Direct-cooling battery pack test system and method and electronic equipment

Abstract

The invention relates to a direct-cooling battery pack test system and method and electronic equipment, and relates to the technical field of batteries. The system comprises a direct cooling battery pack, a battery pack direct cooling rack, a thermal management controller, a thermal management system and calibration equipment, the direct-cooling battery pack is respectively connected with the battery pack direct-cooling rack, the thermal management controller and the thermal management system; the thermal management controller is connected with the thermal management system; the calibration equipment is connected with the thermal management system; the battery pack direct cooling rack is used for controlling the charging and discharging current of the direct cooling battery pack; the calibration equipment is used for configuring a calibration physical quantity required by a target test working condition for the thermal management system; the thermal management controller is configured to obtain the actual outlet temperature of the direct-cooling battery pack under the target test working condition in the operation process of the thermal management system according to the calibration physical quantity; and controlling a thermal management system to execute a thermal management strategy of the direct-cooling battery pack based on the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature corresponding to the target test working condition.

Description

Technical Field

[0001] The present application relates to the technical field of batteries, and in particular to a direct-cooling battery pack test system, method and electronic device. Background Art

[0002] With the continuous development of new energy vehicle technology, the direct-cooling method for battery packs, as one of the key technologies to improve the thermal management efficiency of battery packs, accordingly, a special research bench for the direct-cooling system has emerged. In view of the fact that an air-conditioning system is integrated inside the vehicle and the dual requirements of both passenger comfort and efficient cooling of the battery pack need to be considered, most current direct-cooling system test benches adopt the design principle of the enthalpy difference method, that is, by precisely controlling the rotational speed of the compressor and the opening degree of the expansion valve, the performance of the cooling system of the battery pack is scanned and verified under all working conditions to meet the direct-cooling requirements of users and the battery.

[0003] In the related art, it is disclosed that through a refrigerant direct-cooling system, the superheat at the outlets of the air-conditioning evaporator and the battery evaporator is controlled to be stable at a preset temperature, and the thermocouple temperatures and pressure values of the battery, the air-conditioning and the pipeline are recorded to pre-check the refrigerant direct-cooling system and performance of the parallel connection of the battery and the air-conditioning. Another related art discloses that by connecting the VCU to be tested and the HIL bench, a simulation test environment for the management function of the vehicle control unit (VCU) is built, and according to the thermal management mode under each test condition, different test strategies are obtained, and a test control method for the simulation test environment is obtained. In the simulation test environment, according to the test control method and the test strategies, the test results of the thermal management function of the VCU are determined.

[0004] It can be seen that these two methods only consider determining the test results of the thermal management system based on different test strategies to improve the accuracy of the bench test method, and do not consider the problem of excessive calculation amount when determining different test strategies. Moreover, during the actual operation of the vehicle, the test conditions change with the operation of the vehicle, and for different test conditions, the test strategies cannot be switched in time, and thus the test results of the thermal management system cannot be accurately obtained, affecting the accuracy of the direct-cooling bench test method. Summary of the Invention

[0005] The purpose of the present invention is to provide a direct-cooling battery pack test system, method and electronic device, aiming to solve the technical problem of low accuracy during direct-cooling bench testing. To achieve the above purpose, the technical solutions adopted in the embodiments of the present application are as follows: In a first aspect, an embodiment of the present application provides a direct-cooling battery pack test system, which includes: a direct-cooling battery pack, a battery pack direct-cooling bench, a thermal management controller, a thermal management system, and a calibration device; wherein, the direct-cooling battery pack is respectively connected to the battery pack direct-cooling bench, the thermal management controller, and the thermal management system; the thermal management controller is connected to the thermal management system; the calibration device is connected to the thermal management system; the battery pack direct-cooling bench is used to control the charge and discharge current of the direct-cooling battery pack; the calibration device is used to configure the calibration physical quantities required for the target test conditions for the thermal management system; the thermal management controller is configured to obtain the actual outlet temperature of the direct-cooling battery pack under the target test conditions during the operation of the thermal management system according to the calibration physical quantities; and based on the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature corresponding to the target test conditions, control the thermal management system to execute the thermal management strategy of the direct-cooling battery pack.

[0006] According to the above technical means, a direct-cooling battery pack test system is built by using a direct-cooling battery pack, a battery pack direct-cooling bench, a thermal management controller, a thermal management system, and a calibration device. The charge and discharge current of the direct-cooling battery pack is controlled by the battery pack direct-cooling bench, and the calibration physical quantities required for the target test conditions are configured by the calibration device, which can realize the normal operation of the bench, enabling the direct-cooling battery pack test system to simulate the actual operating environment of the vehicle to the greatest extent and improve the accuracy of battery pack testing. In addition, during the operation of the thermal management system according to the calibration physical quantities, the target outlet temperature corresponding to the target test conditions is obtained by the thermal management controller, and the thermal management system is controlled to execute the thermal management strategy of the direct-cooling battery pack to simulate the operation process of the thermal management system in the vehicle, which can verify the performance of the thermal management system through the direct-cooling battery pack test system and reduce the cost of real vehicle testing. Thus, the direct-cooling battery pack test system provided by the present application can more completely simulate the environment of the whole vehicle and the working process of the battery pack, thereby improving the accuracy of battery pack testing.

[0007] In a possible implementation manner, the thermal management system includes a compressor and an expansion valve; the thermal management controller is configured to control the thermal management system to execute the thermal management strategy of the direct-cooling battery pack based on the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature corresponding to the target test conditions, including: when the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is greater than or equal to a preset threshold, gradually adjust the rotation speed of the compressor and the opening degree of the expansion valve until the set conditions are met; wherein, the set conditions include at least one of the following: the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is less than the preset threshold; the number of adjustment times is greater than or equal to the preset number of times.

[0008] According to the above technical means, the rotational speed of the compressor and the opening degree of the expansion valve can be automatically adjusted based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack. Compared with the solution in the related art where the rotational speed of the compressor and the opening degree of the expansion valve are set values, the present application maximally restores the actual operating environment of the vehicle and improves the accuracy of the test method. When the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack is less than the preset threshold, it indicates that the thermal management system can control the direct-cooled battery pack to be at the target outlet temperature. Or, if the direct-cooled battery pack is not at the target outlet temperature after the number of adjustments is greater than or equal to the preset number of times, it can reflect the performance of the thermal management system and improve the applicability of the test method.

[0009] In a possible implementation manner, the thermal management controller is configured to gradually adjust the rotational speed of the compressor and the opening degree of the expansion valve, including: during each adjustment, obtaining the actual outlet temperature of the direct-cooled battery pack at the current moment, and adjusting the rotational speed of the compressor and the opening degree of the expansion valve based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature.

[0010] According to the above technical means, by adjusting the rotational speed of the compressor and the opening degree of the expansion valve in real time based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature, the operating states of the direct-cooled battery pack and the thermal management system during the actual operation of the vehicle can be maximally restored, and the accuracy of the direct-cooled battery pack test system is improved.

[0011] In a possible implementation manner, the calibrated physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, maximum compressor power, cut-off valve enabled, charge and discharge mode of the direct-cooled battery pack.

[0012] According to the above technical means, calibrating the ambient temperature, vehicle speed, thermal management function enabled, maximum compressor power, cut-off valve enabled, and charge and discharge mode of the direct-cooled battery pack, and calibrating the actual operating data of the vehicle to simulate the actual operating process of the vehicle, thereby improving the accuracy of the direct-cooled battery pack test system.

