, precise adjustment of the temperature control unit is achieved, enabling rapid temperature switching within the range of -40℃ to 80℃, while maintaining temperature fluctuations within ±0.5℃.

Description

Technical Field

[0001] The invention relates to the technical field of battery testing, in particular to an ice water shock testing system. Background Art

[0002] With the rapid development of new energy battery technology, various types of batteries such as lithium-ion batteries and nickel-metal hydride batteries have been widely used in electric vehicles, energy storage systems, consumer electronics and other fields. However, batteries are affected by a variety of complex environments during actual use, such as temperature changes, mechanical shock and vibration, etc. These external factors will have a significant impact on the performance, life and safety of the battery. Therefore, in order to ensure the stability and safety of the battery in various extreme environments, it is particularly important to conduct strict environmental simulation tests on the battery.

[0003] At present, for the temperature shock, mechanical shock and environmental adaptability tests of batteries, the existing technology usually adopts a single-function test system. For example, temperature testing mainly relies on heating devices or cooling devices to control temperature, but the temperature control response speed of the system is slow, and it is impossible to quickly switch extreme temperatures, resulting in low test efficiency; in terms of impact testing, existing water flow impact devices or vibration devices often work alone, and cannot perform water flow impact and mechanical vibration tests at the same time, making it difficult to simulate the actual stress conditions of batteries in complex environments. In addition, the data acquisition function of existing test systems is relatively simple, and they often only monitor basic parameters such as voltage or temperature, and lack intelligent analysis of key indicators such as battery performance changes and life prediction.

[0004] There is still a problem of insufficient safety protection in the existing technology. When testing batteries under extreme temperature, pressure or impact conditions, gas leakage, thermal runaway or even fire may occur inside the battery, posing safety risks to experimental equipment and personnel. However, the existing testing system lacks a complete safety protection mechanism and cannot promptly detect and respond to abnormal situations such as gas leakage and excessive temperature, posing a large safety hazard. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present invention provides an ice water shock test system, which solves the problem that when testing batteries under extreme temperature, pressure or shock conditions, gas leakage, thermal runaway or even fire may occur inside the battery, posing safety risks to experimental equipment and personnel.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: an ice water shock test system, comprising: a temperature control unit, for adjusting the temperature of the test environment, the temperature control unit comprising a liquid nitrogen cooling device and an electric heating device, and using a PID algorithm to adjust the temperature fluctuation within the range of ±0.5°C; An impact unit, used to simulate the water flow impact and mechanical vibration of the battery sample during the test process, the impact unit includes a high-pressure water pump and a mechanical vibration device, which can adjust the water flow pressure and vibration acceleration; Data acquisition and analysis module, which is used to collect temperature, humidity, pressure and battery voltage data in real time during the test process, and evaluate battery performance through intelligent analysis algorithms; Safety protection system, including gas leakage monitoring, overpressure protection, over-temperature alarm and automatic fire extinguishing system, to ensure the safety of the experimental process; The control system is used to receive input experimental parameters and control the operation of each module.

[0007] Preferably, the temperature control unit realizes rapid switching of the temperature from -40°C to 80°C by combining liquid nitrogen and electric heating, and the temperature adjustment rate does not exceed 20°C / min.

[0008] Preferably, the PID control algorithm of the temperature control unit performs temperature regulation by the following formula: Among them, U(t) is the control output of the temperature control system, which represents the cooling or heating power required to adjust the temperature; e(t) is the temperature deviation at the current time t, that is, the difference between the set temperature and the actual temperature; K p K is the proportional gain, which is the degree to which the control system responds to temperature deviation; d is the differential gain, which is used to predict and adjust the system response according to the temperature change rate; K i is the integral gain, which is used to deal with the cumulative effect of temperature deviation and eliminate steady-state error; is the integral term of the temperature deviation e(t), is the rate of change of temperature deviation, indicating a rapid change in temperature error.

[0009] Preferably, the water flow impact pressure of the impact unit is calculated by the following formula: Among them, P is the pressure of water flow impact, ρ is the density of water, and v is the velocity of water flow.

[0010] Preferably, the mechanical vibration device simulates the dynamic impact of the battery sample during transportation and storage by adjusting the vibration frequency and acceleration, and the vibration acceleration is between 0.1 and 2 m / s. 2 Adjustable range.

[0011] Preferably, the data acquisition and analysis module collects battery voltage, battery current, temperature, and pressure data, and uses a machine learning algorithm to predict the remaining life and safety of the battery.

[0012] Preferably, the data acquisition and analysis module performs analysis based on the following battery capacity decay formula: C t =C0·(1-α·ΔT) Among them, C t is the battery capacity at time t, C0 is the initial battery capacity, α is the temperature coefficient, and ΔT is the temperature change.

[0013] Preferably, the safety protection system includes a gas leakage sensor for real-time monitoring of the concentration of hydrogen and carbon dioxide harmful gases, and automatically stopping the experiment and sounding an alarm when the concentration exceeds the standard.

