Test system and test methods

Abstract

This application relates to the field of battery testing technology, and specifically discloses a testing system and its testing method. The testing system includes a test circuit board, a testing device, a lower-level computer, and a higher-level computer. The test circuit board is equipped with a testing circuit, which includes multiple main lines arranged side by side. One end of each main line is used to connect to the positive or negative terminal of each battery cell in the battery module, and the other end of each main line is connected to a first branch and a second branch. Each first branch is equipped with a control switch, and each second branch is equipped with a control switch. The lower-level computer is electrically connected to the control switches to control the first branch connected to one of the main lines to be electrically connected to the positive terminal of the testing device, and the second branch connected to another main line to be electrically connected to the negative terminal of the testing device. The higher-level computer controls the operation of the lower-level computer and reads the parameter information of the testing device.

Description

Technical Field

[0001] This application relates to the field of battery module testing technology, and in particular to a testing system and testing method thereof. Background Technology

[0002] In automotive power battery systems, battery modules are composed of individual cells connected in series and parallel. The module's sampling harness is used to collect the voltage of each individual cell, the total open-circuit voltage after series and parallel connections, and the temperature at a monitoring point, and outputs this data through standard connectors. If the module's sampling harness has poor contact or is open-circuited, it will result in the loss of voltage and temperature data, rendering the vehicle unable to drive or causing malfunctions. Therefore, continuity testing of the module's wiring harness is crucial in the battery module manufacturing process.

[0003] Currently, the main method for testing the continuity of module wiring harnesses is to use testing equipment to test the voltage of individual battery cells. This process requires frequent wiring, resulting in slow testing speed and low efficiency. Summary of the Invention

[0004] The main purpose of this application is to provide a testing system designed to improve testing efficiency and accuracy.

[0005] To achieve the above objectives, the testing system proposed in this application includes:

[0006] The test circuit board is provided with a test circuit, which includes multiple main lines arranged side by side. One end of each main line is used to connect to the positive or negative terminal of each battery cell of the battery module, and the other end of each main line is connected to a first branch and a second branch. Each first branch is provided with a control switch, and each second branch is provided with a control switch.

[0007] Testing equipment is used to test the parameter information of multiple battery cells in the battery module;

[0008] The lower-level machine, electrically connected to the control switch, controls the first branch of one of the main circuits to be electrically connected to the positive terminal of the test equipment, and the second branch of the other main circuit to be electrically connected to the negative terminal of the test equipment; and

[0009] The host computer is communicatively connected to both the testing equipment and the slave computer to control the operation of the slave computer and read the parameter information of the testing equipment.

[0010] In the aforementioned testing system, one end of each main circuit is connected to the positive terminal of each individual battery cell in the battery module, and the other end is connected to the testing equipment via a branch circuit. The host computer sends test commands to the slave computer, which can control the switches that need to be activated, connecting the first branch of one main circuit to the positive terminal of the testing equipment and the second branch of another main circuit to the negative terminal. This allows the testing equipment to detect the parameter information of the individual battery cells within the battery module. The two main circuits can be adjacent or selected based on the connector pin definitions on the battery module's wiring harness board. Then, according to the test commands, the first branch of one of the other two main circuits is connected to the positive terminal of the testing equipment, and the second branch of the other is connected to the negative terminal, thereby detecting the parameter information of other battery cells, such as voltage or resistance. This process is repeated, eliminating the need for repeated plugging and unplugging of the testing equipment and the battery module to detect the parameter information of multiple battery cells within the battery module. The host computer in this testing system can acquire the detection data from the testing equipment, process and analyze it, and then obtain the continuity status of the wire harness.

[0011] Therefore, the testing system in this application can sequentially test multiple battery cells in a battery module without the need for manual repeated plugging and unplugging of wires, thereby improving testing efficiency and accuracy.

[0012] In one embodiment of this application, the ends of a plurality of first branches away from the main line are connected to form a first connection terminal, and the ends of a plurality of second branches away from the main line are connected to form a second connection terminal. One of the first connection terminal and the second connection terminal is electrically connected to the positive electrode of the test device, and the other is electrically connected to the negative electrode of the test device.

[0013] Here, setting a first connection end and a second connection end allows multiple first branches and multiple second branches to avoid repeated plugging and unplugging with the test equipment, further reducing operation procedures, improving testing efficiency, and protecting the circuit and reducing the probability of damage.

[0014] In one embodiment of this application, at least two first connection terminals are provided, and at least two first connection terminals are arranged in parallel;

[0015] And / or, the second connection terminal is provided with at least two, and at least two second connection terminals are arranged in parallel.

[0016] Here, at least two first connection terminals and two second connection terminals are set up so that the others can be used as backups when one of them fails, thereby improving the performance of the test circuit.

[0017] In one embodiment of this application, the test circuit further includes a plurality of fuses, each of which is disposed on a bus circuit.

[0018] Each bus line is equipped with a fuse to effectively prevent short circuits in the battery module caused by damage to the battery module connectors or intermediate connection plugs, which could damage the equipment.

[0019] In one embodiment of this application, the testing device is a multimeter, which includes a voltage mode and a resistance mode. The multimeter is electrically connected to the host computer or the slave computer to switch between the voltage mode and the resistance mode.

[0020] Here, a multimeter can be used as the testing device. It can have multiple operating modes and ranges. When the host computer or slave computer controls the multimeter to switch to resistance mode, it can also detect thermistors at multiple battery cells and obtain the corresponding temperature values. Using a multimeter can further improve testing efficiency and simplify the structure.

[0021] In one embodiment of this application, the testing system further includes an adapter test harness, one end of the plurality of main lines is connected to an aviation plug, and the two ends of the adapter test harness are respectively plugged into the aviation plug and the plug-in terminals of the battery module.

[0022] Here, by using an adapter test harness and aviation plug, during testing, it is only necessary to connect the adapter test harness to the connector of the battery module, without repeatedly plugging and unplugging the interface of the main circuit of the test circuit. This reduces the wear rate of the test circuit board and aviation plug, achieving the purpose of convenient maintenance and cost reduction.

[0023] In one embodiment of this application, the testing system further includes a reading mechanism electrically connected to the host computer. The reading mechanism is used to read the barcode information of the battery module and send it to the host computer, which then invokes the test plan based on the barcode information.

[0024] Here, after the reading mechanism obtains the barcode information of the battery module, the host computer can obtain the corresponding testing formula for the battery module, thereby improving applicability and testing accuracy.

[0025] In one embodiment of this application, the testing system further includes a testing frame, which includes multiple horizontal beams and multiple vertical beams connected longitudinally and transversely. The multiple horizontal beams and the vertical beams enclose a testing channel through which the battery module passes, and the reading mechanism is disposed within the testing channel.

[0026] This test frame provides a testing environment for battery modules, preventing external interference, effectively improving protection performance, and facilitating the assembly and fixing of various components, such as the reading mechanism.

[0027] In one embodiment of this application, the testing system further includes an image acquisition device, which is disposed on one of the crossbeams and electrically connected to the host computer to capture images of the battery modules in the testing channel and send them to the host computer.

[0028] This image acquisition device can capture and store the overall condition of the battery module and the connection status of individual battery cells, thereby providing a basis for subsequent performance analysis.

[0029] In one embodiment of this application, the testing system further includes a light source, which is disposed on another of the crossbeams and located on one side of the image acquisition device;

[0030] And / or, the testing system further includes a safety light curtain, which is disposed between two opposing vertical beams and connected to the host computer to block the testing channel.

[0031] The light source can be set to provide supplemental lighting for the battery module under test, thereby improving the image acquisition effect.

[0032] The installation of safety light curtains can further enhance protection.

[0033] In one embodiment of this application, the testing system further includes an integrated cabinet, which has a receiving cavity and is located on one side of the testing frame. The testing circuit board, testing equipment, and lower-level computer are all disposed in the receiving cavity, and the aviation plug is at least partially exposed in the integrated cabinet.

[0034] Here, integrating all components into a single cabinet effectively saves floor space and improves the flexibility of equipment installation. Furthermore, placing the cabinet outside the test rack, outside the production line, enhances the maintainability of the equipment.

[0035] In one embodiment of this application, the testing system further includes a warning device, which is installed on the test frame and / or the integrated cabinet and is electrically connected to the host computer to reflect the operating status of the testing system.

[0036] This warning device can display the operating status of the testing system, such as normal operation, fault, or standby, thereby enabling early prediction, avoiding rework, and improving testing efficiency.

[0037] In one embodiment of this application, the testing system further includes a human-computer interaction device, which is installed on the testing frame and electrically connected to the host computer to display testing information or debug the testing system.

[0038] Human-computer interaction devices enable operators to monitor the test data of the testing system and adjust the operating parameters of the testing system at any time to ensure the testing performance of the testing system.

[0039] In one embodiment of this application, a vertical beam is rotatably connected to a mounting frame, and the human-computer interaction device is mounted on the mounting frame so as to be rotatably set relative to the test frame on a horizontal plane.

