Direct-cooling battery pack testing system, method and electronic equipment

Abstract

The present application relates to a direct-cooling battery pack test system, method and electronic equipment, and relates to the field of battery technology. The system includes: a direct-cooling battery pack, a battery pack direct-cooling test bench, a thermal management controller, a thermal management system and a calibration device; the direct-cooling battery pack is respectively connected to the battery pack direct-cooling test 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 test 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 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 condition during the operation of the thermal management system according to the calibration physical quantities; 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.

Description

Technical Field

[0001] The present application relates to the field of battery technology, and in particular to a direct-cooling battery pack testing system, method, and electronic equipment. Background Art

[0002] With the continuous development of new energy vehicle technology, direct cooling of battery packs has become one of the key technologies to improve the thermal management efficiency of battery packs. Based on this, special research benches for direct cooling systems have also emerged. In view of the air-conditioning system integrated into the car and the dual needs of passenger comfort and efficient cooling of the battery pack need to be taken into account, most of the current direct cooling system test benches adopt the enthalpy difference method design principle, that is, by precisely controlling the compressor speed and the opening of the expansion valve, the battery pack cooling system is scanned and verified under all working conditions to meet the direct cooling needs of users and batteries.

[0003] Related technologies disclose using a refrigerant direct cooling system to stabilize the outlet superheat of the air conditioner and battery evaporators at a preset temperature. Thermocouple temperatures and pressures of the battery, air conditioner, and piping are recorded to pre-calibrate the refrigerant direct cooling system and performance of the battery and air conditioner in parallel. Another related technology discloses connecting the VCU to be tested to a HIL test bench to create a simulated test environment for the vehicle control unit (VCU) management function. Based on the thermal management mode under various test conditions, different test strategies are developed, along with a test control method for the simulated test environment. Within the simulated test environment, the test results of the VCU's thermal management function are determined based on the test control method and test strategy.

[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, but do not consider the problem of excessive computational complexity when determining different test strategies. Moreover, during the actual operation of the vehicle, the test conditions change with the operation of the vehicle. It is impossible to switch the test strategy in time for different test conditions, and thus it is impossible to accurately obtain the test results of the thermal management system, which affects 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 equipment to solve the technical problem of low accuracy during direct cooling bench testing.

[0006] In order to achieve the above objectives, the technical solutions adopted in the embodiments of the present application are as follows:

[0007] In a first aspect, an embodiment of the present application provides a direct-cooled battery pack testing system, which includes: a direct-cooled battery pack, a battery pack direct-cooling test bench, a thermal management controller, a thermal management system and a calibration device; wherein the direct-cooled battery pack is respectively connected to the battery pack direct-cooling test 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 test bench is used to control the charge and discharge current of the direct-cooled battery pack; the calibration device is used to configure the calibration physical quantities required for the target test condition for the thermal management system; the thermal management controller is configured to obtain 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 calibration physical quantities; based on the actual outlet temperature of the direct-cooled 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-cooled battery pack.

[0008] According to the above technical means, a direct-cooled battery pack test system is built by using a direct-cooled battery pack, a battery pack direct-cooling test bench, a thermal management controller, a thermal management system and a calibration device. The charge and discharge current of the direct-cooled battery pack is controlled by the battery pack direct-cooling test bench, and the calibration device configures the calibration physical quantities required for the target test conditions, which can achieve normal operation of the test bench, so that the direct-cooled battery pack test system can simulate the actual operating environment of the vehicle to the greatest extent, thereby improving the accuracy of the battery pack test. In addition, in the process of the thermal management system operating according to the calibration physical quantities, the target outlet temperature corresponding to the target test condition is obtained through the thermal management controller, and the thermal management system is controlled to execute the thermal management strategy of the direct-cooled 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-cooled battery pack test system, reducing the cost of actual vehicle testing. In this way, the direct-cooled battery pack test system provided by the present application can more completely simulate the environment of the entire vehicle and the working process of the battery pack, thereby improving the accuracy of the battery pack test.