[0013] In a possible implementation manner, a sensor group is provided at the inlet and outlet of the direct-cooled battery pack; the sensor group includes a pressure sensor and a temperature sensor.

[0014] According to the above technical means, by using the sensors to monitor the inlet and outlet temperatures and pressures of the direct-cooled battery pack in real time, the changes in the temperature and pressure of the battery pack during the operation of the thermal management system can be tracked in real time, thereby improving the precision of the direct-cooled battery pack test system.

[0015] In a possible implementation, the thermal management system includes a condenser, and a liquid flow meter is arranged at the outlet of the condenser to detect the liquid flow rate of the condenser.

[0016] According to the above technical means, by arranging a liquid flow meter at the outlet of the condenser to detect the liquid flow rate of the condenser, the liquid flow rate of the direct-cooling battery pack can be controlled more precisely, so as to more accurately control the thermal management system to execute the thermal management strategy.

[0017] In a possible implementation, the direct-cooling battery pack test system further includes a display device, and the display device is connected to the thermal management system; the display device is used to display at least one of the following: the operation data of the direct-cooling battery pack, the operation data of the thermal management system, the working state of the thermal management system, and the failure reason of the thermal management system.

[0018] According to the above technical means, by displaying the operation data of the direct-cooling battery pack, the operation data of the thermal management system, the working state of the thermal management system, and the failure principle of the thermal management system through the display device, the performance of the thermal management system can be intuitively presented to the user, facilitating the user to understand the state of the thermal management system in real time.

[0019] In a possible implementation, the direct-cooling battery pack test system further includes a vehicle controller; the twisted pair of the low-voltage communication line of the direct-cooling battery pack is connected in parallel to the vehicle controller; the ground wire of the vehicle controller is disconnected.

[0020] According to the above technical means, by connecting the twisted pair of the low-voltage communication line of the direct-cooling battery pack in parallel to the vehicle controller and disconnecting the ground wire of the vehicle controller, the vehicle controller is put into the sleep state, reducing the possibility of the direct-cooling battery pack malfunctioning when the direct-cooling battery pack test bench and the vehicle controller send signals to the direct-cooling battery pack simultaneously.

[0021] In a second aspect, an embodiment of the present application provides a method for testing a direct-cooling battery pack, which is applied to a thermal management controller in a direct-cooling battery pack test system. The method includes: during the operation of the thermal management system according to the calibrated physical quantities required by the target test condition, obtaining the actual outlet temperature of the direct-cooling battery pack under the target test condition; the calibrated physical quantities required by the target test condition are configured by a calibration device for the thermal management system; based on the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature corresponding to the target test condition, controlling the thermal management system to execute the thermal management strategy of the direct-cooling battery pack.

[0022] According to the above technical means, during the operation of the thermal management system according to the calibrated physical quantities required by the target test conditions, the target outlet temperature corresponding to the target test conditions is obtained. Based on the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature corresponding to the target test conditions, the thermal management system is controlled to execute the thermal management strategy of the direct-cooled battery pack, so as to simulate the operation process of the thermal management system in the vehicle. The performance of the thermal management system can be verified through the direct-cooled battery pack test system, and the cost of real vehicle testing is reduced. In this way, the direct-cooled battery pack test system provided by this application can more completely simulate the environment of the whole vehicle and the working process of the battery pack, thereby improving the accuracy of battery pack testing.

[0023] In a possible implementation, the thermal management system includes a compressor and an expansion valve; controlling the thermal management system to execute the thermal management strategy of the direct-cooled battery pack based on the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature corresponding to the target test conditions includes: when the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is greater than or equal to a preset threshold, gradually adjusting the rotational speed of the compressor and the opening degree of the expansion valve until the set conditions are met; where the set conditions include at least one of the following: the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than the preset threshold; the number of adjustments is greater than or equal to the preset number of times.

[0024] According to the above technical means, the rotational speed of the compressor and the opening degree of the expansion valve can be automatically adjusted based on the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature. Compared with the related art where the rotational speed of the compressor and the opening degree of the expansion valve are set values, this application maximally restores the real operating environment of the vehicle and improves the accuracy of the test method. When the condition that the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than the preset threshold is met, it indicates that the thermal management system can control the direct-cooled battery pack to be at the target outlet temperature. Or, after the number of adjustments is greater than or equal to the preset number of times, the direct-cooled battery pack is not yet at the target outlet temperature, which can reflect the performance of the thermal management system and improve the applicability of the test method.

[0025] In a possible implementation, gradually adjusting the rotational speed of the compressor and the opening degree of the expansion valve includes: during each adjustment, obtaining the actual outlet temperature of the direct-cooled battery pack at the current moment, and adjusting the rotational speed of the compressor and the opening degree of the expansion valve based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature.

[0026] According to the above technical means, based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature, the rotational speed of the compressor and the opening degree of the expansion valve are adjusted in real time, which can maximally restore the operating states of the direct-cooled battery pack and the thermal management system during the actual operation of the vehicle and improve the accuracy of the direct-cooled battery pack test system.

[0027] In a third aspect, an embodiment of the present application provides a direct-cooling battery pack testing device, including: an acquisition module and a control module; the acquisition module is configured to acquire the actual outlet temperature of the direct-cooling battery pack under a target test condition during the operation of the thermal management system according to the calibrated physical quantities required by the target test condition; the calibrated physical quantities required by the target test condition are configured by the calibration device for the thermal management system; the control module is configured to control the thermal management system to execute the thermal management strategy of the direct-cooling battery pack based on the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature corresponding to the target test condition.

[0028] In a possible implementation, the thermal management system includes a compressor and an expansion valve; specifically, the control module is configured to gradually adjust the rotational speed of the compressor and the opening degree of the expansion valve until a set condition is met when the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is greater than or equal to a preset threshold; wherein, the set condition includes at least one of the following: the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is less than the preset threshold; the number of adjustments is greater than or equal to a preset number.

[0029] In a possible implementation, the control module is specifically configured to acquire the actual outlet temperature of the direct-cooling battery pack at the current moment during each adjustment, and adjust the rotational speed of the compressor and the opening degree of the expansion valve based on the difference between the actual outlet temperature of the direct-cooling battery pack at the current moment and the target outlet temperature.

[0030] In a fourth aspect, an embodiment of the present application provides an electronic device, which includes: a processor and a memory; the memory stores instructions executable by the processor; when the processor is configured to execute the instructions, the electronic device implements the method of the second aspect described above.

[0031] In a fifth aspect, an embodiment of the present application provides a computer-readable storage medium, on which computer program instructions are stored, and when the computer program instructions are executed by a processor, the direct-cooling battery pack testing method of any one of the embodiments provided in the second aspect is implemented.

[0032] In a sixth aspect, an embodiment of the present application provides a computer program product, which includes computer program instructions, and when the computer program instructions are executed by a processor, the direct-cooling battery pack testing method of any one of the embodiments provided in the second aspect is implemented.

[0033] It should be noted that the technical effects brought by any one of the implementations in the third aspect to the sixth aspect can refer to the technical effects brought by the corresponding implementations in the first aspect and the second aspect, which will not be elaborated here.