[0014] Preferably, the control system interacts via a touch screen, and the user can set the experimental parameters, including temperature range, impact strength, and experimental duration, via the touch screen, and monitor the experimental status in real time.

[0015] Ice water shock test methods, including: Step 1: Set the experimental parameters, including temperature range, impact strength, humidity requirements and test time; Step 2: Start the temperature control unit, adjust the test environment temperature to the set value, and adjust the temperature in real time through the PID control algorithm; Step 3: Start the impact unit to apply water flow impact and mechanical vibration; Step 4: Monitor the battery temperature and battery voltage performance parameters in real time through the data acquisition and analysis module, and perform data analysis; Step 5: Use the safety protection system to detect gas leakage and overpressure safety indicators in real time to ensure experimental safety; Step 6. After the experiment, export the data report and analyze it.

[0016] The present invention provides an ice water impact test system. It has the following beneficial effects: 1. The present invention combines a liquid nitrogen cooling device with an electric heating device and adopts a PID control algorithm to achieve precise adjustment of the temperature control unit. It can quickly switch the temperature within the range of -40°C to 80°C and keep the temperature fluctuation within ±0.5°C. This technology can accurately simulate the performance of batteries in extreme temperature environments and ensure the reliability and authenticity of experimental data. Through this system, users can test batteries under different temperature conditions and evaluate their performance in various extreme environments.

[0017] 2. The impact unit of the present invention can simulate two common physical impacts, water flow impact and mechanical vibration, and comprehensively evaluate the stability and safety of the battery in humid and vibrating environments. The high-pressure water pump and adjustable nozzle structure allow the water flow impact pressure to be precisely adjusted, and the mechanical vibration device can simulate vibration scenarios ranging from mild to strong. By precisely controlling the intensity and frequency of the impact, the present invention can simulate in experiments various impact conditions that the battery may encounter in actual use, thereby comprehensively testing the battery's impact resistance and long-term stability.

[0018] 3. The data acquisition and analysis module of the present invention monitors the important parameters of the battery such as voltage, current, temperature, humidity, etc. in real time through a variety of sensors, and combines machine learning algorithms to perform real-time analysis to evaluate the performance changes and life prediction of the battery. The module can analyze key indicators such as capacity decay and internal resistance changes through the collected real-time data, providing a scientific basis for the reliability assessment of the battery. At the same time, through real-time processing and intelligent analysis of data, the system can issue an alarm in time when the battery performance declines or potential safety hazards occur, thereby maximizing the safety of the experiment. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is the main framework diagram of the present invention; Figure 2 It is a structural schematic diagram of the present invention; Figure 3 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION

[0020] The following will be combined with the drawings of the present invention specification to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. Embodiment 1: Please refer to the attached Figure 1 The embodiment of the present invention provides an ice water shock test system, comprising: The temperature control unit is used to adjust the temperature of the test environment. The temperature control unit includes a liquid nitrogen cooling device and an electric heating device. The PID algorithm is used to adjust the temperature fluctuation within the range of ±0.5℃. Impact unit, used to simulate water flow impact and mechanical vibration of battery samples during testing. The impact unit includes a high-pressure water pump and a mechanical vibration device, which can adjust the water flow pressure and vibration acceleration; Data acquisition and analysis module, which is used to collect temperature, humidity, pressure and battery voltage data in real time during the test process, and evaluate battery performance through intelligent analysis algorithms; Safety protection system, including gas leakage monitoring, overpressure protection, over-temperature alarm and automatic fire extinguishing system, to ensure the safety of the experimental process; The control system is used to receive input experimental parameters and control the operation of each module.

[0021] Please refer to the attached Figure 2 In one embodiment, the temperature control unit In this embodiment, the temperature control unit includes a pure water bucket, a heater, a water level control device and a delivery pipeline.

[0022] The pure water barrel is used to store high-purity water, and the water is transported to the heater through an electric water pump.

[0023] The heater has a built-in heating device, which uses a PID control algorithm to accurately control the heating power and keep the water temperature stable at the target temperature. The water level control device includes a water level sensor and a control valve to detect the water level in real time and adjust the flow rate through the control valve to prevent the water level from being too high or too low. Impact unit In this embodiment, the impact unit includes a water pipe, a valve group and a connecting pipe.

[0024] Water enters the heater from the pure water bucket through the delivery pipe, and flows into the impact module after being heated.

[0025] The valve group includes an inlet valve, an outlet valve and a pressure relief valve, which respectively control the input and output of water flow and the release of system pressure to ensure that the water flow pressure is adjustable; Data acquisition and analysis module The system collects data such as water temperature, pressure and battery voltage in real time through temperature sensors, water pressure sensors and voltage sensors.

[0026] The data is transmitted to the analysis module through the control system to analyze the relationship between water temperature and battery performance and generate a test report; control system In this embodiment, the control system is connected to each module via electrical signals and is responsible for the automatic control of the system.

[0027] The user sets parameters through the touch screen interface, including temperature range, impact strength and test duration.

