Special tool for sampling and testing voltage of single battery

Abstract

The invention discloses a special tool for sampling and testing the voltage of a single battery, which belongs to the technical field of tools for testing batteries and comprises a test protection cover and a test switching clamp. The test protection cover is provided with a fastening hole combined with the test part of the single battery and a positioning pin for positioning the test switching clamp; the test switching clamp comprises a switching test plate, a test probe group, a switching electric connector and a clamping part, the switching test plate is provided with a positioning hole combined with the positioning pin, and the test probe group is installed on the switching test plate; the switching electric connector is adaptively connected with the test probe group to form a plug structure used for connecting a test cable, and the clamping component is mounted on the switching test board and applies pressure to the switching test board to enable the test probe group to abut against the test part of the single battery. The special tool for sampling and testing the voltage of the single battery has the advantages of accurate positioning, quick clamping, high universality, low cost, reusability and the like.

Description

Technical Field

[0001] The invention belongs to the technical field of battery testing tooling, and in particular relates to a special tooling for single cell voltage sampling testing. Background Art

[0002] The single cell voltage sampling test is an important part of the battery management system (BMS) performance monitoring and optimization. By accurately measuring the voltage of each single cell, the voltage distribution balance in the battery pack can be understood in real time, thereby identifying potential faulty cells and preventing performance degradation and safety hazards caused by overcharging, over-discharging or imbalance. This test can not only improve the overall safety and reliability of the battery pack, but also provide data support for the balance control strategy and life prediction. It is of great significance to extend battery life, improve energy utilization efficiency and ensure the stability of equipment operation, especially in high-demand scenarios such as new energy vehicles and energy storage systems.

[0003] At present, the single cell voltage sampling test usually adopts an adapted rectangular electrical connector. The main feature of this method is that it can achieve accurate sampling of the single cell voltage signal by cooperating with the test pad on the battery equalization board. The rectangular electrical connector relies on its specific positioning structure and installation features to accurately adapt to the test part structure of the battery, thereby ensuring reliable electrical connection for sampling. Through high-precision structural design and manufacturing process, the connector can maintain stable performance during the test process and reduce measurement errors caused by poor contact. Therefore, it is widely used in single cell voltage sampling of lithium-ion battery packs.

[0004] However, the shortcomings of rectangular electrical connectors are also prominent. First, its cost is high. Since rectangular electrical connectors need to adapt to the specific structure of different batteries and have strict requirements on their quality and reliability, their design and manufacturing processes are complicated, resulting in expensive purchase prices. Secondly, poor versatility is another significant problem. Rectangular electrical connectors are usually designed for specific models of batteries, and it is difficult to use them in batteries of different specifications or types, which limits their scope of application. Thirdly, the non-reusability of rectangular electrical connectors further increases the cost of use. After repeated use, its connection reliability may decrease due to wear or deformation, and it needs to be replaced frequently, which wastes resources and increases testing costs. Finally, the operational complexity of rectangular electrical connectors also increases the difficulty of testing. The installation of the connector requires strict positioning and high process precision, which not only requires high skills of the operator, but also prolongs the test time and reduces the overall efficiency.

[0005] In summary, although rectangular electrical connectors perform well in ensuring the accuracy and reliability of single cell voltage sampling tests, their high cost, poor versatility, non-reusability, and complex operation restrict their widespread application. Therefore, it is urgent to develop a more economical, efficient, and versatile connection solution to further optimize the technology and cost of single cell voltage sampling tests. Summary of the invention

[0006] Aiming at the problems of high cost, poor versatility, non-reusability and complicated operation of the rectangular electrical connector currently used in single cell voltage sampling test, the present invention provides a special tool for single cell voltage sampling test.

[0007] The present invention is implemented as follows: a special tool for single cell voltage sampling test, characterized in that it includes a test protection cover and a test adapter clamp; the test protection cover is provided with a fastening hole combined with the test part of the single cell and a positioning pin for positioning the test adapter clamp; the test adapter clamp includes a transfer test board, a test probe group, a transfer electrical connector and a clamping component, the transfer test board is provided with a positioning hole combined with the positioning pin, the test probe group is installed on the transfer test board, the transfer electrical connector is adapted to be connected with the test probe group and forms a plug structure for connecting a test cable, and the clamping component is installed on the transfer test board and applies pressure to the transfer test board to make the test probe group press against the test part of the single cell.