[0034] It should be understood that the above general description and the following detailed description are merely exemplary and explanatory, and do not limit the present application. Description of the Drawings

[0035] The drawings herein are incorporated into the specification and form a part of this specification, showing embodiments consistent with the present application, and are used together with the specification to explain the principles of the present application, and do not constitute an improper limitation to the present application.

[0036] Figure 1 is a block diagram of a direct-cooling battery pack test system shown according to an exemplary embodiment; Figure 2 is a block diagram of a thermal management system shown according to an exemplary embodiment; Figure 3 is a block diagram of another direct-cooling battery pack test system shown according to an exemplary embodiment; Figure 4 is a flowchart of a direct-cooling battery pack test method shown according to an exemplary embodiment; Figure 5 is a block diagram of a direct-cooling battery pack test device shown according to an exemplary embodiment; Figure 6 is a block diagram of an electronic device shown according to an exemplary embodiment. Detailed Embodiments

[0037] In order to enable those of ordinary skill in the art to better understand the technical solutions of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.

[0038] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and do not have to be used to describe a specific order or sequence. It should be understood that such data may be interchanged under appropriate circumstances so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present application as detailed in the appended claims.

[0039] In the embodiments of the present application, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, such that a process, article or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, article or device. Without further limitation, an element defined by the phrase "comprising a..." does not exclude the presence of additional identical elements in the process, article or device comprising such element.

[0040] In the embodiments of the present application, words such as "exemplary" or "for example" are used to indicate examples, illustrations or explanations. Any embodiment or design described as "exemplary" or "for example" in the embodiments of the present application should not be construed as being more preferred or having more advantages than other embodiments or designs. Rather, the use of words such as "exemplary" or "for example" is intended to present relevant concepts in a specific manner.

[0041] The direct-cooling battery pack test system provided by the present application will be specifically introduced below in conjunction with the accompanying drawings.

[0042] In some embodiments, as Figure 1 shown, the direct-cooling battery pack test system includes: a direct-cooling battery pack 110, a battery pack direct-cooling bench 120, a thermal management controller 130, a thermal management system 140, and a calibration device 150; wherein, the direct-cooling battery pack 110 is respectively connected to the battery pack direct-cooling bench 120, the thermal management controller 130, and the thermal management system 140; the thermal management controller 130 is connected to the thermal management system 140; and the calibration device 150 is connected to the thermal management system 140.

[0043] As a feasible implementation, the battery pack direct-cooling bench 120 is used to control the charge and discharge current of the direct-cooling battery pack 110.

[0044] It should be understood that the battery pack direct-cooling bench 120 is connected to the low-voltage plug-in of the direct-cooling battery pack 110 to achieve communication between the direct-cooling battery pack 110 and the battery pack direct-cooling bench 120.

[0045] It should be noted that the battery pack direct-cooling bench 120 needs to obtain the maximum charge and discharge current of the direct-cooling battery pack 110 to prevent the charge and discharge current of the direct-cooling battery pack 110 from being too large, thereby affecting the service life of the direct-cooling battery pack 110.

[0046] As a feasible implementation, the battery pack direct-cooling bench 120 can be a bench with high-precision test capabilities and an open software architecture. For example, the battery pack direct-cooling bench 120 can be an AVL bench.

[0047] It should be understood that the AVL bench is equipped with a high-precision programmable DC power supply and an electronic load, which supports rapid adjustment of current or voltage. The AVL bench integrates a high-sampling-rate data acquisition module, which can monitor parameters such as the current, voltage, and temperature of the direct-cooling battery pack 110 in real time. In addition, the AVL bench supports the development of custom test scripts, and users can control the charge and discharge current of the direct-cooling battery pack 110 through custom test scripts.

[0048] It should be noted that the direct-cooling battery pack 110 is used to represent a battery pack that uses direct cooling technology for battery thermal management. The direct cooling technology uses a refrigerant to directly evaporate and absorb heat in the cooling plates or cooling channels inside the battery pack, thereby taking away the heat generated by the battery.

[0049] As a feasible implementation method, controlling the charge and discharge current of the direct-cooling battery pack 110 can make the direct-cooling battery pack 110 work under different test conditions. Among them, the test conditions can include: constant current charging condition, constant voltage charging condition, constant current discharging condition, constant power discharging condition, etc.

[0050] It should be understood that through the battery pack direct-cooling bench 120, the direct-cooling battery pack 110 is controlled to operate under different test conditions to simulate the actual operating environment of the vehicle, and then verify the test results of the thermal management system 140, improving the accuracy of the direct-cooling battery pack test system.

[0051] In some embodiments, the calibration device 150 is used to configure the calibration physical quantities required for the target test conditions for the thermal management system 140.

[0052] It can be understood that the calibration device 150 is a device for providing a virtual boundary for the thermal management system 140. If calibration physical quantities are configured, the calibration device 150 is a device or apparatus capable of calibrating physical quantities. Exemplarily, the calibration device 150 can be an Interactive Calibration and Measurement (INCA calibration system).

[0053] It should be noted that the INCA calibration system has high flexibility and scalability and can be customized according to different project requirements.

[0054] It should be understood that the thermal management system 140 is used to regulate the temperature of the direct-cooling battery pack 110 so that the direct-cooling battery pack 110 operates within the target temperature range to improve the performance, safety, and service life of the direct-cooling battery pack 110.

[0055] As a feasible implementation method, the calibrated physical quantities are essential for representing the target test conditions. For the physical quantities that are not set in the direct-cooling battery pack bench, the required physical quantities of the thermal management system 140 can be debugged based on the working state of the thermal management system 140 and combined with the fault codes of the thermal management system 140 to determine the physical quantities that must be calibrated. This application does not limit this.

[0056] It should be understood that the target test condition can be any one of at least one test condition to be tested.

[0057] The target test condition refers to a series of physical quantities and operating conditions (for example, the working mode of the direct-cooling battery pack) calibrated to evaluate the performance, safety, and reliability of the direct-cooling battery pack during the actual operation of the vehicle. The target test condition usually simulates the typical conditions that the battery pack may encounter in actual use to verify the effectiveness of the thermal management system.

[0058] As another feasible implementation method, the calibrated physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, maximum power of the compressor 141, cut-off valve enabled, charge and discharge mode of the direct-cooling battery pack 110.

[0059] It should be understood that the ambient temperature is used to represent the temperature of the external environment. The direct-cooling battery pack 110 generates heat during operation, and the thermal management system 140 is used to dissipate the heat to prevent the battery from overheating. The ambient temperature has a significant impact on the performance of the thermal management system 140. In the case of too high ambient temperature, the temperature difference of the thermal management system 140 decreases, resulting in a reduction in the heat conduction efficiency, which in turn causes the temperature of the direct-cooling battery pack 110 to be too high, affecting the performance and safety of the direct-cooling battery pack 110. Therefore, when testing the direct-cooling battery pack 110, it is necessary to calibrate the ambient temperature to facilitate restoring the operating environment of the vehicle.

[0060] The vehicle speed is used to represent the driving speed of the vehicle. The change in vehicle speed affects the air flow. As the vehicle speed increases, the air flow accelerates, thereby enhancing the heat dissipation efficiency and improving the cooling effect of the thermal management system 140. Therefore, when testing the direct-cooling battery pack 110, it is necessary to calibrate the vehicle speed to facilitate restoring the operating environment of the vehicle.