[0028] The control system receives sensor data and automatically adjusts each module to ensure that the system operates according to the set conditions.

[0029] When the temperature control unit or water level control device is abnormal, the control system triggers an alarm and stops the experiment; System workflow The system workflow is as follows: The pure water bucket provides the water source, and the water is transported to the heater through an electric water pump.

[0030] The heater heats the water and the heated water flows into the impact module through the pipe.

[0031] The impact module adjusts the water flow pressure through the valve group to perform water flow impact on the sample under test.

[0032] The data acquisition module monitors the water temperature, pressure and sample voltage in real time and transmits the data to the control system for analysis.

[0033] When the temperature is detected to be too high or the water level is abnormal, the system triggers safety protection and automatically stops the experiment.

[0034] The temperature control unit achieves rapid switching of temperature from -40°C to 80°C through the combination of liquid nitrogen and electric heating, and the temperature adjustment rate does not exceed 20°C / min.

[0035] Please refer to the attached Figure 2 The ice water impact test system of the present invention is shown in the attached figure, and includes: a pure water bucket, a heater, a water delivery pipe, a water level control device, a valve group, a control box, a lighting distribution box and related pipeline connection structures. Each module is connected through pipes, valves and electrical signals to achieve system temperature regulation, water flow delivery, impact control and system monitoring.

[0036] Pure water bucket and water system In this embodiment, the pure water bucket is used to store high-purity water source to ensure that the cleanliness of the water source meets the experimental requirements.

[0037] Water delivery pipe: connected to the heater through a water pipe, and the water flow is driven by an electric water pump and delivered to the heater.

[0038] Water level control device: The water level control device includes a water level sensor and a control valve to monitor the water level in the heater in real time.

[0039] When the water level is too high or too low, the control valve automatically adjusts the water flow input to prevent the abnormal water level from affecting the experiment.

[0040] Heater and temperature control system The heater is the core component of the temperature control unit and is used to heat the water flow.

[0041] The heater heats the water source through a built-in heating element and uses a PID control algorithm to achieve precise temperature control, ensuring that the water temperature fluctuates no more than ±0.5℃ within the experimental setting range.

[0042] The input end of the heater is connected to the pure water bucket, and the output end is connected to the impact module to form a closed-loop water circulation system.

[0043] Temperature monitoring: A temperature sensor is installed inside the heater to detect the water temperature in real time and feed it back to the control system for temperature regulation.

[0044] Valve Group and Water Flow Control The valve group shown in the attached figure includes: Water inlet valve: controls the water flow input from the pure water barrel to the heater.

[0045] Water outlet valve: controls the water flow output from the heater to the impact module.

[0046] Pressure relief valve: used to release excessive water pressure to ensure that the system pressure is maintained within a safe range.

[0047] Water flow path: pure water bucket to water delivery pipe to heater to water flow output to impact unit.

[0048] Control system and power module The system is equipped with a control box and a lighting distribution box: Control box: It is connected to the temperature control unit, water flow system and safety monitoring module by electrical signals. It is used to receive the experimental parameters input by the user and automatically adjust the working status of each module.

[0049] Lighting distribution box: Provides stable power supply for the system, monitors the power status during the experiment, and ensures the normal operation of the system.

[0050] System workflow The system's workflow is as follows: Water supply: Pure water barrels store water, and the water is transported to the heater through water pipes and electric water pumps.

[0051] Temperature regulation: The heater receives instructions from the control system and starts to heat the water. It uses the PID control algorithm to adjust the water temperature to the set range and keeps the water level stable through the water level control device.

[0052] Water flow control: Water flows into the impact unit through the valve group. The valve group adjusts the water flow input, output and pressure relief according to the instructions of the control system to form a stable water flow impact path.

[0053] System monitoring: Temperature sensors, water level sensors and pressure sensors monitor the system status in real time and feed the data back to the control box. The control system adjusts the working parameters in real time according to the feedback data.

[0054] Power supply and safety monitoring: The lighting distribution box provides power supply, and the control box is responsible for monitoring various parameters of the system. When abnormal temperature, low water level or high water pressure is detected, the system automatically triggers the protection mechanism and stops running.

[0055] The PID control algorithm of the temperature control unit adjusts the temperature through the following formula: Among them, U(t) is the control output of the temperature control system, which represents the cooling or heating power required to adjust the temperature; e(t) is the temperature deviation at the current time t, that is, the difference between the set temperature and the actual temperature; K p K is the proportional gain, which is the degree to which the control system responds to temperature deviation; d is the differential gain, which is used to predict and adjust the system response according to the temperature change rate; K i is the integral gain, which is used to deal with the cumulative effect of temperature deviation and eliminate steady-state error; is the integral term of the temperature deviation e(t), is the rate of change of temperature deviation, indicating a rapid change in temperature error.

[0056] The water flow impact pressure of the impact unit is calculated by the following formula: Among them, P is the pressure of water flow impact, ρ is the density of water, and v is the velocity of water flow.