[0009] In one possible embodiment, 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-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, including: 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 speed of the compressor and the opening 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 a preset threshold; the number of adjustments is greater than or equal to a preset number.

[0010] According to the above-mentioned technical means, the compressor speed and expansion valve opening 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 to the scheme in the related art where the compressor speed and expansion valve opening are set values, this application achieves the greatest restoration of the vehicle's actual operating environment, improving the accuracy of the test method. If the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than a preset threshold, it indicates that the thermal management system is capable of controlling the direct-cooled battery pack to the target outlet temperature. Alternatively, if the direct-cooled battery pack is not at the target outlet temperature after a preset number of adjustments, it can reflect the performance of the thermal management system and improve the applicability of the test method.

[0011] In one possible implementation, the thermal management controller is configured to gradually adjust the speed of the compressor and the opening of the expansion valve, including: during each adjustment process, obtaining the actual outlet temperature of the direct-cooled battery pack at the current moment, and adjusting the speed of the compressor and the opening 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.

[0012] 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 speed of the compressor and the opening of the expansion valve are adjusted in real time, which can restore the operating status of the direct-cooled battery pack and the thermal management system during the actual operation of the vehicle to the greatest extent, and improve the accuracy of the direct-cooled battery pack test system.

[0013] In one possible implementation, the calibrated physical quantity includes at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, compressor maximum power, shutoff valve enabled, and direct-cooling battery pack charge and discharge mode.

[0014] Based on the above technical means, the ambient temperature, vehicle speed, thermal management function activation, compressor maximum power, shut-off valve enable, and direct-cooled battery pack charge and discharge mode are calibrated, and the actual vehicle operation data is calibrated to simulate the actual operation process of the vehicle and improve the accuracy of the direct-cooled battery pack test system.

[0015] In a possible implementation, a sensor group is provided at the inlet and outlet of the direct-cooling battery pack; the sensor group includes a pressure sensor and a temperature sensor.

[0016] According to the above technical means, the inlet and outlet temperatures and pressures of the direct-cooled battery pack are monitored in real time by sensors, and 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 accuracy of the direct-cooled battery pack test system.

[0017] In a possible implementation, the thermal management system includes a condenser, and a liquid flow meter is provided at an outlet of the condenser to detect the liquid flow of the condenser.

[0018] According to the above technical means, a liquid flow meter is set at the outlet of the condenser to detect the liquid flow of the condenser, which can more accurately control the liquid flow of the direct-cooled battery pack, thereby more accurately controlling the thermal management system to execute the thermal management strategy.

[0019] In one possible implementation, the direct-cooled battery pack testing system also includes a display device, which is connected to the thermal management system; the display device is used to display at least one of the following: operating data of the direct-cooled battery pack, operating data of the thermal management system, working status of the thermal management system, and cause of failure of the thermal management system.

[0020] According to the above technical means, the operating data of the direct-cooled battery pack, the operating data of the thermal management system, the working status of the thermal management system and the failure principle of the thermal management system are displayed through the display device, which can intuitively show the performance of the thermal management system to the user, making it convenient for the user to understand the status of the thermal management system in real time.

[0021] In one possible implementation, the direct-cooled battery pack testing system further includes a vehicle controller; the twisted pair of the low-voltage communication line of the direct-cooled battery pack is connected in parallel to the vehicle controller; and the ground wire of the vehicle controller is disconnected.

[0022] According to the above technical means, the twisted pair of the low-voltage communication line of the direct-cooled battery pack is connected in parallel to the vehicle controller, and the ground wire of the vehicle controller is disconnected, so that the vehicle controller is in a dormant state, reducing the possibility of failure of the direct-cooled battery pack when the battery pack direct-cooling test bench and the vehicle controller send signals to the direct-cooled battery pack at the same time.