[0061] The thermal management function enabled is used to represent the state in which the thermal management system 140 is operating. When the thermal management function is enabled, the thermal management system 140 can control the direct-cooling battery pack 110 to operate within a certain range of the target temperature, effectively reducing the possibility of overheating of the direct-cooling battery pack 110. Based on this, when testing the direct-cooling battery pack 110, it is necessary to enable the thermal management function.

[0062] The maximum power of the compressor 141 is used to represent the maximum energy output that the compressor 141 can provide during operation. The maximum power of the compressor 141 directly affects the flow rate and pressure of the liquid in the thermal management system 140. If the maximum power of the compressor 141 is relatively high, the thermal management system 140 can provide a higher cooling effect, thereby better controlling the actual outlet temperature of the direct-cooled battery pack 110. Therefore, when conducting tests on the direct-cooled battery pack 110, it is necessary to calibrate the maximum power of the compressor 141 to detect the performance of the thermal management system 140.

[0063] The cut-off valve enabling is used to control the state of the cut-off valve. The cut-off valve is used to control the liquid flow rate flowing into the passenger compartment in the thermal management system 140, and can indirectly affect the cooling effect of the thermal management system 140 on the direct-cooled battery pack 110. When conducting tests on the direct-cooled battery pack 110, the cut-off valve needs to be in a power-off state.

[0064] The charge-discharge mode of the direct-cooled battery pack 110 is used to represent that the direct-cooled battery pack 110 is in the process of charging or discharging. During the discharge process of the direct-cooled battery pack 110, the influence of temperature on the discharge capacity of the direct-cooled battery pack 110 is more significant. Therefore, it is necessary to control the difference between the actual outlet temperature and the target temperature of the direct-cooled battery pack 110 to be smaller. Therefore, when conducting tests on the direct-cooled battery pack 110, it is necessary to determine the charge-discharge mode of the direct-cooled battery pack 110.

[0065] It can be understood that by calibrating the ambient temperature, vehicle speed, enabling of the thermal management function, maximum power of the compressor 141, cut-off valve enabling, and charge-discharge mode of the direct-cooled battery pack 110, and calibrating the actual vehicle operation data, the actual operation process of the vehicle is simulated, and the accuracy of the direct-cooled battery pack test system is improved.

[0066] As a feasible implementation method, the thermal management controller 130 is configured to obtain the actual outlet temperature of the direct-cooled battery pack 110 under the target test conditions during the operation of the thermal management system 140 according to the calibrated physical quantities; based on the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature corresponding to the target test conditions, control the thermal management system 140 to execute the thermal management strategy of the direct-cooled battery pack 110.

[0067] It should be understood that the thermal management system 140 operates according to the calibrated physical quantities, simulating the actual operation process of the vehicle to simulate the working process of the direct-cooled battery pack 110 and the thermal management system 140 in the vehicle.

[0068] As a feasible implementation method, the actual outlet temperature of the direct-cooled battery pack 110 refers to the actual outlet temperature of the liquid flowing out of the direct-cooled battery pack 110.

[0069] As another feasible implementation, the target outlet temperature of the direct-cooling battery pack 110 is used to represent the desired outlet temperature of the direct-cooling battery pack 110 when the charge and discharge current is determined, which can ensure that the direct-cooling battery pack 110 operates in an optimal state. It should be noted that when the direct-cooling battery pack 110 operates at different charge and discharge currents, the heat generation rate is different. The target outlet temperature of the direct-cooling battery pack 110 can be determined based on the heat balance principle. The greater the heat generation rate of the direct-cooling battery pack 110, the lower the target outlet temperature, so as to prevent the direct-cooling battery pack 110 from overheating.

[0070] It should be noted that the direct-cooling battery pack 110 has a corresponding target outlet temperature under the target test conditions. When the direct-cooling battery pack 110 operates at the target outlet temperature, the performance and service life of the direct-cooling battery pack 110 can be effectively improved. Therefore, the thermal management controller 130 can determine the thermal management strategy based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack 110, and then control the thermal management system 140 to execute the thermal management strategy of the direct-cooling battery pack 110, so that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack 110 is less than or equal to a preset threshold. The specific description of the preset threshold can be referred to the following steps and will not be elaborated here.

[0071] It can be understood that by building a direct-cooling battery pack test system with the direct-cooling battery pack 110, the battery pack direct-cooling bench 120, the thermal management controller 130, the thermal management system 140, and the calibration device 150, controlling the charge and discharge current of the direct-cooling battery pack 110 through the battery pack direct-cooling bench 120, and configuring the calibration physical quantities required for the target test conditions by the calibration device 150, the normal operation of the bench can be realized, so that the direct-cooling battery pack test system can simulate the actual operating environment of the vehicle to the greatest extent and improve the accuracy of the battery pack test. In addition, during the operation of the thermal management system 140 according to the calibration physical quantities, the target outlet temperature corresponding to the target test conditions is obtained through the thermal management controller 130, and the thermal management system 140 is controlled to execute the thermal management strategy of the direct-cooling battery pack 110 to simulate the operation process of the thermal management system 140 in the vehicle, so that the performance of the thermal management system 140 can be verified through the direct-cooling battery pack test system, and the cost of real vehicle testing is reduced. In this way, the direct-cooling battery pack test system provided by the present application can more completely simulate the environment of the whole vehicle and the working process of the battery pack, thereby improving the accuracy of the battery pack test.

[0072] In some embodiments, as Figure 1 shown, the thermal management system 140 includes a compressor 141 and an expansion valve 142.

[0073] Exemplarily, the compressor 141 is used to power the flow of the liquid in the thermal management system 140. The compressor 141 mechanically does work to compress the low-temperature and low-pressure liquid refrigerant into a high-temperature and high-pressure liquid refrigerant, thereby increasing the pressure and temperature of the liquid refrigerant, so that the liquid can smoothly release heat after passing through the condenser 143 to reduce the temperature of the direct-cooling battery pack 110.

[0074] Exemplarily, the expansion valve 142 is used to control the flow rate of the liquid refrigerant in the thermal management system 140 to adjust the actual outlet temperature of the direct-cooling battery pack 110.

[0075] As a feasible implementation manner, the thermal management controller 130 is configured to control the thermal management system 140 to execute the thermal management strategy of the direct-cooling battery pack 110 based on the actual outlet temperature of the direct-cooling battery pack 110 and the target outlet temperature corresponding to the target test condition, including: when the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack 110 is greater than or equal to a preset threshold, gradually adjust the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 until the set condition is met.

[0076] It should be understood that the preset threshold is the maximum difference between the outlet temperature that can maintain the direct-cooling battery pack 110 in the best operating state and the target outlet temperature. It should be noted that the preset threshold can be determined based on factors such as the characteristics of the direct-cooling battery pack 110 and the control accuracy of the thermal management system 140, and the present application does not limit this.

[0077] As a feasible implementation manner, the increase in the rotational speed of the compressor 141 can increase the compression amount of the liquid, thereby increasing the flow rate of the liquid to the direct-cooling battery pack 110. Therefore, there is a negative correlation between the rotational speed of the compressor 141 and the actual outlet temperature. The higher the rotational speed of the compressor 141, the lower the actual outlet temperature.