[0040] The vertical beam is rotatably connected to the mounting bracket, allowing it to be rotated in the horizontal plane. This enables the orientation of the human-machine interface device to be adjusted, further facilitating the operator's viewing and operation.

[0041] In one embodiment of this application, the testing system further includes a receiving component disposed on one of the horizontal or vertical beams to receive the adapter test harness.

[0042] The storage unit allows for easy storage of the adapter test harness, making the test system neater and preventing damage to the adapter test harness.

[0043] In one embodiment of this application, the testing system further includes a starter, which is disposed on the periphery of the testing frame. The starter has two start parts, which are electrically connected to the host computer to start the testing system.

[0044] And / or, the testing system further includes a card reader, which is installed on the testing frame and electrically connected to the host computer.

[0045] The starter is used to start the test system. By controlling two starters simultaneously with both hands, the operator's hands can be kept outside the test channel, thereby avoiding interference with the test and improving protection.

[0046] Based on the structure with or without a starter, the card reader enhances the security level of the test system, allowing debugging and control of the test system only after identity verification via card swipe.

[0047] This application also proposes a testing method for a testing system, the testing system comprising a test circuit board, testing equipment, a host computer, and a slave computer, the testing method comprising the following steps:

[0048] The host computer sends a test command to the slave computer;

[0049] The lower-level machine receives the test command and controls one of the two main circuits on the test circuit board to connect the first branch to the positive terminal of the test equipment, and the other to connect the second branch to the negative terminal of the test equipment.

[0050] The testing equipment detects the parameter information of individual battery cells;

[0051] The host computer sends an instruction to read the parameter information of the test equipment and receives and stores the parameter information.

[0052] This method involves the host computer sending test commands to the slave computer. The slave computer can control the control switches that need to be activated, connecting the first branch of one main circuit to the positive terminal of the test equipment and the second branch of another main circuit to the negative terminal of the test equipment. This allows the test equipment to detect the parameter information of the individual battery cells within the battery module. The two main circuits can be selected as adjacent lines or based on the connector pins on the battery module wiring harness board. This process can be repeated to sequentially detect the parameter information of multiple battery cells. The test system method described in this application enables the sequential detection of parameters of multiple battery cells within a battery module, eliminating the need for repeated manual plugging and unplugging of wires, thus improving testing efficiency and accuracy.

[0053] In one embodiment of this application, the testing device includes a multimeter, which has a voltage mode and a resistance mode, and is electrically connected to the lower-level machine, wherein the parameter information is voltage data;

[0054] After the host computer sends an instruction to read the parameter information of the test device and receives the step of storing the parameter information, the following steps are included:

[0055] The lower-level machine sends a mode switching command to the multimeter;

[0056] The multimeter was switched to resistance mode;

[0057] One of the two main circuits on the lower-level control test circuit board is connected to the positive terminal of the test equipment via a first branch, and the other is connected to the negative terminal of the test equipment via a second branch, so that the multimeter can obtain resistance data.

[0058] The host computer sends an instruction to read the resistance data of the multimeter and receives and stores the resistance data.

[0059] This testing method uses a multimeter to test the voltage and NTC resistance of individual battery cells within a battery module, as well as the voltage of connector pins that need to be tested. Based on the test results, it determines whether the sampling harness within the battery module is continuous. This method allows for two-value testing using a multimeter, eliminating the need for repeated plugging and unplugging of the harness, thus improving testing efficiency and protecting the harness and connectors, enhancing overall performance.

[0060] In one embodiment of this application, after the host computer sends an instruction to read the resistance data of the multimeter and receives and stores the resistance data, the method further includes:

[0061] The host computer determines that the sampling harness of the battery module is qualified based on the voltage and resistance data, and then uploads the test data to the main execution platform.

[0062] Alternatively, if the host computer determines that the sampling harness of the battery module is unqualified based on the voltage and resistance data, it will mark it and upload the detection data to the main execution platform.

[0063] This method enables the detection of wiring harnesses in battery modules through processing by a host computer, thereby quickly identifying defects in the battery modules and avoiding rework. It also distinguishes between different test results, thus providing traceable data for subsequent processing.

[0064] In one embodiment of this application, the testing system further includes a test frame and a reading mechanism, wherein the test frame forms a test channel;

[0065] Before the step of the host computer sending test commands to the slave computer, the following step is also included:

[0066] After the host computer detects that the test channel has entered the battery module, it sends a command to the reading mechanism to read the barcode of the battery module.

[0067] The reading mechanism reads the barcode of the battery module and sends the barcode information to the host computer;

[0068] The host computer calls the corresponding detection formula based on the barcode information and triggers the detection mechanism.

[0069] By configuring the reading mechanism, more targeted testing can be performed on different types of battery modules, thereby improving testing efficiency.

[0070] In one embodiment of this application, the testing system further includes an image acquisition device. Before the step of the host computer sending an instruction to read the barcode of the battery module to the reading mechanism after detecting that the test channel has entered the battery module, the system further includes:

[0071] The host computer sends an image acquisition command to the image acquisition device;

[0072] The image acquisition device acquires image data of the battery module and sends it to the host computer;

[0073] The host computer receives and stores the image data.

[0074] Here, the image acquisition device can collect and store the overall condition of the battery module and the connection status of individual battery cells, thereby providing a basis for subsequent performance analysis.

[0075] This application also proposes a testing method for a testing system, the testing system comprising a test circuit board, testing equipment, a host computer, and a slave computer, the testing method comprising the following steps:

[0076] Send a first test command to the lower-level machine so that the lower-level machine controls the first branch of one of the two main lines on the test circuit board to be electrically connected to the positive terminal of the test equipment, and the second branch of the other line to be electrically connected to the negative terminal of the test equipment, so that the test equipment can detect the parameter information of the battery cell.

[0077] Send an instruction to read the parameter information of the test device, and receive and store the parameter information.

[0078] This method involves the host computer sending test commands to the slave computer. The slave computer can control the control switches that need to be activated, connecting the first branch of one main circuit to the positive terminal of the test equipment and the second branch of another main circuit to the negative terminal of the test equipment. This allows the test equipment to detect the parameter information of the individual battery cells within the battery module. The two main circuits can be selected as adjacent lines or based on the connector pins on the battery module wiring harness board. This process can be repeated to sequentially detect the parameter information of multiple battery cells. The test system method described in this application enables the sequential detection of parameters of multiple battery cells within a battery module, eliminating the need for repeated manual plugging and unplugging of wires, thus improving testing efficiency and accuracy.

[0079] In one embodiment of this application, the testing device includes a multimeter having voltage mode and resistance mode, and is electrically connected to the lower-level machine. The parameter information is voltage data. After sending an instruction to read the parameter information of the testing device and receiving and storing the parameter information, the method further includes:

[0080] A second test command is sent to the lower-level machine, so that the lower-level machine controls the multimeter to switch to resistance mode and obtain resistance data;

[0081] Send a command to read the resistance data from the multimeter, and receive and store the resistance data.

[0082] This testing method uses a multimeter to test the voltage and NTC resistance of individual battery cells within a battery module, as well as the voltage of connector pins that need to be tested. Based on the test results, it determines whether the sampling harness within the battery module is continuous. This method allows for two-value testing using a multimeter, eliminating the need for repeated plugging and unplugging of the harness, thus improving testing efficiency and protecting the harness and connectors, enhancing overall performance.

[0083] In one embodiment of this application, after sending an instruction to read the resistance data of a multimeter and receiving and storing the resistance data, the method further includes:

[0084] If the sampling harness of the battery module is deemed qualified based on the voltage and resistance data, the test data is uploaded to the main execution platform.

[0085] Alternatively, if the sampling harness of the battery module is determined to be unqualified based on the voltage and resistance data, then the detection data is marked and uploaded to the main execution platform.

[0086] This method enables the detection of wiring harnesses in battery modules through processing by a host computer, thereby quickly identifying defects in the battery modules and avoiding rework. It also distinguishes between different test results, thus providing traceable data for subsequent processing.

[0087] In one embodiment of this application, the testing system further includes a test frame and a reading mechanism. The test frame forms a test channel. Before the step of sending the first test command to the lower-level machine, the system further includes the following step:

[0088] The test channel was detected to be entering the battery module;

[0089] Send a command to the reading mechanism to read the barcode of the battery module;

[0090] Obtain the barcode information and trigger the detection mechanism by calling the corresponding detection formula based on the barcode information.

[0091] By configuring the reading mechanism, more targeted testing can be performed on different types of battery modules, thereby improving testing efficiency.

[0092] In one embodiment of this application, the testing system further includes an image acquisition device. After detecting the step of the test channel entering the battery module, the system sends an instruction to the reading mechanism to read the barcode of the battery module. Before the step of reading the barcode of the battery module, the system further includes:

[0093] Send image acquisition commands to the image acquisition device;

[0094] The image acquisition device acquires and stores the image data of the battery module.