[0057] The mechanical vibration device simulates the dynamic impact of battery samples during transportation and storage by adjusting the vibration frequency and acceleration. The vibration acceleration is between 0.1 and 2 m / s. 2 Adjustable range.

[0058] The data acquisition and analysis module collects battery voltage, battery current, temperature, and pressure data, and uses machine learning algorithms to predict the remaining life and safety of the battery.

[0059] The data acquisition and analysis module performs analysis based on the following battery capacity decay formula: C t =C0·(1-α·ΔT) Among them, C t is the battery capacity at time t, C0 is the initial battery capacity, α is the temperature coefficient, and ΔT is the temperature change.

[0060] The safety protection system includes a gas leakage sensor, which is used to monitor the concentration of harmful gases such as hydrogen and carbon dioxide in real time, and automatically stop the experiment and sound an alarm when the concentration exceeds the standard.

[0061] The control system interacts via a touch screen, through which the user can set the experimental parameters, including temperature range, impact intensity, and experiment duration, and monitor the experimental status in real time.

[0062] The key technology of the temperature control unit includes the combined use of a liquid nitrogen cooling device and an electric heating device, and the temperature change is adjusted in real time by means of a PID control algorithm. By combining the low temperature environment provided by the liquid nitrogen cooling device with the high temperature environment provided by the electric heating device, fast and stable temperature regulation can be achieved. In this embodiment, the combined use of liquid nitrogen and electric heating elements enables the temperature control unit to cover a temperature range from -40°C to 80°C.

[0063] Specifically, the liquid nitrogen cooling device in the temperature control unit is responsible for rapidly lowering the temperature of the test chamber, and the cooling rate is adjusted according to the set requirements. Liquid nitrogen is transported to the cooling coil through a pipeline, and heat is exchanged with the airflow in the test chamber to ensure that the temperature drops quickly to the preset value. The electric heating device quickly heats up through ceramic heating elements, and can raise the temperature of the test environment from a lower ambient temperature to the required value in a relatively short period of time. The maximum output power of the electric heating device is 2kW, which can provide sufficient heat in a short period of time to meet the demand for a high temperature environment during the test process.

[0064] In one possible implementation, liquid nitrogen and electric heating elements cooperate with each other through a PID control system. The liquid nitrogen flow rate and electric heating power are adjusted by the PID controller according to the deviation between the actual temperature and the target temperature. The PID control algorithm enables the temperature control unit to maintain a stable test temperature by continuously adjusting the heating and cooling power. As an option, the specific formula of the PID control algorithm is: Among them, U(t) is the control output, which represents the adjustment amount of liquid nitrogen flow or heating power; e(t) is the temperature deviation between the current temperature and the target temperature; K p , K i , K d are proportional, integral and differential control parameters respectively; is the integral term of temperature deviation, is the differential term of temperature deviation.

[0065] It should be noted that the PID controller can monitor temperature changes in real time and adjust the working state of the temperature control system according to the set control algorithm. For example, when the temperature is lower than the set value, the PID controller will increase the heating power, and when the temperature reaches the target value, the controller will gradually reduce the heating power to ensure stable operation of the system and avoid temperature overshoot. Similarly, when the temperature exceeds the target value, the liquid nitrogen flow rate will automatically increase to quickly restore the temperature to the set range.

[0066] In some embodiments, the temperature control unit measures the temperature difference in real time and adjusts the liquid nitrogen and heating power to achieve a smooth temperature change. For example, the temperature change rate can be set to no more than 20°C / min to avoid damage to the battery sample caused by excessive temperature changes. Specifically, the PID control algorithm can intelligently adjust the output power of heating or cooling according to the current temperature change rate to avoid overshoot or lag in the system.

[0067] It is understandable that the combination of liquid nitrogen cooling device and electric heating device enables the temperature control unit to meet the requirements of a wide temperature range, whether it is low temperature test (such as -40°C) or high temperature test (such as 80°C), it can stably and reliably provide the required temperature environment. For some batteries that require special test conditions, the design of the temperature control unit provides flexibility and can adapt to a variety of extreme environmental conditions.

[0068] In some embodiments, the design of the temperature control unit not only takes into account rapid temperature adjustment, but also fully considers the uniformity of temperature distribution. By optimizing the layout of the cooling coils and the distribution of the heating elements, it is possible to ensure uniform temperature distribution throughout the test chamber, avoiding local temperature unevenness that affects the test results of the battery samples. This optimized design is crucial for accurate experimental data, especially in application fields such as new energy batteries with high testing requirements.

[0069] In general, the temperature control unit in this embodiment can achieve fast and accurate temperature control through the combination of liquid nitrogen and electric heating elements, and adjust the cooling and heating power in real time through the PID control algorithm to ensure that the temperature fluctuation during the experiment is always kept within ±0.5°C. This design not only meets the testing requirements under different environmental conditions, but also ensures the stability of the battery test process and the reliability of the data.