[0078] As another feasible implementation manner, the opening degree of the expansion valve 142 can directly determine the flow rate of the liquid flowing to the direct-cooling battery pack 110. There is a negative correlation between the opening degree of the expansion valve 142 and the actual outlet temperature. As the opening degree of the expansion valve 142 increases, the flow rate of the liquid flowing to the direct-cooling battery pack 110 increases, thereby reducing the actual outlet temperature of the direct-cooling battery pack 110.

[0079] It should be understood that as the direct-cooling battery pack 110 operates, heat is continuously generated, and the actual outlet temperature of the direct-cooling battery pack 110 is too high, resulting in the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack 110 being greater than or equal to the preset threshold. It is necessary to gradually increase the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 to increase the flow rate and flow velocity of the liquid coolant passing through the direct-cooling battery pack 110, thereby reducing the actual outlet temperature of the direct-cooling battery pack 110.

[0080] As a feasible implementation method, the set conditions include at least one of the following: Condition 1: The difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 is less than a preset threshold.

[0081] It should be understood that adjusting the opening degree of the expansion valve 142 and the rotational speed of the compressor 141 is to adjust the actual outlet temperature of the direct-cooled battery pack 110, so that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 is less than the preset threshold, and the direct-cooled battery pack 110 can operate in an optimal working state. Therefore, after the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 is less than the preset threshold, it indicates that the thermal management system 140 can quickly and effectively adjust the temperature of the direct-cooled battery pack 110.

[0082] Condition 2: The number of adjustments is greater than or equal to a preset number.

[0083] It should be understood that the preset number is the maximum number to prevent the direct-cooled battery pack 110 from being damaged due to changes in the outlet temperature.

[0084] It should be noted that when the actual outlet temperature of the direct-cooled battery pack 110 is greater than or equal to the preset threshold, the thermal management system 140 can quickly respond and adjust the rotational speed of the compressor 141 and the opening degree of the expansion valve 142, so that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 is less than the preset threshold, avoiding damage to the direct-cooled battery pack 110 due to continuous changes in the outlet temperature caused by multiple adjustments. After the number of adjustments is greater than or equal to the preset number, the thermal management system 140 may malfunction and fail to adjust the actual outlet temperature of the direct-cooled battery pack 110 in a timely manner. The malfunction may be caused by insufficient refrigeration or heating capacity, blockage of the liquid circulation pipeline, etc.

[0085] It can be understood that through the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110, the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 can be automatically adjusted, achieving the maximum degree of restoration of the actual operating environment of the vehicle and improving the accuracy of the test method. When the condition that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 is less than the preset threshold is met, it indicates that the thermal management system 140 can control the direct-cooled battery pack 110 to be at the target outlet temperature. Or, after the number of adjustments is greater than or equal to the preset number and the direct-cooled battery pack 110 is not yet at the target outlet temperature, it can reflect the performance of the thermal management system 140 and improve the applicability of the test method.

[0086] As another feasible implementation, the thermal management controller 130 is configured to gradually adjust the rotational speed of the compressor 141 and the opening degree of the expansion valve 142, including: during each adjustment process, obtaining the actual outlet temperature of the direct-cooled battery pack 110 at the current moment, and adjusting the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 at the current moment.

[0087] It should be understood that in order to achieve precise control of the outlet temperature of the direct-cooled battery pack 110, it is necessary to continuously adjust the rotational speed of the compressor 141 and the opening degree of the expansion valve 142. During each adjustment process, it is necessary to compare the actual outlet temperature of the direct-cooled battery pack 110 at the current moment with the target outlet temperature. If the actual outlet temperature at the current moment is greater than the target outlet temperature, and the difference between the actual outlet temperature and the target outlet temperature at the current moment is greater than or equal to the preset threshold, increase the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 to reduce the actual outlet temperature. If the actual outlet temperature at the current moment is less than the target outlet temperature, and the difference between the actual outlet temperature and the target outlet temperature at the current moment is greater than or equal to the preset threshold, decrease the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 to increase the actual outlet temperature.

[0088] It can be understood that by adjusting the rotational speed of the compressor 141 and the opening degree of the expansion valve 142 in real time based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110, the operating states of the direct-cooled battery pack 110 and the thermal management system 140 during the actual operation of the vehicle can be restored to the greatest extent, improving the accuracy of the direct-cooled battery pack test system.

[0089] In some embodiments, a sensor group is provided at the inlet and outlet of the direct-cooled battery pack 110.

[0090] As a feasible implementation, the sensor group includes a pressure sensor and a temperature sensor.

[0091] It should be noted that in order to obtain the inlet and outlet temperature and pressure of the direct-cooled battery pack 110 in real time, a sensor group is provided at the inlet and outlet of the direct-cooled battery pack 110 to facilitate the determination of the thermal management strategy.

[0092] It should be understood that since the direct-cooling battery pack test system is a high-voltage system, and the direct-cooling battery pack 110 and the expansion valve 142 can be integrated into a combined component with no pipelines in between, custom pipelines and corresponding tooling are required to set up the sensor group at the inlet and outlet of the direct-cooling battery pack 110. Moreover, since the pressure sensors and temperature sensors are newly added devices, the data of the pressure sensors and temperature sensors can be collected by the enthalpy difference test bench. It should be noted that the custom pipelines and corresponding tooling are determined based on the structure of the thermal management system 140, and the present application does not limit this.

[0093] In some embodiments, the pressure sensors and temperature sensors are newly added devices, and new equipment is needed to collect the data of the pressure sensors and temperature sensors. The new equipment can be a conventional enthalpy difference test bench.

[0094] It can be understood that by using sensors to monitor the inlet and outlet temperature and pressure of the direct-cooling battery pack 110 in real time, the changes in the temperature and pressure of the battery pack during the operation of the thermal management system 140 can be tracked in real time, thereby improving the accuracy of the direct-cooling battery pack test system.

[0095] In some embodiments, as Figure 1 shown, the thermal management system 140 further includes a condenser 143.

[0096] As a feasible implementation method, a liquid flow meter is provided at the outlet of the condenser 143 to detect the liquid flow rate of the condenser 143.

[0097] It should be understood that the liquid flow rate of the condenser 143 is used to represent the volume or mass of the refrigerant liquid passing through the condenser 143 per unit time, and the liquid flow rate of the condenser 143 can directly affect the pressure of the thermal management system 140. If the liquid flow rate of the condenser 143 is too small, the pre-cooling in the condenser 143 cannot be cooled in time, resulting in an increase in the pressure of the thermal management system 140; if the liquid flow rate of the condenser 143 is too large, the pressure of the thermal management system 140 may be too low, leading to unstable pressure of the thermal management system 140, affecting the normal operation of equipment such as the compressor 141, and further affecting the normal operation of the thermal management system 140.

[0098] It can be understood that by providing a liquid flow meter at the outlet of the condenser 143 to detect the liquid flow rate of the condenser 143, the liquid flow rate of the direct-cooling battery pack 110 can be controlled more precisely, thereby more accurately controlling the thermal management system 140 to execute the thermal management strategy.