[0095] Here, the image acquisition device can collect and store the overall condition of the battery module and the connection status of individual battery cells, thereby providing a basis for subsequent performance analysis. Attached Figure Description

[0096] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0097] Figure 1 This is a schematic diagram of the test system of this application;

[0098] Figure 2 This is a schematic diagram of the structure of a test circuit board in the test system of this application;

[0099] Figure 3 This is a schematic diagram of the connection structure between the multimeter and the battery module in the test system of this application;

[0100] Figure 4 This is a flowchart of the first embodiment of the test method for the test system of this application;

[0101] Figure 5 This is a flowchart of the second embodiment of the test method for the test system of this application;

[0102] Figure 6 This is a flowchart of the third embodiment of the test method for the test system of this application;

[0103] Figure 7 This is a flowchart of the fourth embodiment of the test method for the test system of this application;

[0104] Figure 8 This is a flowchart of the fifth embodiment of the test method for the test system of this application;

[0105] Figure 9 This is a flowchart of the sixth embodiment of the test method for the test system of this application;

[0106] Figure 10 This is a flowchart of the seventh embodiment of the test method for the test system of this application;

[0107] Figure 11This is a flowchart of the eighth embodiment of the test method for the test system of this application;

[0108] Figure 12 This is a flowchart of the ninth embodiment of the test method for the test system of this application.

[0109] Explanation of icon numbers:

[0110]

[0111]

[0112] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0113] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0114] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0115] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0116] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the word "and / or" throughout the text means including three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of a person skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0117] Batteries, as discussed in this field, can be categorized into primary batteries and rechargeable batteries based on whether they are rechargeable. Common types of rechargeable batteries include lead-acid batteries, nickel-metal hydride batteries, and lithium-ion batteries. Lithium-ion batteries are currently widely used in pure electric vehicles and hybrid vehicles. Lithium-ion batteries used in these applications have relatively lower capacity but offer higher output and charging current, as well as longer lifespans, although they are more expensive.

[0118] The batteries described in the embodiments of this application refer to rechargeable batteries. The embodiments disclosed in this application will be described below primarily using lithium-ion batteries as an example. It should be understood that the embodiments disclosed in this application are applicable to any other suitable type of rechargeable battery. The batteries mentioned in the embodiments disclosed in this application can be directly or indirectly used in suitable devices to power those devices.

[0119] The battery mentioned in the embodiments disclosed in this application refers to a single physical module comprising one or more battery cells to provide a predetermined voltage and capacity. A battery cell is the basic unit of a battery, comprising a positive electrode, a negative electrode, an electrolyte, and a separator. Lithium-ion battery cells primarily function by the movement of lithium ions between the positive and negative electrodes. Generally, they can be classified according to their packaging method as: cylindrical battery cells, cuboid battery cells, and pouch battery cells. The following discussion will primarily focus on cuboid battery cells. It should be understood that the embodiments described below are also applicable in some respects to cylindrical battery cells or pouch battery cells.

[0120] The development of battery technology must consider multiple design factors simultaneously, such as energy density, cycle life, discharge capacity, and charge / discharge rate. In the battery manufacturing process, batteries often require numerous steps and stations to complete production, measurement, and the final product. First, the positive electrode, negative electrode, electrolyte, and separator are formed into a single battery cell. Then, processes such as casing, welding, and formation are performed to complete the battery cell.

[0121] In automotive power battery systems, battery modules are composed of battery cells connected in series and parallel. The module's sampling harness is used to collect the voltage of each battery cell, the total open-circuit voltage after series and parallel connections, and the temperature at the monitoring point, outputting the data through standard connectors. Poor soldering, poor terminal crimping, or external force causing breakage can lead to poor contact or open circuits in the module's wiring harness, resulting in the loss of voltage and temperature readings, rendering the vehicle unable to drive or causing malfunctions. Therefore, continuity testing of the module's wiring harness is crucial in the battery module (battery pack) production process.

[0122] In related technologies, the continuity testing method for module wiring harnesses mainly involves manual wiring and handheld multimeter testing. For multiple battery cells, frequent wiring and wire replacement are required, resulting in slow testing speed and low efficiency. Due to human factors, it is easy to miss tests, and the testing accuracy is low, failing to accurately detect connection quality issues between the sampling wiring harness board and the battery module.

[0123] Therefore, to address the problem of low testing efficiency in related technologies, this application improves the testing system structure. By setting up a test circuit board in the testing system that can simultaneously test the voltage of multiple battery cells in a battery module, repeated plugging and unplugging of wires is eliminated for multiple battery cells within the same module, thereby improving testing efficiency and accuracy.

[0124] Please refer to Figures 1 to 3 In one embodiment of this application, the testing system 100 includes a test circuit board 10, a testing device, a lower-level computer, and a higher-level computer. The testing device is used to test the parameter information of multiple battery cells in the battery module. The test circuit board 10 is provided with a test circuit 11, which includes multiple main lines 111 arranged side by side. One end of each main line 111 is used to connect to the positive or negative terminal of each battery cell in the battery module, and the other end of each main line 111 is connected to a first branch and a second branch. Each first branch is provided with a control switch 115, and each second branch is provided with a control switch 115.

[0125] The lower-level computer is electrically connected to the control switch 115 to control the first branch of one of the two main lines 111 to be electrically connected to the positive terminal of the test equipment, and the second branch of the other line to be electrically connected to the negative terminal of the test equipment; the upper-level computer is communicatively connected to both the test equipment and the lower-level computer to control the operation of the lower-level computer and read the parameter information of the test equipment.

[0126] Here, the test circuit board 10 serves as the carrier for the test circuit 11. It has multiple main lines 111, one end of which can be arranged side-by-side on one side of the width of the test circuit board 10, facilitating the connection of the battery module wiring harness. The other end of the main lines 111 branches into first and second branches, and multiple first and second branches are located on the other side of the width of the test circuit board 10. This allows the multiple main lines 111 to be arranged side-by-side at intervals along the length of the board, and the multiple first and second branches are also arranged side-by-side at intervals along the length of the board, and can be configured as pin-type connectors to further facilitate wiring harness docking. A control switch 115 is provided on each first branch and each second branch. The opening and closing of the control switch 115 affects the on / off state of the main line 111, thereby enabling the testing of different battery cells.

[0127] The positive and negative terminals of the test equipment are electrically connected to the positive and negative terminals of the battery cells in the battery module through the test circuit board 10. This is used to detect and display the parameter information of the battery cells. The parameter information can be voltage data or resistance data, etc. When it is voltage data, the type of test equipment can be a multimeter, voltmeter, or oscilloscope, etc., which is not limited here.

[0128] The lower-level device is a Programmable Logic Controller (PLC). The test circuit 11 is electrically connected to the lower-level device. The two can be directly connected by a line or wirelessly connected, as long as it can control the opening and closing of the control switch 115.

[0129] The host computer is the carrier of software that can send instructions to the slave computer and read and process various data. For example, as the main controller, it can send test instructions to the slave computer and finally obtain the test results, perform analysis and processing, and determine whether the wire harness is open or closed.

[0130] In the aforementioned testing system 100, one end of each main line 111 is connected to the positive terminal of each individual battery cell in the battery module, and the other end is connected to the testing equipment via a branch line 113. The host computer sends a test command to the slave computer, which can control the control switch 115 to be activated, causing the first branch of one main line 111 to be electrically connected to the positive terminal of the testing equipment, and the second branch of another main line 111 to be electrically connected to the negative terminal of the testing equipment. This allows the testing equipment to detect the parameter information of the individual battery cells in the battery module. The two main lines 111 can be selected as adjacent lines, or two corresponding main lines 111 can be selected according to the connector pin definitions on the battery module wiring harness board. Then, by controlling the first branch of one of the other two main lines 111 to be electrically connected to the positive terminal of the testing equipment, and the second branch of the other to be electrically connected to the negative terminal of the testing equipment, the parameter information of another individual battery cell can be detected. This process is repeated, eliminating the need for repeated plugging and unplugging of the testing equipment and the battery module, thus enabling voltage detection of multiple individual battery cells within the battery module. The host computer in the testing system 100 can obtain the parameter information of the battery cells detected by the testing equipment, process and analyze it, and then obtain the status of the wiring harness continuity.

[0131] Therefore, the testing system 100 in this application can sequentially test multiple battery cells in a battery module without the need for manual repeated plugging and unplugging of wires, thereby improving testing efficiency and accuracy.

[0132] Please continue to refer to Figure 2 In one embodiment of this application, the ends of a plurality of first branches away from the main line 111 are connected to form a first connection terminal 112, and the ends of a plurality of second branches away from the main line 111 are connected to form a second connection terminal 114. One of the first connection terminal 112 and the second connection terminal 114 is electrically connected to the positive electrode of the test equipment, and the other is electrically connected to the negative electrode of the test equipment.

[0133] Here, each main line 111 branches into a first branch and a second branch at the other end. The first branch extends along the extension direction of the main line 111, and the second branch bends and extends along the extension direction of the main line 111. In this way, multiple first branches of multiple main lines 111 are arranged side by side at intervals and eventually converge to form a first connection end 112. Multiple second branches of multiple main lines 111 are arranged side by side at intervals and eventually converge to form a second connection end 114. The first connection end 112 is directly connected to one of the positive and negative poles of the test equipment, and the second connection end 114 is directly connected to the other of the positive and negative poles of the test equipment. Only the lower-level computer needs to control the opening and closing of the control switch 115.