[0070] In this embodiment, the impact unit includes a high-pressure water pump, a mechanical vibration device and an adjustment system, which can accurately control the pressure of the water flow and the acceleration of the vibration. Specifically, the water flow impact simulates the reaction of the battery in a humid or liquid environment, while the mechanical vibration simulates the physical stress of the battery in a transportation or vibration environment. The design of the impact unit ensures that the impact force can be adjusted according to different test requirements, simulating the working state of the battery in various possible usage environments.

[0071] In some embodiments, the water flow impact device includes a high-pressure water pump, a nozzle and a pipe. The high-pressure water pump provides a certain pressure of water flow, which is transported to the nozzle through the pipe and sprayed out at the nozzle. The design of the nozzle can adjust the pressure and spray angle of the water flow to ensure that the water flow is evenly distributed. There is a direct relationship between the pressure of the water flow impact and the water flow speed. The specific calculation formula is as follows: Where P is the pressure of water flow impact (unit: Pa), ρ is the density of water (unit: kg / m 3 ), v is the velocity of the water flow (unit: m / s). This formula describes the relationship between the kinetic energy of the water flow and the impact force. By adjusting the pressure of the water pump and the structural design of the nozzle, the velocity and impact strength of the water flow can be accurately controlled.

[0072] Specifically, the control system can accurately adjust the pressure and injection speed of the water flow by adjusting the output power of the water pump and the opening of the nozzle. For example, when simulating a strong water flow impact, the control system will increase the power of the water pump and increase the speed of the water flow, thereby increasing the impact pressure and achieving the desired test effect. It is understandable that the design of the impact unit can simulate water flow impacts of different intensities to ensure that battery samples can be tested under a variety of extreme environmental conditions.

[0073] In one possible implementation, the mechanical vibration device consists of a vibration motor, a vibration platform, and a control system. The vibration motor drives the vibration platform through electricity to generate vibrations of a certain frequency and amplitude, thereby simulating the physical impact that the battery may encounter during transportation. Specifically, the vibration device adjusts the output frequency and amplitude of the motor to control the intensity and period of the vibration to simulate different types of environmental impacts. The calculation formula for vibration acceleration is as follows: F=m·a Where F is the impact force (unit: N), m is the mass of the battery sample (unit: kg), and a is the vibration acceleration (unit: m / s 2 ). This formula describes the relationship between the force applied during vibration and the acceleration. Depending on the mass of the battery sample and the impact acceleration that needs to be simulated, the system can adjust the vibration frequency and amplitude to ensure that the impact force is within the required range.

[0074] For example, if you need to simulate the behavior of a battery in a strong vibration environment, the system can set a higher vibration frequency (such as 100Hz) and a larger amplitude (such as 2mm) to simulate the impact force caused by high-frequency strong vibration. This adjustment function enables the impact unit to work effectively in a variety of environments and adapt to different battery testing needs.

[0075] In some embodiments, the vibration frequency and amplitude are adjusted in the range of 10 Hz to 100 Hz and 0.1 mm to 5 mm, respectively. Through such a range of adjustment, the impact unit can simulate various situations from slight vibration to strong impact, ensuring that the performance of the battery sample in different situations is fully evaluated.

[0076] It should be noted that the design of the impact unit is not limited to the simulation of water flow and mechanical vibration, it also takes into account how to achieve precise control. By collaborating with the temperature control unit and the data acquisition module, the impact unit can perform precise tests under the guidance of the control system. Specifically, the impact unit will accurately adjust the magnitude of the impact force according to the objectives of the experiment and the characteristics of the battery to ensure that each test meets the standards.

[0077] In one implementation, water flow shock and mechanical vibration can be performed simultaneously to simulate more complex environmental conditions. For example, when simulating the performance of a battery floating in water or in a transportation vibration environment, the water flow shock and mechanical vibration functions can be activated at the same time to achieve a more realistic test scenario.

[0078] In this embodiment, the data acquisition and analysis module is mainly composed of multiple sensors, a data acquisition system, a data storage and processing unit, and a data analysis algorithm. The sensors mainly include temperature sensors, humidity sensors, pressure sensors, battery voltage and current sensors. All these sensors transmit the data during the test process to the control system in real time, and the control system collects, stores and performs subsequent analysis and processing on the data.

[0079] Specifically, the data acquisition module includes temperature, humidity and pressure sensors, which are used to monitor changes in environmental conditions and transmit these data to the data acquisition unit through analog or digital signals. The voltage and current of the battery are monitored in real time through the built-in battery management system (BMS), and the data is transmitted to the data acquisition module. The data of all sensors are connected to the control system through a data transmission bus (such as RS-485, CAN or Ethernet) for centralized storage and real-time monitoring.

[0080] In some embodiments, the data acquisition and analysis module also includes a conditioning circuit for signal conversion, which converts the analog signal collected by the sensor into a digital signal for subsequent processing and analysis. For data storage, the system uses an embedded storage unit (e.g., a solid-state drive or flash memory) to save the data collected during the experiment. These data will be transmitted to the analysis module in real time for performance evaluation and trend prediction.