[0099] As a feasible implementation method, as Figure 2As shown, the compressor 141 is connected to the expansion valve 142 through the condenser 143. The expansion valve 142 is connected to the direct-cooling battery pack 110 and is used to control the flow rate of the liquid entering the direct-cooling battery pack 110. A sensor group is arranged at the inlet and outlet of the direct-cooling battery pack 110 for detecting the inlet and outlet temperature and pressure of the direct-cooling battery pack 110. A liquid flow meter and a liquid storage tank are arranged at the outlet of the condenser 143. The liquid flow meter is used to detect the liquid flow rate of the condenser 143. When the direct-cooling battery pack 110 is operating at a low load or a large amount of liquid refrigerant is not required, the excess liquid can be stored in the liquid storage tank for subsequent use. In addition, a stop valve is connected in parallel with the expansion valve 142, and the stop valve is used to control the liquid entering the evaporator to control the temperature of the passenger compartment.

[0100] In some embodiments, as Figure 3 shown, the direct-cooling battery pack test system further includes a display device 160.

[0101] As a feasible implementation manner, the display device 160 is connected to the thermal management system 140; the display device 160 is used to display at least one of the following: the operation data of the direct-cooling battery pack 110, the operation data of the thermal management system 140, the working state of the thermal management system 140, and the failure reason of the thermal management system 140.

[0102] Exemplarily, the operation data of the direct-cooling battery pack 110 may include: the highest temperature of the direct-cooling battery pack 110, the lowest temperature of the direct-cooling battery pack 110, the remaining power of the direct-cooling battery pack 110, the voltage of the direct-cooling battery pack 110, the current of the direct-cooling battery pack 110, the actual outlet temperature of the direct-cooling battery pack 110, the outlet pressure of the direct-cooling battery pack 110, and the outlet superheat degree of the direct-cooling battery pack 110, etc.

[0103] Exemplarily, the operation data of the thermal management system 140 may include: the rotation speed of the compressor 141, the opening degree of the expansion valve 142, and the highest pressure of the thermal management system 140.

[0104] Exemplarily, the working state of the thermal management system 140 may include: the stop valve state, the enable signal of the compressor 141, and the working mode of the thermal management system 140. Among them, when the stop valve state is the closed state, the thermal management system 140 only controls the temperature of the direct-cooling battery pack 110.

[0105] Exemplarily, the failure reason of the thermal management system 140 may include: the reason for the shutdown of the compressor 141.

[0106] It should be noted that the display device 160 is a device or equipment that can visually display the operation data. Exemplarily, the display device 160 may be a conventional enthalpy difference test bench for displaying test results.

[0107] It can be understood that by displaying the operating data of the direct-cooled battery pack 110, the operating data of the thermal management system 140, the working status of the thermal management system 140, and the fault principle of the thermal management system 140 through the display device 160, the performance of the thermal management system 140 can be visually presented to the user, facilitating the user to understand the status of the thermal management system 140 in real time.

[0108] In some embodiments, as shown in Table 1, the direct-cooled battery pack test system provided in the present application can configure calibrated physical quantities through the calibration device 150 and can also display test results through the display device 160.

[0109] Table 1: Calibrated Physical Quantities and Test Results

[0110] In some embodiments, as Figure 3 shown, the direct-cooled battery pack test system further includes a vehicle controller 170.

[0111] As a feasible implementation method, the twisted pair wires of the low-voltage communication line of the direct-cooled battery pack 110 are connected in parallel to the vehicle controller 170; the ground wire of the vehicle controller 170 is disconnected.

[0112] It should be understood that the direct-cooled battery pack 110 is simultaneously connected and communicates with the vehicle controller 170 and the battery pack direct-cooling bench 120. When the vehicle controller 170 and the battery pack direct-cooling bench 120 communicate with the direct-cooled battery pack 110 simultaneously, it will cause the direct-cooled battery pack 110 to be unable to identify the specific signal direction, resulting in the direct-cooled battery pack 110 being unable to enter the target test condition. To solve the above problems, it is necessary to connect the twisted pair wires of the low-voltage communication line of the direct-cooled battery pack 110 in parallel to the vehicle controller 170, and at the same time disconnect the ground wire of the vehicle controller 170, so that the vehicle controller 170 is in a sleep state and unable to send signals to the direct-cooled battery pack 110. Based on this, the battery pack direct-cooling bench 120 can interact with the direct-cooled battery pack 110. At the same time, the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack 110 can be sent to the thermal management controller 130, and the thermal management controller 130 controls the thermal management system 140 to execute the thermal management strategy of the direct-cooled battery pack 110, realizing the automatic control of the outlet temperature of the direct-cooled battery pack 110.

[0113] It can be understood that connecting the twisted pair wires of the low-voltage communication line of the direct-cooled battery pack 110 in parallel to the vehicle controller 170 and disconnecting the ground wire of the vehicle controller 170 makes the vehicle controller 170 in a sleep state, reducing the possibility of the direct-cooled battery pack 110 malfunctioning when the battery pack direct-cooling bench 120 and the vehicle controller 170 send signals to the direct-cooled battery pack 110 simultaneously.

[0114] In some embodiments, the direct cooling battery pack testing method provided by the present application can be applied to a thermal management controller in a direct cooling battery pack testing system as shown in Figure 1 shown, as shown in Figure 4 shown, the method includes the following steps: S401. During the operation of the thermal management system according to the calibrated physical quantities required for the target test condition, obtain the actual outlet temperature of the direct cooling battery pack under the target test condition.

[0115] Among them, the calibrated physical quantities required for the target test condition are configured by the calibration device for the thermal management system.

[0116] It should be understood that the target test condition can be any one of at least one test condition to be tested.

[0117] The target test condition refers to a series of physical quantities and operating conditions (for example, the operating mode of the direct cooling battery pack) calibrated in order to evaluate the performance, safety, and reliability of the direct cooling battery pack during actual vehicle operation. The target test condition usually simulates typical conditions that the battery pack may encounter during actual use to verify the effectiveness of the thermal management system.

[0118] As another feasible implementation manner, the calibrated physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, maximum compressor power, cut-off valve enabled, charge and discharge mode of the direct cooling battery pack.

[0119] As a feasible implementation manner, the actual outlet temperature of the direct cooling battery pack is used for the actual outlet temperature of the liquid flowing out of the direct cooling battery pack.

[0120] S402. Based on the actual outlet temperature of the direct cooling battery pack and the target outlet temperature corresponding to the target test condition, control the thermal management system to execute the thermal management strategy of the direct cooling battery pack.

[0121] As another feasible implementation manner, the target outlet temperature of the direct cooling battery pack is used to represent the expected outlet temperature of the direct cooling battery pack under the condition that the charge and discharge current is determined, which can ensure that the direct cooling battery pack operates in the best state. It should be noted that when the direct cooling battery pack works under different charge and discharge currents, the heat generation rate is different. The target outlet temperature of the direct cooling battery pack can be determined based on the heat balance principle. The greater the heat generation rate of the direct cooling battery pack, the lower the target outlet temperature to prevent the direct cooling battery pack from overheating.

[0122] It should be noted that the direct-cooling battery pack has a corresponding target outlet temperature under the target test condition. When the direct-cooling battery pack operates at the target outlet temperature, the performance and service life of the direct-cooling battery pack can be effectively improved. Therefore, the thermal management controller can determine the thermal management strategy based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack, and then control the thermal management system to execute the thermal management strategy of the direct-cooling battery pack, so that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is less than or equal to the preset threshold. The specific description of the preset threshold can refer to the following steps and will not be elaborated here.