[0134] Setting up the first connection terminal 112 and the second connection terminal 114 allows multiple first branches and multiple second branches to be connected to the test equipment without repeated plugging and unplugging, further reducing operation steps, improving testing efficiency, protecting the lines, and reducing the probability of damage.

[0135] Please continue to refer to Figure 2 In one embodiment of this application, at least two first connection terminals 112 are provided, and at least two first connection terminals 112 are arranged in parallel;

[0136] And / or, at least two second connection terminals 114 are provided, and at least two second connection terminals 114 are arranged in parallel.

[0137] To improve the performance of the test circuit board 10, at least two first connection terminals 112 can be provided, for example, two, three, or more. Here, by providing two first connection terminals 112, if a failure occurs at the connection between one of the first connection terminals 112 and the test equipment, the test can be performed through the other first connection terminal 112, effectively saving costs and improving the performance of the test circuit board 10.

[0138] Similarly, at least two second connection terminals 114 can be set up so that if one of the second connection terminals 114 fails, the other second connection terminal 114 can be switched to further improve the performance of the test circuit board 10.

[0139] Please refer to this again. Figure 2 In one embodiment of this application, the test circuit 11 further includes a plurality of fuses 117, each fuse 117 being disposed on a main line 111.

[0140] Here, fuse 117 is located on the main circuit 111, meaning that fuse 117 is connected in series with the main circuit 111, so that it can automatically melt and break in the event of a short circuit or fault in this circuit, thus protecting the equipment. In one example, the connection between the main circuit 111 and fuse 117 can be plug-in type. For example, fuse 117 has a fuse holder, and part of the wires of the main circuit 111 are inserted into the fuse holder to complete the wiring. In other examples, a threaded connection can also be selected, which will not be elaborated here.

[0141] Each main circuit 111 is equipped with a fuse 117, which can effectively prevent short circuits in the battery module caused by damage to the battery module connectors or intermediate connection plugs, thereby damaging the equipment and improving the safe operation of the test circuit 11.

[0142] In one embodiment of this application, the testing device is a multimeter, which includes voltage mode and resistance mode. The multimeter is electrically connected to a host computer or a slave computer to switch between voltage mode and resistance mode.

[0143] In one example, the multimeter can be a 6.5-digit or 7.5-digit digital multimeter 20, thus providing high accuracy and significantly improving detection precision to enhance the timeliness of wire harness continuity testing. Here, the testing device can be a multimeter with multiple operating modes and ranges, such as voltage or resistance. When the host computer or slave computer controls the multimeter to switch to resistance mode, it can also detect thermistors at multiple battery cells, thereby obtaining the temperature value corresponding to the resistance; or the resistance value of the battery cell.

[0144] Using a multimeter can further improve testing efficiency and simplify the structure.

[0145] Please combine Figure 3 In one embodiment of this application, the test system 100 further includes an adapter test harness, one end of a plurality of main lines 111 is connected to an aviation plug, and the two ends of the adapter test harness are respectively plugged into the aviation plug and the plug-in terminals of the battery module.

[0146] Here, the adapter test harness is a wire segment that can be connected via a plug-in method, facilitating plug-and-play connections and improving efficiency and convenience. One end of the adapter test harness is electrically connected to the test circuit board 10 via an aviation connector. The number of pins and the number of aviation connectors can be set as needed to correspond to the number of multiple total lines 111 and the number of battery cells in the battery module. For example, two sets of 64-pin aviation connectors can be selected. This aviation connector configuration facilitates the replacement and connection of the adapter test harness. The length of the adapter test harness should not be too long to save costs. To protect the adapter test harness, a harness channel can also be provided, through which the adapter test harness is connected to the connector of the battery module, effectively reducing the probability of damage.

[0147] By using an adapter test harness and aviation plug, during testing, it is only necessary to connect the adapter test harness to the connector of the battery module, without repeatedly plugging and unplugging the interface of the main line 111 of the test circuit 11. This reduces the wear rate of the test circuit board and aviation plug, achieving the purpose of convenient maintenance and cost reduction.

[0148] In one embodiment of this application, the test system 100 further includes a reading mechanism electrically connected to a host computer. The reading mechanism is used to read the barcode information of the battery module and send it to the host computer, which then calls the test plan based on the barcode information.

[0149] Here, the reading mechanism can be a radio frequency identification (RFID) device or a barcode scanner; no specific limitation is made. Due to the different structures and types of battery modules, a reading mechanism is set up to read the barcode information of the battery module, thereby obtaining the corresponding type or structure of the battery module. This allows the host computer to select the appropriate test scheme based on the obtained battery module type or structure, improving applicability and testing accuracy.

[0150] The test plan is based on the test requirements of the battery product (the requirements are generally single cell voltage test, single cell voltage difference test, NTC resistance test) and connector pin definition. First, the test sequence, multimeter measurement mode (voltage mode or resistance mode) and the relay number to be closed are edited in the host computer software.

[0151] Please continue to refer to Figure 1 In one embodiment of this application, the test system 100 further includes a test frame 30, which includes a plurality of horizontal beams 31 and a plurality of vertical beams 32 connected in the longitudinal and transverse directions. The plurality of horizontal beams 31 and vertical beams 32 enclose a test channel 30a, through which the battery module passes, and the reading mechanism is located within the test channel 30a.

[0152] The test frame 30 can be a frame structure, comprising multiple horizontal beams 31 and multiple vertical beams 32. The horizontal beams 31 and vertical beams 32 can be made of profiles or wood, etc., facilitating processing and ensuring structural stability. The connection method between the horizontal beams 31 and vertical beams 32 can be a fixed connection, such as adhesive or welding, or a detachable connection, such as mortise and tenon joints, plug-in joints, or threaded joints, etc., without limitation. In one example, the test frame 30 includes four vertical beams 32 and multiple horizontal beams 31 connecting two pairs of vertical beams 32 to form a square frame structure. A test channel 30a is formed in the lower middle part of the test frame 30, allowing it to be adapted to other production lines. Battery modules can be directly conveyed through the test channel 30a via a transfer structure, forming a complete battery module testing process. In other examples, three or more vertical beams 32 can also be provided. The reading mechanism can be located on one of the horizontal beams 31 or one of the vertical beams 32, without limitation, as long as it corresponds to the barcode of the battery module.

[0153] The test frame 30 can provide a testing environment for battery modules, prevent external interference, and effectively improve protection performance; it also facilitates the assembly and fixing of various components, such as the reading mechanism, provides support, and is compatible with the production line, thereby improving the overall testing efficiency of battery modules.

[0154] In one example, the test frame 30 also includes four feet 33, which are respectively installed at the bottom of the vertical beam 32, thereby allowing for leveling of the vertical beam 32 and the horizontal beam 31 and improving support stability. In another example, the test frame 30 may also include a protective plate, which is installed at the top of the vertical beam 32 and the connection between it and the top horizontal beam 31, or on the side of the vertical beam 32, thereby protecting the test channel 30a from interference from the external environment.

[0155] Please continue to refer to Figure 1 In one embodiment of this application, the test system 100 further includes an image acquisition device 40, which is mounted on a crossbeam 31 and electrically connected to a host computer to capture images of the battery modules in the test channel 30a and send them to the host computer.

[0156] As an example, the image acquisition device 40 can be a line scan camera, which has high resolution and good image quality. In other examples, the image acquisition device 40 can also be a 3D camera, a surface camera, or a scanner, etc., and is not limited here. The image acquisition device 40 is mounted on a crossbeam 31, which is close to the top of the vertical beam 32, and its projection on the horizontal plane is located at the center or one end of the test channel 30a, thereby facilitating comprehensive acquisition of the overall structure of the battery module.

[0157] The image acquisition device 40 can collect data on the overall condition of the battery module and the connection status of individual battery cells, and send the data to the host computer for storage, thereby providing a basis for subsequent performance analysis.

[0158] Please refer to Figure 1 In one embodiment of this application, the test system 100 further includes a light source 50, which is disposed on another crossbeam 31 and located on one side of the image acquisition device 40;

[0159] And / or, the test system 100 also includes a safety light curtain 60, which is disposed between two opposing vertical beams 32 and connected to the host computer to block the test channel 30a.

[0160] In one example, the light source 50 is a strip light source 50, which has a wide light emission range and can provide better supplementary lighting for the image acquisition device 40. In other examples, the light source 50 can also be a dot matrix LED structure. The light source 50 is located on one side of the image acquisition device 40 on the horizontal plane and emits light towards the battery module.

[0161] The light source 50 can provide supplementary lighting for the battery module to be tested, thereby improving the image acquisition effect.

[0162] To enhance safety, a safety light curtain 60 is installed on the test frame 30, with or without the light source 50. This safety light curtain 60, also known as a photoelectric safety protection device, includes a transmitter and a receiver, which are respectively installed on two opposing vertical beams 32. The transmitter emits light, and when the receiver receives the emitted light, it indicates that there is no obstruction. When the receiver does not receive the emitted light, it indicates that an obstruction has entered the test channel 30a, which will affect the detection. The signal is then sent to the host computer, which can send a pause command to the slave computer, thereby controlling the detection equipment to stop the detection.