[0081] The functions of the data analysis module include real-time analysis of battery performance, capacity attenuation prediction, battery internal resistance change monitoring, etc. The data analysis module processes and analyzes the collected data through machine learning algorithms such as support vector machines (SVM), decision trees, or deep neural networks (DNN) to evaluate the performance changes of batteries under different environmental conditions. These analysis results will be used to predict the remaining life of the battery, capacity changes, internal resistance changes, etc.

[0082] In a specific implementation, the data analysis module performs analysis based on the following battery capacity attenuation model: C t =C0·(1-α·ΔT) Among them, C t is the battery capacity at time t, C0 is the initial battery capacity, α is the temperature coefficient, and ΔT is the temperature change. This model can be used to evaluate the impact of temperature changes on battery capacity, especially the impact on battery performance in an environment with extreme temperature changes. It can be understood that this formula helps analyze the performance degradation of the battery under different test conditions and provides a scientific basis for the evaluation of battery life.

[0083] For example, the data analysis module uses the above model to predict the capacity change of the battery by real-time monitoring of the battery's voltage, current, temperature changes, and charge and discharge cycle times. During the test, the data analysis module records the battery status at each stage and generates a detailed report that includes not only the current status of the battery, but also the possible battery degradation trend in the next few cycles.

[0084] It should be noted that the data acquisition and analysis module also includes interfaces with the temperature control system, impact unit and safety protection system. Through this integration, the data analysis module can provide comprehensive experimental analysis based on temperature changes, impact intensity and safety monitoring data during the test, combined with changes in battery performance. For example, the system can monitor in real time whether the battery is overheating, overcharging or internal gas leakage, and analyze the performance stability and safety of the battery in combination with temperature, pressure and other data.

[0085] In one possible implementation, the data acquisition and analysis module is also connected to an external cloud platform to support uploading experimental data to the cloud for storage and further analysis. In this way, users can not only view data in real time locally, but also view historical data through the cloud platform for more extensive analysis and comparison. This function is of great significance for long-term monitoring of battery performance, especially for the testing and management of large-scale battery packs.

[0086] It is understandable that the data acquisition and analysis module not only provides real-time feedback for each experiment through detailed recording and real-time analysis of the battery status, but also provides important support for the long-term tracking and data accumulation of battery performance. With efficient algorithms and precise sensors, the data acquisition and analysis module can efficiently and accurately evaluate the long-term reliability and safety of batteries in extreme environments, thereby providing decision support for battery design and application.

[0087] In this embodiment, the safety protection system includes four main submodules: gas leakage monitoring, overpressure protection, overtemperature alarm and automatic fire extinguishing device. Each submodule has independent monitoring and response functions, but is closely integrated with the entire test system to jointly ensure the safety of the test process.

[0088] First, the gas leakage monitoring module is used to detect harmful gases that may be released by the battery during the test process, especially in high temperature or impact environments, where the battery may release dangerous gases such as hydrogen or carbon dioxide due to thermal runaway and other reasons. This module monitors the gas concentration in real time through a gas sensor. The gas sensor used can detect harmful gases such as hydrogen and carbon dioxide, and issue an alarm when the concentration reaches a safe threshold. Specifically, the monitoring of gas leakage concentration can be calculated using the following formula: Where, C is the gas concentration (ppm), V is the volume of the leaked gas (m 3 ), A is the volume of the detection area (m 3 ), ρ is the density of the gas (kg / m 3 ). When the gas concentration exceeds the set threshold, the gas leakage monitoring module will trigger an alarm and stop the experiment through the control system to ensure safety.

[0089] Specifically, the gas leakage monitoring system will be linked with the control system. If the gas concentration exceeds the predetermined safety threshold (such as hydrogen concentration greater than 100 ppm), the system will automatically shut down the power supply and start the exhaust system to ensure that the gas concentration in the test environment returns to a safe range.

[0090] As an option, the gas leakage monitoring module can also be connected to an external safety system, such as an air purification device. When excessive gas leakage is detected, the system can start an external exhaust system or a gas adsorption device to quickly remove harmful gases.

[0091] Secondly, the overpressure protection module is used to prevent the excessive air pressure generated in the system from damaging the device or battery. The overpressure protection module monitors the air pressure in the test chamber in real time through a pressure sensor. When the system detects that the air pressure exceeds the set safety threshold, the pressure sensor will send a signal to trigger the overpressure protection mechanism. The control system will automatically cut off the test power supply and start the pressure release valve according to the feedback signal of the pressure sensor to quickly reduce the pressure to avoid accidents such as equipment damage or battery explosion.

[0092] It should be noted that the design of the overvoltage protection mechanism takes into account the working pressure range under different environments. Specifically, the system will set different safety pressure thresholds according to different battery types and test conditions. For example, for lithium battery samples, the overvoltage protection threshold is usually set to above 3MPa. If the pressure exceeds this value during the test, the system will immediately activate the safety protection function.

[0093] In some embodiments, the overpressure protection system cooperates with the temperature control unit to automatically lower the temperature when the temperature is too high to prevent excessive pressure due to high temperature, thereby ensuring the safety of the entire testing process.