[0123] It can be understood that during the operation of the thermal management system according to the calibrated physical quantities required by the target test condition, the target outlet temperature corresponding to the target test condition is obtained. Based on the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature corresponding to the target test condition, the thermal management system is controlled to execute the thermal management strategy of the direct-cooling battery pack to simulate the operation process of the thermal management system in the vehicle. The performance of the thermal management system can be verified through the direct-cooling battery pack test system, and the cost of real vehicle testing is reduced. In this way, the direct-cooling battery pack test system provided by the present application can more completely simulate the environment of the whole vehicle and the working process of the battery pack, thereby improving the accuracy of battery pack testing.

[0124] In some embodiments, the thermal management system includes a compressor and an expansion valve.

[0125] As a feasible implementation manner, the above step S402 can be specifically implemented as: when the difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is greater than or equal to the preset threshold, gradually adjust the rotation speed of the compressor and the opening degree of the expansion valve until the set conditions are met.

[0126] As a feasible implementation manner, the increase in the rotation speed of the compressor can compress the liquid, thereby increasing the liquid flow rate to the direct-cooling battery pack. Therefore, the rotation speed of the compressor is negatively correlated with the actual outlet temperature. The higher the rotation speed of the compressor, the lower the actual outlet temperature.

[0127] As another feasible implementation manner, the opening degree of the expansion valve can directly determine the liquid flow rate to the direct-cooling battery pack. The opening degree of the expansion valve is negatively correlated with the actual outlet temperature. As the opening degree of the expansion valve increases, the liquid flow rate to the direct-cooling battery pack increases, thereby reducing the actual outlet temperature of the direct-cooling battery pack.

[0128] Among them, the set conditions include at least one of the following: Condition a: The difference between the actual outlet temperature and the target outlet temperature of the direct-cooling battery pack is less than the preset threshold.

[0129] It should be understood that adjusting the opening degree of the expansion valve and the rotational speed of the compressor is to adjust the actual outlet temperature of the direct-cooled battery pack, so that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack is less than the preset threshold, and the direct-cooled battery pack can operate in the best working state. Therefore, after the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack is less than the preset threshold, it indicates that the thermal management system can quickly and effectively adjust the temperature of the direct-cooled battery pack.

[0130] Condition b: The number of adjustments is greater than or equal to the preset number.

[0131] It should be understood that the preset number is the maximum number to prevent the direct-cooled battery pack from being damaged due to changes in the outlet temperature.

[0132] It can be understood that through the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack, the rotational speed of the compressor and the opening degree of the expansion valve can be automatically adjusted to achieve the maximum degree of restoration of the vehicle's real operating environment and improve the accuracy of the test method. When the condition that the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack is less than the preset threshold is met, it indicates that the thermal management system can control the direct-cooled battery pack at the target outlet temperature. Or, after the number of adjustments is greater than or equal to the preset number and the direct-cooled battery pack is not at the target outlet temperature yet, it can reflect the performance of the thermal management system and improve the applicability of the test method.

[0133] In some embodiments, the above "gradually adjusting the rotational speed of the compressor and the opening degree of the expansion valve" can be specifically implemented as follows: During each adjustment process, obtain the actual outlet temperature of the direct-cooled battery pack at the current moment, and based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature, adjust the rotational speed of the compressor and the opening degree of the expansion valve.

[0134] It should be understood that in order to achieve precise control of the outlet temperature of the direct-cooled battery pack, it is necessary to continuously adjust the rotational speed of the compressor and the opening degree of the expansion valve. During each adjustment process, it is necessary to make a comparison based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature. If the actual outlet temperature at the current moment is greater than the target outlet temperature and the difference between the actual outlet temperature and the target outlet temperature at the current moment is greater than or equal to the preset threshold, increase the rotational speed of the compressor and the opening degree of the expansion valve to reduce the actual outlet temperature. If the actual outlet temperature at the current moment is less than the target outlet temperature and the difference between the actual outlet temperature and the target outlet temperature at the current moment is greater than or equal to the preset threshold, decrease the rotational speed of the compressor and the opening degree of the expansion valve to increase the actual outlet temperature.

[0135] It can be understood that by adjusting the rotational speed of the compressor and the opening degree of the expansion valve in real time based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack at the current moment, the operating states of the direct-cooled battery pack and the thermal management system during the actual operation of the vehicle can be restored to the greatest extent, improving the accuracy of the direct-cooled battery pack test system.

[0136] The above mainly introduced the solution provided by the embodiments of the present application from the perspective of methods. To implement the above functions, the direct-cooled battery pack test device or electronic device includes the corresponding hardware structures and / or software modules for executing each function. Those skilled in the art should easily realize that, combined with the units and algorithm steps of each example described in the embodiments disclosed herein, the present application can be implemented in the form of hardware or a combination of hardware and computer software. Whether a certain function is executed in the way of hardware or computer software driving hardware depends on the specific application and design constraints of the technical solution. Professional technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of the present application.

[0137] The embodiments of the present application can, according to the above method, exemplarily divide the functions of the direct-cooled battery pack test device or electronic device. For example, the direct-cooled battery pack test device or electronic device can include each function module corresponding to each function division, or two or more functions can be integrated into one processing module. The above integrated module can be implemented in the form of hardware or in the form of a software function module. It should be noted that the division of modules in the embodiments of the present application is illustrative, only a logical function division, and there can be other division methods in actual implementation.

[0138] Referring to Figure 5 , the direct-cooled battery pack test device 500 includes: an acquisition module 501 and a control module 502; the acquisition module 501 is configured to acquire the actual outlet temperature of the direct-cooled battery pack under the target test condition during the operation of the thermal management system according to the calibrated physical quantities required by the target test condition; the calibrated physical quantities required by the target test condition are configured by the calibration device for the thermal management system; the control module 502 is configured to control the thermal management system to execute the thermal management strategy of the direct-cooled battery pack based on the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature corresponding to the target test condition.

[0139] In a possible implementation, the thermal management system includes a compressor and an expansion valve; the control module 502 is specifically configured to gradually adjust the rotational speed of the compressor and the opening degree of the expansion valve until a set condition is met when the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack is greater than or equal to a preset threshold; wherein, the set condition includes at least one of the following: the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack is less than the preset threshold; the number of adjustments is greater than or equal to the preset number of times.

[0140] In a possible implementation, the control module 502 is specifically configured to, during each adjustment, obtain the actual outlet temperature of the direct-cooled battery pack at the current moment, and adjust the rotational speed of the compressor and the opening degree of the expansion valve based on the difference between the actual outlet temperature and the target outlet temperature of the direct-cooled battery pack at the current moment.

[0141] Figure 6 is a block diagram of an electronic device shown according to an exemplary embodiment. As Figure 6 shown, the electronic device 600 includes, but is not limited to: a processor 601 and a memory 602.

[0142] Among them, the above-mentioned memory 602 is used to store the executable instructions of the above-mentioned processor 601. It can be understood that the above-mentioned processor 601 is configured to execute instructions to implement the direct-cooled battery pack test method in the above-mentioned embodiment.

[0143] It should be noted that those skilled in the art can understand that Figure 6 the structure of the electronic device shown in Figure 6 does not constitute a limitation on the electronic device. The electronic device may include more or fewer components than

[0144] shown, or combine certain components, or have different component arrangements.