[0163] The installation of the safety light curtain 60 can further enhance protection and improve detection effectiveness.

[0164] Please combine Figure 1 In one embodiment of this application, the test system 100 further includes an integrated cabinet 70, which has a receiving cavity and is located on one side of the test frame 30. The test circuit board 10, the test equipment and the lower computer are all located in the receiving cavity, and the aviation plug is at least partially exposed in the integrated cabinet 70.

[0165] The integrated cabinet 70 can be arranged in a cuboid structure for easy placement on the ground, forming a stable support structure. In other examples, the integrated cabinet 70 can also be cylindrical or other shapes. The integrated cabinet 70 can be made of metal, such as stainless steel or aluminum alloy, which has high structural strength and durability. The surface of the integrated cabinet 70 can be treated with anti-static treatment to prevent it from affecting the internal components. Optionally, the integrated cabinet 70 includes a cabinet body and a cabinet door. The cabinet body forms an open receiving cavity, and the cabinet door is movably connected to the cabinet body, so that the opening of the receiving cavity can be closed or opened, facilitating maintenance and installation by operators. The test circuit board 10, the test equipment, and the lower-level machine are all located within the receiving cavity, which can avoid interference and improve protection. The fixed installation of the test equipment can also improve the detection accuracy. In one example, a viewing window can be provided in the cabinet body as needed to observe the dial of the test equipment. Other auxiliary components, such as power supplies or heat sinks, can also be installed within the receiving cavity, which is not limited here. When aviation plugs and adapter test harnesses are provided, the aviation plug portion is exposed in the cabinet to facilitate the insertion of the adapter test harness.

[0166] In one example, a wire harness sleeve can also be installed between the integrated cabinet 70 and the test frame 30. The wire harness sleeve forms a wire harness channel, through which the adapter test wire harness can pass to connect to the battery module and the aviation plug respectively. This can improve the protection of the adapter test wire harness and extend its service life.

[0167] Here, integrating all components into the integrated cabinet 70 effectively saves floor space and improves the flexibility of equipment installation. The integrated cabinet 70 can be set up independently and placed on one side of the test frame 30, that is, outside the production line, which improves the maintainability of the equipment.

[0168] Please refer to Figure 1 In one embodiment of this application, the test system 100 further includes a warning element 81, which is installed on the test frame 30 and / or the integrated cabinet 70 and connected to the host computer to reflect the operating status of the test system 100.

[0169] Here, the warning element 81 can be a light or an alarm. For example, when the warning element 81 is a three-color light, it can have four output states: three colors of light and a buzzer. When the test system 100 is running normally, it can output a green light; when the test system 100 is waiting for materials, it can output a yellow light; when the test system 100 crashes or malfunctions, it can output a red light and emit a buzzer sound to provide a reminder.

[0170] The warning device 81 can reflect the operating status of the test system 100 in real time, thereby enabling timely handling and maintenance, avoiding excessive rework testing of battery modules, and improving testing efficiency.

[0171] Please combine Figure 1 In one embodiment of this application, the test system 100 further includes a human-computer interaction device, which is installed on the test frame 30 and connected to the host computer to display test information or debug the test system 100.

[0172] In one example, the human-computer interaction device includes a display 91, a keyboard, and a mouse. The display 91 can show the parameter information of the battery cells obtained from the test equipment, allowing the operator to monitor them in real time. The keyboard and mouse can also facilitate the operator to adjust the parameters of the test system 100 and display the data. In another example, the human-computer interaction device can also be a touch screen.

[0173] The human-computer interaction device allows operators to monitor the test data of the test system 100 and adjust the operating parameters of the test system 100 at any time to improve the test performance of the test system 100.

[0174] In one embodiment of this application, a vertical beam 32 is rotatably connected to a mounting frame 93, and a human-machine interface device is mounted on the mounting frame 93 so as to be rotatably set relative to the test frame 30 on a horizontal plane.

[0175] In one example, one side of the mounting bracket 93 and one of the vertical beams 32 are provided with a pivot, and the other is provided with a shaft hole. The mounting bracket 93 rotates relative to the vertical beam 32 through the engagement of the pivot and the shaft hole. In other examples, the rotational connection can also be achieved through other components, such as hinges. To limit the rotation angle of the mounting bracket 93, a locking fastener can be provided to lock the rotation of the mounting bracket 93 and the vertical beam 32, thereby limiting it to a certain rotation angle. When adjustment is needed, the locking fastener can be released. Alternatively, a damping element can be provided in the rotation structure of the mounting bracket 93 so that the mounting bracket 93 can rotate dampedly, allowing it to be limited to any position. In an optional example, the mounting bracket 93 includes a support portion and a locking portion. The support portion is used to hold the keyboard and mouse, and the locking portion forms a mounting groove into which the display components can be installed.

[0176] The vertical beam 32 is rotatably connected to the mounting bracket 93, which allows the mounting bracket 93 to be rotated in the horizontal plane, thereby adjusting the orientation of the human-machine interface device and further facilitating the operator's viewing and operation.

[0177] In one embodiment of this application, the test system 100 further includes a housing 82, which is disposed on a crossbeam 31 or a vertical beam 32 to house the adapter test harness.

[0178] In one example, the storage component 82 is a hook structure, having a fixing part and a hook connected to the fixing part. The fixing part is used for detachable connection with the vertical beam 32, and the hook is used to hang the adapter test harness. There can be two hooks to prevent excessive bending of the adapter test harness, thus extending its service life. In other examples, the storage component 82 can also be a box structure, etc. After testing, the end of the adapter test harness connected to the battery module can be hung on the storage component 82, or placed inside the storage component 82. In other examples, the fixing part can also be installed on a horizontal beam 31, and the height of the horizontal beam 31 can be located in the lower middle part of the vertical beam 32 for convenient storage.

[0179] The storage unit 82 allows for convenient storage of the adapter test harness, making the test system 100 neater and preventing damage to the adapter test harness.

[0180] In one embodiment of this application, the test system 100 further includes a starter 83, which is disposed on the periphery of the test frame 30. The starter 83 has two start parts, which are connected to the host computer to start the test system 100.

[0181] And / or, the test system 100 also includes a card reader 94, which is installed on the test frame 30 and connected to the host computer.

[0182] The initiator 83 is used to start the test system 100 and can send a start command to the host computer, causing the host computer to enter the test state. The initiator 83 includes two initiating parts; both initiating parts must be pressed simultaneously to send the start command, thereby triggering the host computer to enter the test state. In one example, the initiator 83 is located at a crossbeam 31, which is near the lower middle part of the vertical beam 32, at a height that an adult standing with their arms hanging down can easily reach, facilitating operator operation. By controlling both initiating parts simultaneously with both hands, the operator's hands can remain outside the test channel 30a, thereby avoiding interference with the test and improving protection.

[0183] With or without the starter 83, a card reader 94 can be installed on the support or mounting part of the mounting bracket 93. The card reader 94 allows operators to swipe their cards and connects electrically to the host computer. After the operator swipes their card, the information on the card is sent to the host computer for identity verification. If the verification is successful, the host computer sends instructions for subsequent parameter adjustments and data display. The card reader 94 enhances the security level of the test system 100, ensuring that debugging and control of the test system 100 can only proceed after identity verification via card swiping.

[0184] Please refer to Figure 4 This application also proposes a testing method for a testing system. The testing system includes a test circuit board, testing equipment, a host computer, and a slave computer. The testing method includes the following steps:

[0185] Step S1: The host computer sends a test command to the slave computer;

[0186] Step S2: The lower-level machine receives the test command and controls one of the two main circuits on the test circuit board to connect the first branch to the positive terminal of the test equipment, and the other to connect the second branch to the negative terminal of the test equipment.

[0187] Step S3: The testing equipment detects the parameter information of the individual battery cells;

[0188] Step S4: The host computer sends an instruction to read the parameter information of the test device and receives and stores the parameter information.

[0189] In the above method, in step S1, before the host computer sends the test command to the slave computer, the test system can be started manually by triggering the starter. In step 2, after receiving the test command, the slave computer can control the control switches on the first and second branches one by one, so that one main line is connected to the positive terminal of the test equipment and the other main line is connected to the negative terminal of the test equipment, and the parameter information of the battery cells to be tested is tested one by one until all the battery cells to be tested have been tested. The two main lines 111 mentioned above can be two adjacent ones, or the corresponding two main lines 111 can be selected according to the connector pin definitions on the battery module harness board. The test equipment here can be a multimeter, voltmeter, or oscilloscope, etc., and the parameter information here can be voltage data, resistance data, etc., which can be selected as needed. In step S3, while the test circuit is conducting, the test equipment can obtain the parameter information of the battery cells and can store the parameter information or send it directly to the host computer. In step S4, when the host computer sends a command to read parameter information, the test device sends the parameter information to the host computer. After receiving the information, the host computer stores it and can also analyze it to determine whether the detection harness of the battery cell is open or closed.