[0094] The over-temperature alarm module is used to monitor the temperature changes during the test to prevent the battery from thermal runaway due to over-temperature. The module monitors the temperature of the battery sample and the test environment in real time through the temperature sensor. If the temperature exceeds the safety threshold (for example, over 85°C), the system will issue a warning through the alarm device and automatically cut off the power supply or start the cooling system to ensure that the temperature during the test is controlled within a safe range.

[0095] For example, the over-temperature alarm module can be linked with the temperature control unit. When the temperature in the test chamber exceeds the set upper limit, the system will quickly lower the temperature and automatically turn off the electric heating device, while increasing the liquid nitrogen flow rate to ensure that the temperature remains within a safe range. For tests that require a high temperature environment, the temperature control system will set a higher upper limit and maintain a steady temperature change through a cooling device.

[0096] Finally, as the last barrier of the safety protection system, the automatic fire extinguishing system can respond in time when the battery has thermal runaway or fire to prevent the fire from spreading. The system is equipped with an automatic fire extinguishing device, which automatically starts the fire extinguishing system when it detects excessive temperature or gas leakage. The fire extinguishing device uses a high-efficiency fire extinguisher to quickly extinguish an initial fire. The triggering conditions of the fire extinguishing system can be set according to different types of batteries and test environments. For lithium battery samples, the trigger temperature of the fire extinguishing device is usually set to 90°C. Once the temperature exceeds this value, the fire extinguishing device will automatically start.

[0097] It is understandable that the automatic fire extinguishing system forms a multiple safety protection mechanism by linking with other safety protection modules. If the gas leakage monitoring module detects a hydrogen leak and the temperature is too high, the fire extinguishing system will be activated in the shortest time to minimize the possible fire risk.

[0098] In this embodiment, the control system is composed of a hardware platform and an embedded software program. The hardware platform includes a central processing unit (CPU), a storage unit, a communication interface, a display and operation interface, etc., and the software program is responsible for data processing, system operation management, and automatic adjustment and monitoring during the experiment. Specifically, the core of the control system is the central processing unit (CPU), which is connected to the communication interface of each subsystem, coordinates the work of different modules, and receives and processes input signals from the temperature control unit, the impact unit, the data acquisition and analysis module, and the safety protection system in real time.

[0099] In one possible implementation, the control system interacts with the user through a touch screen operation interface. The user can input basic parameters of the experiment, such as temperature range, test duration, impact intensity, experimental cycle, etc., through the touch screen. The control system automatically adjusts the operating status of each module according to the user's settings to ensure that the experiment can proceed smoothly according to the predetermined plan. Specifically, the user can select different test modes (such as temperature shock test, water flow shock test, mechanical vibration test, etc.) through the touch screen, and the control system automatically adjusts the corresponding working parameters according to the selected mode.

[0100] It should be noted that the control system can efficiently exchange information with each subsystem to ensure that the entire system operates in an orderly manner during the test. For example, when the temperature sensor of the temperature control unit detects an abnormal temperature, the control system will automatically adjust the working state of the heating or cooling device to ensure that the temperature always remains within the set range. At the same time, the control system will also communicate with the data acquisition and analysis module in real time to ensure the accuracy and real-time nature of the experimental data. In some cases, if the system detects abnormal conditions such as overtemperature, gas leakage or equipment failure, the control system can immediately trigger safety protection mechanisms, such as turning off the power, starting cooling, sending alarms, etc.

[0101] As an option, the control system manages the operation of each module through an embedded operating system (such as Linux, RTOS). The operating system has the characteristics of high real-time performance and low latency, and can respond and control the hardware equipment in real time during the experiment. For example, when the temperature sensor detects that the temperature change exceeds the preset range, the operating system will immediately transmit the temperature data to the temperature control unit, instruct the system to start the cooling or heating device, and automatically adjust the heating power or cooling flow according to the PID algorithm to ensure that the temperature is maintained near the set value.

[0102] In one possible implementation, the control system uses industrial standard communication protocols (such as Modbus, CAN bus or Ethernet) to communicate with each module. These communication protocols ensure the stability and reliability of data transmission between the control system and the temperature control unit, impact unit, data acquisition and analysis module, and safety protection system. Through this communication protocol, the control system can receive real-time data feedback from each module and automatically adjust the control strategy based on the feedback information. For example, if the impact unit detects that the water flow impact on the battery sample exceeds the set intensity, the control system will adjust the test parameters according to the impact intensity data to avoid excessive impact on the battery.

[0103] For example, the control system can not only store data during the test, but also perform trend analysis and prediction based on historical data. Through the integrated data analysis module, the system can monitor the performance changes of the battery in real time and analyze the behavior of the battery in different environments through machine learning algorithms. For example, the control system can predict the remaining life of the battery based on the battery voltage and current change data, and issue an alarm in time to prevent accidents caused by battery performance degradation.