[0145] The memory 602 can be used to store software programs and various data. The memory 602 mainly includes a program storage area and a data storage area. Among them, the program storage area can store an operating system, application programs required by at least one functional module (such as a determination unit, a processing unit, etc.). In addition, the memory 602 can include high-speed random access memory and can also include non-volatile memory, such as at least one magnetic disk storage device, a flash memory device, or other volatile solid-state storage devices.

[0146] In an exemplary embodiment, there is also provided a computer-readable storage medium including instructions, such as the memory 602 including instructions. The above instructions can be executed by the processor 601 of the electronic device 600 to implement the direct-cooling battery pack test method in the above embodiment.

[0147] In actual implementation, Figure 5 the functions of the acquisition module 501 and the control module 502 in Figure 6 can both be implemented by the processor 601 in

[0148] calling a computer program stored in the memory 602. The specific execution process can refer to the description of the method part in the above embodiment and will not be elaborated here.

[0149] Optionally, the computer-readable storage medium can be a non-transitory computer-readable storage medium. For example, the non-transitory computer-readable storage medium can be a read-only memory (ROM), a random access memory (RAM), a CD-ROM, a magnetic tape, a floppy disk, and an optical data storage device, etc.

[0149] In an exemplary embodiment, the embodiment of the present application also provides a computer program product including one or more instructions. The one or more instructions can be executed by the processor 601 of the electronic device to complete the direct-cooling battery pack test method in the above embodiment.

[0150] It should be noted that when the instructions in the above computer-readable storage medium or the one or more instructions in the computer program product are executed by the processor of the electronic device, each process of the above method embodiment is implemented, and the same technical effects as the above method can be achieved. To avoid repetition, it will not be elaborated here.

[0151] Through the description of the above embodiments, those skilled in the art can clearly understand that for the convenience and brevity of description, only the above division of each functional module is used as an example. In actual applications, the above functions can be allocated to different functional modules according to needs, that is, the internal structure of the device is divided into different functional modules to complete all or part of the functions described above.

[0152] In several embodiments provided in the present application, it should be understood that the disclosed devices and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of modules or units is only a logical function division. In actual implementation, there may be other division methods. For example, multiple units or components can be combined or integrated into another device, or some features can be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections between each other can be through some interfaces. The indirect couplings or communication connections of devices or units can be in electrical, mechanical or other forms.

[0153] The units described as separate components may or may not be physically separated. The components displayed as units may be one physical unit or multiple physical units, that is, they can be located in one place, or they can be distributed to multiple different places. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0154] In addition, in each embodiment of the present application, the functional units can be integrated in a processing unit, or each unit can exist physically alone, or two or more units can be integrated in one unit. The above-mentioned integrated units can be implemented in the form of hardware or in the form of software functional units.

[0155] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a readable storage medium. Based on such an understanding, the technical solution of the embodiments of the present application, in essence, or the part that contributes to the prior art, or all or part of this technical solution, can be embodied in the form of a software product. This software product is stored in a storage medium and includes several instructions for causing a device (which can be a single-chip microcomputer, a chip, etc.) or a processor to execute all or part of the steps of the methods in the various embodiments of the present application. The foregoing storage medium includes: various media such as USB flash drives, mobile hard disks, ROM, RAM, magnetic disks or optical discs that can store program codes.

[0156] The above is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions within the technical scope disclosed in the present application should be covered by the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A direct-cooling battery pack test system, characterized in that, Including: A direct-cooling battery pack, a direct-cooling battery pack bench, a thermal management controller, a thermal management system, and a calibration device; the thermal management system includes the rotational speed of a compressor and the opening degree of an expansion valve; wherein, the direct-cooling battery pack is respectively connected to the direct-cooling battery pack bench, the thermal management controller, and the thermal management system; the thermal management controller is connected to the thermal management system; the calibration device is connected to the thermal management system; The direct-cooling battery pack bench is used to control the charging and discharging current of the direct-cooling battery pack; The calibration device is used to configure the calibration physical quantities required for the target test condition for the thermal management system; wherein, the calibration physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, maximum compressor power, cut-off valve enabled, charging and discharging mode of the direct-cooling battery pack; The thermal management controller is configured to obtain the actual outlet temperature of the direct-cooling battery pack under the target test condition during the operation of the thermal management system according to the calibration physical quantities; in the case where the difference between the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature is greater than or equal to a preset threshold, gradually adjust the rotational speed of the compressor and the opening degree of the expansion valve until the set conditions are met; wherein, the set conditions include at least one of the following: The difference between the actual outlet temperature of the direct-cooling battery pack and the target outlet temperature is less than the preset threshold; The number of adjustment times is greater than or equal to a preset number of times.

2. The direct-cooling battery pack testing system according to claim 1, wherein The thermal management controller is configured to gradually adjust the rotational speed of the compressor and the opening degree of the expansion valve, including: During each adjustment, obtain the actual outlet temperature of the direct-cooling battery pack at the current moment, and adjust the rotational speed of the compressor and the opening degree of the expansion valve based on the difference between the actual outlet temperature of the direct-cooling battery pack at the current moment and the target outlet temperature.

3. The direct-cooling battery pack testing system according to claim 1, wherein Sensor groups are arranged at the inlet and outlet of the direct-cooling battery pack; the sensor groups include pressure sensors and temperature sensors.

4. The direct-cooling battery pack test system according to claim 1, wherein The thermal management system includes a condenser, and a liquid flow meter is arranged at the outlet of the condenser for detecting the liquid flow of the condenser.

5. The direct-cooling battery pack test system according to claim 1, wherein The direct-cooling battery pack test system further includes a display device, and the display device is connected to the thermal management system; The display device is used to display at least one of the following: the operation data of the direct-cooling battery pack, the operation data of the thermal management system, the working state of the thermal management system, the cause of the failure of the thermal management system.

6. The direct-cooling battery pack testing system according to claim 1, wherein The direct-cooling battery pack test system further includes a vehicle controller; the twisted pair of the low-voltage communication line of the direct-cooling battery pack is connected in parallel to the vehicle controller; the ground wire of the vehicle controller is disconnected.

7. A direct cooling battery pack testing method, characterized in that, A thermal management controller applied to the direct-cooling battery pack test system according to any one of claims 1 to 6, the thermal management system includes a compressor and an expansion valve; the method includes: During the operation of the thermal management system according to the calibrated physical quantities required for the target test condition, obtain the actual outlet temperature of the direct-cooled battery pack under the target test condition; the calibrated physical quantities required for the target test condition are configured for the thermal management system by the calibration device; wherein, the calibrated physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, maximum compressor power, stop valve enabled, charge and discharge mode of the direct-cooled battery pack. When the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is greater than or equal to a preset threshold, gradually adjust the rotational speed of the compressor and the opening degree of the expansion valve until the set conditions are met; wherein, the set conditions include at least one of the following: The difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than the preset threshold. The number of adjustment times is greater than or equal to a preset number of times.

8. The direct-cooling battery pack testing method according to claim 7, wherein The gradually adjusting the rotational speed of the compressor and the opening degree of the expansion valve includes: During each adjustment, obtain the actual outlet temperature of the direct-cooled battery pack at the current moment, and based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature, adjust the rotational speed of the compressor and the opening degree of the expansion valve.

9. An electronic device, characterized in that, It includes a processor and a memory, and the processor is coupled to the memory; the memory is used to store computer instructions, and the computer instructions are loaded and executed by the processor to enable the computer device to implement the direct-cooled battery pack test method according to any one of claims 7 to 8.

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