[0190] This method involves the host computer sending test commands to the slave computer. The slave computer can control the control switches that need to be activated, connecting the first branch of one main circuit to the positive terminal of the test equipment and the second branch of another main circuit to the negative terminal of the test equipment. This allows the test equipment to detect parameter information, such as voltage, of the individual battery cells in the battery module. This process can be repeated to sequentially detect the parameter information of the battery cells to be tested. The test system method described in this application enables the sequential testing of multiple battery cells in a battery module without the need for repeated manual plugging and unplugging of wires, improving testing efficiency and accuracy.

[0191] Please refer to Figure 5 In one embodiment of this application, the testing device includes a multimeter, which has voltage mode and resistance mode, and is electrically connected to a lower-level electromechanical device, and the parameter information is voltage data;

[0192] After the host computer sends the instruction to read the parameter information of the test equipment and receives and stores the parameter information, the process includes:

[0193] Step S5: The lower-level machine sends a mode switching command to the multimeter;

[0194] Step S6: Switch the multimeter to resistance mode;

[0195] Step S7: The first branch of one of the two main circuits on the lower-level control test circuit board is connected to the positive terminal of the test equipment, and the second branch of the other circuit is connected to the negative terminal of the test equipment, so that the multimeter can obtain resistance data.

[0196] Step S8: The host computer sends a command to read the resistance data from the multimeter and receives and stores the resistance data.

[0197] In the above method, step S5, by sending the switching mode to the multimeter via the lower-level computer, enables faster signal transmission and improves control efficiency, thus increasing the switching efficiency of the multimeter. In other examples, the upper-level computer can directly communicate with the multimeter and send the switching mode command to the multimeter. After the multimeter switches to resistance mode, the lower-level computer, similar to the test voltage data, controls the corresponding control switches of the two main lines to close, thereby connecting with the multimeter and performing individual tests on the NTC resistance of multiple battery cells until all the required battery cells have been tested. The two main lines 111 can be selected as two adjacent lines, or the corresponding two main lines 111 can be selected according to the connector pin definitions on the battery module harness board. While the test circuit is conducting, the test equipment can acquire the resistance data of the battery cells and store the resistance data directly. When the upper-level computer sends a command to read the parameter information, the test equipment sends the parameter information to the upper-level computer, which receives and stores it, and can also analyze it to determine whether the detection harness of the battery cell is open or closed. Alternatively, in other examples, the multimeter sends the resistance data directly to the host computer while obtaining it.

[0198] This testing method uses a multimeter to test the voltage and resistance of individual battery cells within a battery module, thereby calculating the voltage difference and the corresponding temperature values ​​for the resistance. Based on these results, the continuity of the sampling harness within the battery module can be determined, improving testing accuracy. This method allows for the measurement of two values ​​using a multimeter, eliminating the need for repeated plugging and unplugging of the harness, further improving testing efficiency. It also protects the harness and connectors, enhancing overall performance.

[0199] Please refer to Figure 6 In one embodiment of this application, after the host computer sends an instruction to read the resistance data from the multimeter and receives and stores the resistance data, the method further includes:

[0200] Step S91: The host computer determines that the sampling harness of the battery module is qualified based on the voltage and resistance data, and then uploads the test data to the main execution platform;

[0201] Alternatively, in step S92: if the host computer determines that the sampling harness of the battery module is unqualified based on the voltage and resistance data, it will mark it and upload the detection data to the main execution platform.

[0202] In step S91, the host computer can calculate the voltage difference of a single battery cell based on the voltage data, obtain the temperature value corresponding to the NTC resistor based on the resistance data, compare the detected actual voltage difference and temperature value with the standard voltage difference and temperature value, and if they are consistent, it can be determined that the sampling harness at a certain location of the battery module is qualified, and store the voltage, voltage difference, NTC temperature and other data of a single battery cell locally, while also uploading them directly to the main execution platform.

[0203] In step S92, the judgment criteria are the same as above. If the comparison results are inconsistent, it indicates that there is a fault or disconnection in the sampling harness at that location. In this case, the obtained data needs to be marked before being uploaded to the main execution platform.

[0204] This method enables the detection of the sampling harness of the battery module through processing by the host computer, thereby quickly identifying defects in the battery module and avoiding rework. It also distinguishes between different test results, thus providing traceable data for subsequent processing.

[0205] Please refer to Figure 7 In one embodiment of this application, the testing system further includes a test frame and a reading mechanism, wherein the test frame forms a test channel;

[0206] Before step S1, where the host computer sends the test command to the slave computer, the following steps are also included:

[0207] Step S01: After the host computer detects and tests the battery module, it sends a command to the reading mechanism to read the barcode of the battery module.

[0208] Step S02: The reading mechanism reads the barcode of the battery module and sends the barcode information to the host computer;

[0209] Step S03: The host computer calls the corresponding detection formula based on the barcode information and triggers the detection mechanism.

[0210] The test frame provides a testing environment for battery modules, preventing external interference and effectively improving protection performance; it also facilitates the assembly and fixing of various components, such as the reading mechanism, provides support, and is compatible with the production line, thereby improving the overall testing efficiency of battery modules.

[0211] The reading mechanism can be a radio frequency identification (RFID) device or a barcode scanner; no specific limitation is made here. Due to the different structures and types of battery modules, a reading mechanism is set up to read the barcode information of the battery modules, thereby obtaining the corresponding type or structure of the battery module. This allows the host computer to select the appropriate test scheme based on the obtained battery module type or structure. Therefore, before the host computer sends the test command, in step S01, the test channel is first checked to determine if any battery modules requiring testing have entered. If so, their barcode information needs to be read first. In step S02, after the reading mechanism drives the barcode, it sends the obtained barcode information to the host computer. Then, in step S03, the host computer retrieves the corresponding test scheme and test mechanism based on the barcode information, making the control of the lower-level machine more targeted and accurate.

[0212] The testing plan is based on the testing requirements of battery products (typically single-cell voltage testing, single-cell voltage difference testing, and NTC resistance testing) and connector pin definitions. The test sequence, multimeter measurement mode (voltage or resistance mode), and relay numbers to be closed are first edited in the host computer software. By configuring the reading mechanism, more targeted testing can be performed on different types of battery modules, improving applicability and testing accuracy.

[0213] Please refer to Figure 8 In one embodiment of this application, the testing system further includes an image acquisition device. Before step S01, after the host computer detects the battery module entering the test channel, it sends an instruction to read the barcode of the battery module to the reading mechanism, the system further includes:

[0214] Step S001: The host computer sends an image acquisition command to the image acquisition device;

[0215] Step S002: The image acquisition device acquires image data of the battery module and sends it to the host computer;

[0216] Step S003: The host computer receives and stores the image data.

[0217] The type of image acquisition device is not limited; it can be a line scan camera, a surface camera, a 3D camera, etc. This image acquisition device can capture the overall condition of the battery module and the connection status of individual battery cells, obtain image data, and send it to a host computer. The host computer stores the data, thus providing a basis for subsequent performance analysis.

[0218] In other examples, the barcode information of the battery module can be read first, and then the image data can be collected.

[0219] Please refer to Figure 9This application also proposes a testing method for a testing system. The testing system includes a test circuit board, testing equipment, a host computer, and a slave computer. The testing method includes the following steps:

[0220] Step S10: Send the first test command to the lower-level machine so that the lower-level machine controls the first branch of one of the two main lines on the test circuit board to conduct electricity to the positive terminal of the test equipment, and the second branch of the other line to conduct electricity to the negative terminal of the test equipment, so that the test equipment can detect the parameter information of the battery cell.

[0221] Step S20: Send an instruction to read the parameter information of the test device and receive the stored parameter information.

[0222] In step S10 of this testing method, the host computer sends a first test command to the slave computer. The slave computer can control the control switch that needs to be turned on, so that the first branch of one main circuit is connected to the positive terminal of the test equipment, and the second branch of another main circuit is connected to the negative terminal of the test equipment. In this way, the test equipment can detect the parameter information of the battery cells of the battery module. The two main circuits 111 mentioned above can be two adjacent ones, or the corresponding two main circuits 111 can be selected according to the connector pin definitions on the battery module wiring harness board. In this way, the parameter information of multiple battery cells can be detected sequentially. The parameter information can be voltage data, resistance data, or other parameters, etc. The test equipment is selected according to the parameter information to be tested, such as a multimeter, voltmeter, or oscilloscope. In step S20, the host computer will acquire and store the parameter information, and at the same time perform analysis and processing to determine the continuity of the sampling wiring harness of the battery module.

[0223] The testing system method described in this application enables sequential testing of multiple individual battery cells in a battery module, eliminating the need for repeated manual plugging and unplugging of wires, thus improving testing efficiency and accuracy.

[0224] Please refer to Figure 10 In one embodiment of this application, the testing device includes a multimeter, which has voltage mode and resistance mode and is electrically connected to a lower-level machine; the parameter information is voltage data; after step S20 of sending an instruction to read the parameter information of the testing device and receiving the stored parameter information, the method further includes:

[0225] Step S30: Send a second test command to the lower-level machine so that the lower-level machine controls the multimeter to switch to resistance mode and obtain resistance data;

[0226] Step S40: Send a command to read the resistance data from the multimeter and receive the stored resistance data.