[0008] In the above technical solution, preferably, the test protective cover includes a protective cover body, the upper part of the protective cover body forms an opening for allowing the test probe group to enter, the lower bottom of the protective cover body forms a guide hole for guiding the test probe group, and the two sides of the protective cover body are provided with the fastening holes and positioning pins.

[0009] In the above technical solution, preferably, the front portion of the adapter test board is a flat plate portion, the test probe group is installed on the flat plate portion and the axis of the probe is perpendicular to the plate surface of the flat plate portion, and the positioning holes are provided in the flat plate portion and located on both sides of the test probe group.

[0010] In the above technical solution, preferably, the adapter electrical connector is installed at the rear of the adapter test board.

[0011] In the above technical solution, preferably, the clamping component is installed at the rear of the adapter test plate, and the clamping component has two clamping plates that form a clamping force, and one of the clamping plates is connected to the adapter test plate.

[0012] In the above technical solution, preferably, a locking assembly is installed between the two clamping plates of the clamping component, and the locking assembly is used to lock the clamping component in a clamped state.

[0013] In the above technical solution, preferably, the other front part of the clamping plate of the clamping component is connected to an auxiliary clamping plate, and the auxiliary clamping plate is located below the adapter test plate and the front part forms a test clamp with the flat plate part of the adapter test plate.

[0014] In the above technical solution, preferably, the locking assembly includes a threaded pull rod and a threaded sleeve rod, the lower end of the threaded pull rod is connected to the auxiliary clamping plate, and the threaded pull rod passes through the through hole set in the adapter test plate and is connected to the threaded sleeve rod through a thread.

[0015] In the above technical solution, preferably, a probe protection cap is provided on the upper portion of the test probe group.

[0016] The single cell voltage sampling test tooling of the present invention exhibits superior performance and significant effects in many aspects through the combined design of the test protection cover and the test adapter clip. Among them, the test protection cover is an accessory auxiliary component with a simple structure, and its design is flexible and economical. The customization cost of the test protection cover is low, and it can be adaptively adjusted according to the structure of the single cell test part of different specifications, and this customization will not affect the function and applicability of the test adapter clip used with it, thereby ensuring the compatibility and versatility of the entire tooling.

[0017] The test adapter has the characteristics of quick clamping. Its structural design is simple and efficient. It can quickly connect with the test protection cover and the battery test part through simple operation. Compared with traditional connectors, it is more convenient to install and remove, which effectively improves the operation efficiency. In addition, the test adapter can ensure the accurate transmission of the voltage sampling signal through a firm connection with the test cable, avoiding test errors caused by poor contact, and further improving the reliability and accuracy of the test results.

[0018] At the same time, the overall design of the tooling is highly versatile. The modular design concept enables the test protection cover and test adapter to adapt to a variety of models and specifications of single cells, eliminating the need to repeatedly design accessories for different batteries, which reduces both resource waste and production and use costs. This versatility and efficiency make the tooling suitable for multi-scenario, multi-batch testing needs, demonstrating strong market competitiveness.

[0019] This special tooling for single cell voltage sampling test not only has the advantages of precise positioning, fast clamping, strong versatility, low cost and reusability, but also shows excellent performance in many aspects. First of all, the test protection cover effectively improves the operational safety, reduces the risk of operators contacting battery components or cables during the test, and at the same time enhances the stability and accuracy of the test, avoiding errors caused by looseness or poor contact. In addition, the modular design of the tooling makes it easy to disassemble, clean and maintain, prolongs its service life, simplifies the training process of operators, and reduces training costs. The tooling is also suitable for a variety of test scenarios. It can not only complete single cell voltage sampling, but also be used for other battery tests, which improves market applicability. Its reusable characteristics meet environmental protection requirements, reduce resource waste, and support customized design. It can be fine-tuned according to different battery types to meet diverse testing needs. These advantages make the tooling show obvious advantages in improving test efficiency, ensuring test quality, reducing costs and enhancing operational safety, and become an ideal solution for single cell voltage sampling test. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the use state of the present invention;