[0104] It is understandable that the control system coordinates the work of each part by processing the signals and data from each module in real time to ensure the efficiency, accuracy and safety of the test process. Through the touch screen interface, the operator can flexibly adjust the experimental parameters, and the system automatically completes all control tasks related to the test. In addition, the system can automatically generate test reports and transmit the results to external storage or cloud platforms through the data interface for subsequent analysis and recording.

[0105] Please refer to the attached Figure 3 Based on the ice water shock test system, this embodiment also provides an ice water shock test method, including: Step 1: Set the experimental parameters, including temperature range, impact strength, humidity requirements and test time; Step 2: Start the temperature control unit, adjust the test environment temperature to the set value, and adjust the temperature in real time through the PID control algorithm; Step 3: Start the impact unit to apply water flow impact and mechanical vibration; Step 4: Monitor the battery temperature and battery voltage performance parameters in real time through the data acquisition and analysis module, and perform data analysis; Step 5: Use the safety protection system to detect gas leakage and overpressure safety indicators in real time to ensure experimental safety; Step 6. After the experiment, export the data report and analyze it.

[0106] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. Ice water shock test system, characterized in that: include: A temperature control unit is used to adjust the temperature of the test environment. The temperature control unit includes a liquid nitrogen cooling device and an electric heating device, and uses a PID algorithm to adjust the temperature fluctuation within the range of ±0.5°C; An impact unit, used to simulate the water flow impact and mechanical vibration of the battery sample during the test process, the impact unit includes a high-pressure water pump and a mechanical vibration device, which can adjust the water flow pressure and vibration acceleration; Data acquisition and analysis module, which is used to collect temperature, humidity, pressure and battery voltage data in real time during the test process, and evaluate battery performance through intelligent analysis algorithms; Safety protection system, including gas leakage monitoring, overpressure protection, over-temperature alarm and automatic fire extinguishing system, to ensure the safety of the experimental process; The control system is used to receive input experimental parameters and control the operation of each module.

2. The ice water shock test system according to claim 1, characterized in that: The temperature control unit realizes rapid switching of temperature from -40°C to 80°C by combining liquid nitrogen and electric heating, and the temperature adjustment rate does not exceed 20°C / min.

3. The ice water shock test system according to claim 1, characterized in that: The PID control algorithm of the temperature control unit performs temperature regulation through the following formula: Among them, U(t) is the control output of the temperature control system, which represents the cooling or heating power required to adjust the temperature; e(t) is the temperature deviation at the current time t, that is, the difference between the set temperature and the actual temperature; K p K is the proportional gain, which is the degree to which the control system responds to temperature deviation; d is the differential gain, which is used to predict and adjust the system response according to the temperature change rate; K i is the integral gain, which is used to deal with the cumulative effect of temperature deviation and eliminate steady-state error; is the integral term of the temperature deviation e(t), is the rate of change of temperature deviation, indicating a rapid change in temperature error.

4. The ice water shock test system according to claim 1, characterized in that: The water flow impact pressure of the impact unit is calculated by the following formula: Among them, P is the pressure of water flow impact, ρ is the density of water, and v is the velocity of water flow.

5. The ice water shock test system according to claim 1, characterized in that: The mechanical vibration device simulates the dynamic impact of battery samples during transportation and storage by adjusting the vibration frequency and acceleration. The vibration acceleration is between 0.1 and 2 m / s. 2 Adjustable range.

6. The ice water shock test system according to claim 1, characterized in that: The data acquisition and analysis module collects battery voltage, battery current, temperature, and pressure data, and uses a machine learning algorithm to predict the remaining life and safety of the battery.

7. The ice water shock test system according to claim 1, characterized in that: The data acquisition and analysis module performs analysis based on the following battery capacity attenuation formula: C t =C0·(1-α·ΔT) Among them, C t is the battery capacity at time t, C0 is the initial battery capacity, α is the temperature coefficient, and ΔT is the temperature change.

8. The ice water shock test system according to claim 1, characterized in that: The safety protection system includes a gas leakage sensor for real-time monitoring of the concentration of hydrogen and carbon dioxide harmful gases, and automatically stops the experiment and issues an alarm when the concentration exceeds the standard.

9. The ice water shock test system according to claim 1, characterized in that: The control system interacts via a touch screen, and the user can set experimental parameters, including temperature range, impact strength, and experimental duration, via the touch screen, and monitor the experimental status in real time.

10. Ice water shock test method, according to the ice water shock test system according to any one of claims 1 to 9, characterized in that: include: Step 1: Set the experimental parameters, including temperature range, impact strength, humidity requirements and test time; Step 2: Start the temperature control unit, adjust the test environment temperature to the set value, and adjust the temperature in real time through the PID control algorithm; Step 3: Start the impact unit to apply water flow impact and mechanical vibration; Step 4: Monitor the battery temperature and battery voltage performance parameters in real time through the data acquisition and analysis module, and perform data analysis; Step 5: Use the safety protection system to detect gas leakage and overpressure safety indicators in real time to ensure experimental safety; Step 6. After the experiment, export the data report and analyze it.

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