[0227] Sending the switching mode command from the lower-level computer to the multimeter allows for faster signal transmission and improved control efficiency, resulting in higher switching efficiency for the multimeter. In other examples, the upper-level computer can directly communicate with the multimeter and send switching mode commands. After the multimeter detects the voltage data of the individual battery cells in voltage mode, it receives the switching command and switches to resistance mode. The lower-level computer, similar to the voltage data test, controls the corresponding control switches of the two main circuits to close, thus enabling conduction with the multimeter. This allows for the sequential testing of multiple NTC resistors until all required battery cells have been tested. While the testing circuit is conducting, the testing equipment can acquire the resistance data of the individual battery cells. This resistance data can be directly stored. When the upper-level computer sends a command to read parameter information, the testing equipment then sends the parameter information to the upper-level computer. The upper-level computer receives and stores this information and can simultaneously analyze it to determine the continuity of the detection harness for that battery cell. Alternatively, in other examples, the multimeter directly sends the resistance data to the upper-level computer while acquiring it.

[0228] This testing method uses a multimeter to test the voltage and NTC resistance of each individual battery cell within the battery module, and then determines the continuity of the sampling harness within the battery module based on the test results. This method allows for the measurement of two values ​​using a multimeter, eliminating the need for repeated plugging and unplugging of the harness, simplifying the structure, further improving testing efficiency, and protecting the harness and connectors, thus enhancing performance.

[0229] In one embodiment of this application, after step S40 of sending an instruction to read the resistance data of a multimeter and receiving and storing the resistance data, the method further includes:

[0230] Step S510: If the sampling harness of the battery module is deemed qualified based on the voltage and resistance data, the test data is uploaded to the main execution platform;

[0231] Alternatively, in step S520: if the sampling harness of the battery module is found to be unqualified based on the voltage and resistance data, then mark it and upload the detection data to the main execution platform.

[0232] In step S510, the host computer can calculate the voltage difference of the battery cell based on the voltage data, obtain the temperature value corresponding to the NTC resistor based on the resistance data, compare the actual voltage difference and temperature value with the standard voltage difference and temperature value, and if they are consistent, it can be determined that the sampling harness at a certain position of the battery module is qualified. The voltage, voltage difference, NTC temperature and other data of the individual battery cell are stored locally and uploaded directly to the main execution platform.

[0233] In step S520, the judgment criteria are the same as those mentioned above. If the comparison results are inconsistent, it indicates that there is a fault or disconnection in the sampling harness at that location. In this case, the obtained data needs to be marked before being uploaded to the main execution platform.

[0234] This method enables the detection of wiring harnesses in battery modules through processing by a host computer, thereby quickly identifying defects in the battery modules and avoiding rework. It also distinguishes between different test results, thus providing traceable data for subsequent processing.

[0235] Please refer to Figure 11 In one embodiment of this application, the testing system further includes a test frame and a reading mechanism. The test frame forms a test channel. Before the step of sending the first test command to the lower-level machine, the system further includes the following step:

[0236] Step S11: The test channel is detected to be entering the battery module;

[0237] Step S12: Send a command to the reading mechanism to read the barcode of the battery module;

[0238] Step S13: Obtain barcode information and trigger the detection mechanism by calling the corresponding detection formula based on the barcode information.

[0239] The test frame provides a testing environment for battery modules, preventing external interference and effectively improving protection performance; it also facilitates the assembly and fixing of various components, such as the reading mechanism, provides support, and is compatible with the production line, thereby improving the overall testing efficiency of battery modules.

[0240] The reading mechanism can be a radio frequency identification (RFID) device or a barcode scanner; no specific limitation is made here. Due to the different structures and types of battery modules, a reading mechanism is set up to read the barcode information of the battery modules, thereby obtaining the corresponding type or structure of the battery module. This allows the host computer to select the appropriate test scheme based on the obtained battery module type or structure. Therefore, before the host computer sends the test command, in step S01, the test channel is first checked to determine if any battery modules requiring testing have entered. If so, their barcode information needs to be read first. In step S02, after the reading mechanism drives the barcode, it sends the obtained barcode information to the host computer. Then, in step S03, the host computer retrieves the corresponding test scheme and test mechanism based on the barcode information, making the control of the lower-level machine more targeted and accurate.

[0241] By configuring the reading mechanism, more targeted testing can be performed on different types of battery modules, improving applicability and testing accuracy.

[0242] Please refer to Figure 12In one embodiment of this application, the testing system further includes an image acquisition device. After detecting the step of the test channel entering the battery module, and before sending an instruction to read the barcode of the battery module to the reading mechanism to read the barcode of the battery module, the system further includes:

[0243] Step S111: Send an image acquisition command to the image acquisition device;

[0244] Step S112: Acquire and store image data of the battery module acquired by the image acquisition device.

[0245] Here, the image acquisition device can collect and store the overall condition of the battery module and the connection status of individual battery cells, thereby providing a basis for subsequent performance analysis.

[0246] The type of image acquisition device is not limited; it can be a line scan camera, a surface camera, a 3D camera, etc. This image acquisition device can capture the overall condition of the battery module and the connection status of individual battery cells, obtain image data, and send it to a host computer. The host computer stores the data, thus providing a basis for subsequent performance analysis.

[0247] In other examples, the barcode information of the battery module can be read first, and then the image data can be collected.

[0248] Example of a test process for a test system

[0249] After the host computer of the testing system detects the incoming battery modules, it reads the barcode information of the battery modules on the tray via RFID and sends it to the host computer. The host computer automatically retrieves the test formula based on the barcode information and sends test instructions to the slave computer.

[0250] The lower-level computer controls the continuity of the test circuit on the test circuit board. According to the test formula requirements, the 64-pin aviation connector with an adapter test harness connected to the battery module is connected to the positive and negative probes of the multimeter. Specifically, the upper-level computer instructs the lower-level computer to test the voltage of the first battery cell by issuing the required closed control switches (i.e., contacts K1 and K22). The lower-level computer closes K1 and K22, obtaining the voltage of the first battery cell. This process is repeated for each battery cell, obtaining voltage data for multiple cells. Then, through communication between the upper-level computer and the multimeter, the high-precision multimeter can be switched between voltage and resistance modes and ranges, or the lower-level computer can communicate with the multimeter to control the switching of modes and ranges. The multimeter then sequentially obtains the resistance data for multiple battery cells.

[0251] The host computer sends instructions to read the voltage and resistance data from the digital multimeter, calculates the single-cell voltage difference and the temperature corresponding to the NTC resistance, and stores the voltage, voltage difference, NTC temperature, and other data of a single battery cell in a specified format on the local hard drive, while simultaneously uploading them to the data traceability system.

[0252] The testing system described in this application is an automatic testing device that can be used for continuity testing of battery module wiring harness sampling boards. It has the advantages of high compatibility, traceability, high testing efficiency, high stability, and low cost.

[0253] Another embodiment of the testing process of the testing system:

[0254] When a battery module arrives, the lifting mechanism lifts it off the high-speed chain. The image acquisition device takes a picture and saves it. The operator then installs the test adapter harness and presses the start button.

[0255] The RFID reader scans the barcode on the battery module. The lower-level computer receives the barcode and sends it to the upper-level computer, which automatically retrieves the test formula based on the barcode information. Testing is then performed according to the test formula. After testing, the operator disconnects the test adapter cable, neatly organizes the components, and presses the release button. The battery module then exits the testing system.

[0256] The first test formula: The test equipment is controlled by a host computer.

[0257] 1. The host computer issues instructions for all test items to the slave computer at once, according to the recipe.

[0258] 2. The host computer switches the multimeter mode and range according to the test items and sends instructions to the slave computer simultaneously;

[0259] 3. The lower-level machine closes the corresponding control switch according to the instructions of the first test item and notifies the upper-level machine that the closing action has been completed;

[0260] 4. The host computer reads and saves the test result.

[0261] Perform the remaining test items one by one in the order of steps 2-3-4.

[0262] The second test formula: The test equipment is controlled by a lower-level computer.

[0263] 1. The host computer issues instructions for all test items to the slave computer at once, according to the recipe.

[0264] 2. The host computer notifies the PLC to start the nth test;

[0265] 3. The lower-level computer controls the multimeter to switch to the corresponding mode (voltage / resistance) according to the instructions of the test item, and simultaneously closes the control switch of the corresponding test circuit;

[0266] 4. After the control switch is closed, the lower-level computer reads the multimeter test data and saves it to the data block specified in the test item.

[0267] 5. The host computer compares the data block corresponding to the test item and finds data, then acquires, saves, and displays the data on the software interface.

[0268] Perform the remaining test items one by one in the order of steps 2-3-4-5.