[0021] Figure 2 It is a schematic diagram of the structure of the test protection cover in the present invention;

[0022] Figure 3 It is a diagram of the installation state of the test protection cover in the present invention;

[0023] Figure 4 It is a structural schematic diagram of the test adapter clip in the present invention. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0025] In order to solve the problems of high cost, poor versatility, non-reusability and complicated operation of the rectangular electrical connector currently used in the single cell voltage sampling test, the present invention provides a special tool for single cell voltage sampling test. In order to further illustrate the structure of the present invention, the detailed description is as follows in conjunction with the accompanying drawings:

[0026] See also Figure 1-Figure 4A special tool for single cell voltage sampling test includes a test protection cover 1 and a test adapter 2. The test protection cover is an intermediate component connected to the test pad of the battery equalization board of the single cell, and the structural dimensions are designed for the test structure of the single cell. The structural limitations of the test adapter assembly are released through the targeted adaptation design of this component. The test adapter assembly is the mounting assembly of the test cable plug-in part.

[0027] The test protection cover is provided with a fastening hole 1-1 combined with the test part of the single cell and a positioning pin 1-2 for positioning the test adapter clip. Specifically, the test protection cover includes a protection cover body, the upper part of the protection cover body forms an opening for the test probe group to enter, the lower bottom of the protection cover body forms a guide hole 1-3 for guiding the test probe group, and the two sides of the protection cover body are provided with fastening holes and positioning pins. The positioning pin is a cylindrical straight rod extending in the upper and lower directions of the protection cover body, the lower end is used to position with the battery part, and the upper end is used to position the corresponding position of the test adapter clip. The test protection cover is designed to be detachable. Before the single cell voltage sampling test, it is fixed to the lithium-ion battery pack by an insulating fastening screw. After ensuring that the test probe is in accurate contact with the test pad of the ABU board of the single cell, the insulating fastening screw passing through the fastening hole is locked to fasten it to the battery.

[0028] The test adapter clamp includes an adapter test board 2-1, a test probe group 2-2, an adapter electrical connector 2-3 and a clamping component. The adapter test board is provided with a positioning hole 2-4 combined with a positioning pin. The test probe group is installed on the adapter test board. The adapter electrical connector is adapted to be connected with the test probe group and forms a plug structure for connecting the test cable. The clamping component is installed on the adapter test board and applies pressure to the adapter test board to make the test probe group press against the test part of the single cell. The rear adapter electrical connector is used as a carrier for connecting the front test probe group through the adapter test board, and the adapter electrical connector is electrically connected to the test probe group. The structural requirements for adapting to the test part of the single cable are met by a replaceable test protective cover. The test adapter clamp can be quickly assembled and disassembled by a simple clamping method, so that the tooling has high versatility, low use cost and higher operating efficiency.

[0029] Specifically, the front part of the transfer test board is a flat plate part, the test probe group is installed on the flat plate part and the axis of the probe is perpendicular to the plate surface of the flat plate part, and the positioning holes are provided on the flat plate part and are located on both sides of the test probe group. The transfer electrical connector is installed on the rear part of the transfer test board. There are 26 probes in the test probe group, which are arranged in three rows in parallel. The upper part of the test probe group is provided with a probe protection cap, which is installed above the test probe and is made of insulating material to ensure that the test probe has no short circuit risk.

[0030] The clamping component is installed at the rear of the adapter test board. The clamping component has two clamping plates 2-5 that form a clamping force. As known in the prior art, in a clamping plate type clamping component, the two clamping plates are connected by a rotating shaft. The rear of the clamping plate is a clamping part, and the front is a clamping part. The rotating shaft is installed with a spring or a similar elastic component that applies a clamping force. One of the clamping plates is connected to the adapter test board. Furthermore, the front of the other clamping plate of the clamping component is connected to an auxiliary clamping plate 2-6. The auxiliary clamping plate is located below the adapter test board and the front portion forms a test clamp with the flat plate portion of the adapter test board. As an accessory, the auxiliary clamping plate can be selected in specific size according to the specific model of the single battery.