[0269] The above description is merely a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural transformations made based on the inventive concept of this application and the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A test system for testing harness continuity of a battery module, the battery module comprising a plurality of series and parallel connected battery cells, wherein, The test system comprises: a test circuit board provided with a test circuit, the test circuit comprising a plurality of bus lines arranged side by side, one end of each bus line being used for connection with a positive electrode or a negative electrode of each battery cell of a battery module, the other end of each bus line being connected with a first branch and a second branch; each first branch being provided with a control switch, and each second branch being provided with a control switch; a test device for testing parameter information of the plurality of battery cells of the battery module; a lower computer electrically connected with the control switches to control the positive electrode of the test device to be electrically connected with the first branch connected with one of the bus lines and the negative electrode of the test device to be electrically connected with the second branch connected with another bus line; and an upper computer in communication connection with the test device and the lower computer to control the operation of the lower computer and read the parameter information of the test device; the test device is a multimeter, the multimeter comprising a voltage mode and a resistance mode, and the multimeter is electrically connected with the upper computer or the lower computer to switch between the voltage mode and the resistance mode; the test system further comprises an adapter test harness, one end of each bus line being connected with an aviation plug, and the two ends of the adapter test harness being respectively plugged into the aviation plug and a plugging end of the battery module.

2. The test system of claim 1, wherein, A plurality of first branches are connected away from one end of the bus lines to form a first connection end, and a plurality of second branches are connected away from one end of the bus lines to form a second connection end, one of the first connection end and the second connection end being electrically connected with the positive electrode of the test device, and the other being electrically connected with the negative electrode of the test device.

3. The test system of claim 2, wherein, The first connection end is provided with at least two first connection ends arranged in parallel. And / or, the second connection end is provided with at least two second connection ends arranged in parallel.

4. The test system of any one of claims 1 to 3, wherein, The test circuit further comprises a plurality of fuses, each fuse being arranged on a bus line.

5. The test system of any one of claims 1 to 3, wherein, The test system further comprises a reading mechanism electrically connected with the upper computer, the reading mechanism being used for reading bar code information of the battery module and sending the bar code information to the upper computer, and the upper computer calling a test scheme according to the bar code information.

6. The test system of claim 5, wherein, The test system further comprises a test frame body comprising a plurality of horizontal beams and a plurality of vertical beams connected longitudinally and transversely, a plurality of horizontal beams and vertical beams enclosing a test channel, the test channel being used for the battery module to pass through, and the reading mechanism being arranged in the test channel.

7. The test system of claim 6, wherein, The test system further comprises an image acquisition device arranged on a horizontal beam and electrically connected with the upper computer to take a picture of the battery module in the test channel and send the picture to the upper computer.

8. The test system of claim 7, wherein, The test system further comprises a light source arranged on another horizontal beam and located on one side of the image acquisition device. And / or, the test system further comprises a safety grating arranged between two vertically arranged vertical beams and electrically connected with the upper computer to block the test channel.

9. The test system of claim 6, wherein, The test system further comprises an integrated cabinet, which is formed with a receiving cavity and located at one side of the test frame body, and the test circuit board, the test equipment and the lower computer are arranged in the receiving cavity, and the aviation plug is at least partially exposed from the integrated cabinet.

10. The test system of claim 9, wherein, The test system further comprises a warning member, which is mounted on the test frame body and / or the integrated cabinet and electrically connected with the upper computer to reflect the running state of the test system.

11. The test system of claim 6, wherein, The test system further comprises a human-computer interaction device, which is mounted on the test frame body and electrically connected with the upper computer to display detection information or debug the test system.

12. The test system of claim 11, wherein, One of the vertical beams is rotatably connected with a mounting rack, and the human-computer interaction device is mounted on the mounting rack to be rotatably arranged in a horizontal plane relative to the test frame body.

13. The test system of claim 6, wherein, The test system further comprises a receiving member, which is arranged on one of the vertical beams or the horizontal beams to receive the adapter test harness.

14. The test system of claim 6, wherein, The test system further comprises a starting member, which is arranged on the periphery of the test frame body, and the starting member is provided with two starting portions, which are electrically connected with the upper computer to start the test system. Furthermore, the test system further comprises a card swiping device, which is mounted on the test frame body and electrically connected with the upper computer.

15. A test method of a test system, wherein, The test system is the test system according to any one of claims 1 to 14, which comprises a test circuit board, a test equipment, an upper computer and a lower computer, and the test method comprises the following steps: The upper computer sends a test instruction to the lower computer; The lower computer receives the test instruction and controls a first branch connected with one of the bus lines on the test circuit board to be electrically connected with the positive electrode of the test equipment, and a second branch connected with another bus line to be electrically connected with the negative electrode of the test equipment; The test equipment detects parameter information of the battery monomer; The upper computer sends an instruction to read the parameter information of the test equipment and receives the parameter information.

16. The test method of a test system as claimed in claim 15, wherein, The test equipment comprises a multimeter, which has a voltage mode and a resistance mode and is electrically connected with the lower computer, and the parameter information is voltage data; After the step of the upper computer sending an instruction to read the parameter information of the test equipment and receiving the parameter information, the following steps are further included: The lower computer sends a mode switching instruction to the multimeter; The multimeter switches to the resistance mode; The lower computer controls a first branch connected with one of the bus lines on the test circuit board to be electrically connected with the positive electrode of the test equipment, and a second branch connected with another bus line to be electrically connected with the negative electrode of the test equipment, so that the multimeter obtains resistance data; The upper computer sends an instruction to read the resistance data of the multimeter and receives the resistance data.

17. The test method of a test system as claimed in claim 16, wherein, After the step of the upper computer sending an instruction to read the resistance data of the multimeter and receiving the resistance data, the following steps are further included: If the upper computer determines that the sampling harness of the battery module is qualified according to the voltage data and the resistance data, the detection data is uploaded to a general execution platform; Or, the host computer judges that the sampling harness of the battery module is unqualified according to the voltage data and the resistance data, and then marks and uploads the detection data to the general execution platform.

18. The test method of a test system as claimed in claim 16, wherein, The test system further comprises a test rack and a reading mechanism, the test rack is formed with a test channel; Before the step of sending a test instruction to the lower computer by the host computer, the method further comprises the steps of: After the host computer detects that the battery module enters the test channel, the host computer sends an instruction to read the barcode of the battery module to the reading mechanism; The reading mechanism reads the barcode of the battery module and sends the barcode information to the host computer; The host computer automatically calls the corresponding detection formula according to the barcode information and triggers the detection mechanism.

19. The test method of a test system as claimed in claim 18, wherein, The test system further comprises an image acquisition device, and before the step of sending an instruction to read the barcode of the battery module to the reading mechanism after the host computer detects that the battery module enters the test channel, the method further comprises the steps of: The host computer sends an image acquisition instruction to the image acquisition device; The image acquisition device acquires image data of the battery module and sends it to the host computer; The host computer receives the image data and stores it.

20. A test method of a test system, wherein, The test system is the test system according to any one of claims 1 to 14, the test system comprises a test circuit board, a test device, a host computer and a lower computer, The test method comprises the steps of: sending a first test instruction to the lower computer to make the lower computer control the first branch connected to one of the two buses on the test circuit board to be conductive with the positive electrode of the test device, and the second branch connected to the other to be conductive with the negative electrode of the test device, so that the test device detects the parameter information of the battery monomer; sending an instruction to read the parameter information of the test device and receiving and storing the parameter information.

21. The test method of a test system as claimed in claim 20, wherein, The test device comprises a multimeter, the multimeter has a voltage mode and a resistance mode, and is electrically connected with the lower computer, and the parameter information is voltage data; After the step of sending an instruction to read the parameter information of the test device and receiving and storing the parameter information, the method further comprises the steps of: sending a second test instruction to the lower computer to make the lower computer control the multimeter to switch to the resistance mode and obtain resistance data; sending an instruction to read the resistance data of the multimeter and receiving and storing the resistance data.

22. The test method of a test system as claimed in claim 21, wherein, After the step of sending an instruction to read the resistance data of the multimeter and receiving and storing the resistance data, the method further comprises the steps of: judging that the sampling harness of the battery module is qualified according to the voltage data and the resistance data, and then uploading the detection data to the general execution platform; Or, judging that the sampling harness of the battery module is unqualified according to the voltage data and the resistance data, and then marking and uploading the detection data to the general execution platform.

23. The test method of a test system as claimed in claim 20, wherein, The test system further comprises a test rack and a reading mechanism, the test rack is formed with a test channel, and before the step of sending a first test instruction to the lower computer, the method further comprises the steps of: detecting that the test channel enters the battery module; sending an instruction to read the barcode of the battery module to the reading mechanism to read the barcode information of the battery module; obtaining the barcode information and calling the corresponding detection formula according to the barcode information to trigger the detection mechanism.

24. The test method of a test system as claimed in claim 23, wherein, The test system further comprises an image acquisition device, after the step of detecting that the test channel enters the battery module, before the step of sending an instruction to read the barcode of the battery module to the reading mechanism to read the barcode information of the battery module, further comprising: sending an image acquisition instruction to the image acquisition device; acquiring and storing image data of the battery module collected by the image acquisition device.

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