[0031] A locking assembly is installed between the two clamping plates of the clamping component, and the locking assembly is used to lock the clamping component in the clamping state. The locking assembly includes a threaded pull rod 2-7 and a threaded sleeve rod 2-8, and the lower end of the threaded pull rod is connected to the auxiliary clamping plate. The threaded pull rod passes through the through hole set in the transfer test plate and is connected to the threaded sleeve rod by thread. There is a movable gap between the through hole of the transfer test plate and the threaded sleeve rod, and a threaded section is provided on the upper part of the threaded sleeve rod. The threaded sleeve rod is arranged above the transfer test plate, and the transfer test plate and the auxiliary clamping plate in the clamping state are locked by rotating the threaded sleeve rod.

[0032] How to use this tool:

[0033] C. Test operation process

[0034] The operation process of the special test tool for sampling and testing the single cell voltage proposed by the present invention includes the following steps:

[0035] Step 1: Fix the removable test protection cover on the battery by using the insulating fastening screws;

[0036] Step 2: Insert the auxiliary clamp of the test adapter clamp under the battery insulation cover, use the positioning holes on the test protection cover to position and clamp the adapter test board, and achieve accurate contact between the test probe group and the test pad of the battery balancing board;

[0037] Step 3: Tighten the locking assembly of the test adapter clip to ensure that the contact between the test probe set needle and the test pad is safe and reliable;

[0038] Step 4: Connect the test cable to the transfer electrical connector of the test transfer clip to sample the voltage of the single cell;

[0039] Step 5: After all single cell voltage tests are completed, remove the test protection cover, seal the ABU board test pads, and replace them with new insulation protection covers to ensure no short circuit risk.

[0040] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A special tool for sampling and testing single cell voltage, characterized by: Includes test protection cover and test adapter clip; The test protection cover is provided with a fastening hole for combining with the test part of the single battery and a positioning pin for positioning the test adapter clip; The test adapter clamp includes an adapter test board, a test probe group, an adapter electrical connector and a clamping component. The adapter test board is provided with a positioning hole combined with the positioning pin. The test probe group is installed on the adapter test board. The adapter electrical connector is adapted to be connected with the test probe group and forms a plug structure for connecting a test cable. The clamping component is installed on the adapter test board and applies pressure to the adapter test board so that the test probe group presses against the test part of the single cell.

2. The special tooling for sampling and testing single cell voltage according to claim 1, characterized in that: The test protection cover comprises a protection cover body, the upper part of which forms an opening for the test probe group to enter, the lower bottom of which forms a guide hole for guiding the test probe group, and the two sides of the protection cover body are provided with the fastening holes and positioning pins.

3. The special tooling for sampling and testing single cell voltage according to claim 1, characterized in that: The front part of the transfer test board is a flat plate part, the test probe group is installed on the flat plate part and the axis of the probe is perpendicular to the plate surface of the flat plate part, and the positioning holes are arranged in the flat plate part and located on both sides of the test probe group.

4. The special tooling for sampling and testing single cell voltage according to claim 3, characterized in that: The transfer electrical connector is installed at the rear of the transfer test board.

5. The special tooling for sampling and testing single cell voltage according to claim 4, characterized in that: The clamping component is installed at the rear of the transfer test board. The clamping component has two clamping plates that form a clamping force, and one of the clamping plates is connected to the transfer test board.

6. The special tooling for sampling and testing single cell voltage according to claim 5, characterized in that: A locking assembly is installed between the two clamping plates of the clamping component, and the locking assembly is used to lock the clamping component in a clamped state.

7. The special tooling for sampling and testing single cell voltage according to claim 6, characterized in that: The other front part of the clamping plate of the clamping component is connected to the auxiliary clamping plate, and the auxiliary clamping plate is located below the transfer test board and the front part and the flat plate part of the transfer test board form a test clamping opening.

8. The special tooling for sampling and testing single cell voltage according to claim 7, characterized in that: The locking assembly comprises a threaded rod and a threaded sleeve rod, the lower end of the threaded rod is connected to the auxiliary clamping plate, and the threaded rod passes through a through hole provided on the transfer test plate and is connected to the threaded sleeve rod via threads.

9. The special tooling for sampling and testing single cell voltage according to claim 1, characterized in that: A probe protection cap is provided on the upper part of the test probe group.

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