[0023] In the second aspect, an embodiment of the present application provides a direct-cooled battery pack testing method, which is applied to a thermal management controller in a direct-cooled battery pack testing system. The method includes: obtaining 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 calibration physical quantities required for the target test condition; the calibration physical quantities required for the target test condition are configured by the calibration equipment for the thermal management system; based on the actual outlet temperature of the direct-cooled 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-cooled battery pack.

[0024] According to the above technical means, during the operation of the thermal management system according to the calibrated physical quantities required for 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-cooled 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-cooled battery pack to simulate the operation process of the thermal management system in the vehicle. The direct-cooled battery pack test system can verify the performance of the thermal management system and reduce the cost of actual vehicle testing. In this way, the direct-cooled battery pack test system provided by this application can more completely simulate the environment of the entire vehicle and the working process of the battery pack, thereby improving the accuracy of the battery pack test.

[0025] In one possible implementation, the thermal management system includes a compressor and an expansion valve; based on the actual outlet temperature of the direct-cooled 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-cooled battery pack, including: 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 speed of the compressor and the opening 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 a preset threshold; the number of adjustments is greater than or equal to a preset number.

[0026] According to the above-mentioned technical means, the compressor speed and expansion valve opening 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 to the scheme in the related art where the compressor speed and expansion valve opening are set values, this application achieves the greatest restoration of the vehicle's actual operating environment, improving the accuracy of the test method. If the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than a preset threshold, it indicates that the thermal management system is capable of controlling the direct-cooled battery pack to the target outlet temperature. Alternatively, if the direct-cooled battery pack is not at the target outlet temperature after a preset number of adjustments, it can reflect the performance of the thermal management system and improve the applicability of the test method.

[0027] In one possible implementation, the speed of the compressor and the opening of the expansion valve are gradually adjusted, including: during each adjustment process, obtaining the actual outlet temperature of the direct-cooled battery pack at the current moment, and adjusting the speed of the compressor and the opening 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.

[0028] 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 speed of the compressor and the opening of the expansion valve are adjusted in real time, which can restore the operating status of the direct-cooled battery pack and the thermal management system during the actual operation of the vehicle to the greatest extent, and improve the accuracy of the direct-cooled battery pack test system.

[0029] In a third aspect, an embodiment of the present application provides a direct-cooled battery pack testing device, including: an acquisition module and a control module; the acquisition module is used to obtain 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 calibration physical quantity required for the target test condition; the calibration physical quantity required for the target test condition is configured by the calibration equipment for the thermal management system; the control module is used 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.

[0030] In one possible implementation, the thermal management system includes a compressor and an expansion valve; the control module is specifically used to gradually adjust the speed of the compressor and the opening of the expansion valve until the set conditions are met 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; 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 a preset threshold; the number of adjustments is greater than or equal to a preset number.

[0031] In one possible implementation, the control module is specifically used to obtain the actual outlet temperature of the direct-cooled battery pack at the current moment during each adjustment process, and adjust the speed of the compressor and the opening 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.

[0032] In a fourth aspect, an embodiment of the present application provides an electronic device, comprising: 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 above.

[0033] In a fifth aspect, an embodiment of the present application provides a computer-readable storage medium having computer program instructions stored thereon. When the computer program instructions are executed by a processor, the direct-cooling battery pack testing method of any embodiment provided in the second aspect above is implemented.

[0034] In a sixth aspect, an embodiment of the present application provides a computer program product, which includes computer program instructions. When the computer program instructions are executed by a processor, they implement the direct-cooling battery pack testing method of any embodiment provided in the second aspect above.

[0035] It should be noted that the technical effects brought about by any implementation method in the third to sixth aspects can be referred to the technical effects brought about by the corresponding implementation methods in the first and second aspects, and will not be repeated here.

[0036] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The drawings herein are incorporated into and constitute a part of the specification, illustrate embodiments consistent with the present application, and together with the specification are used to explain the principles of the present application, and do not constitute an improper limitation on the present application.

[0038] Figure 1 is a block diagram of a direct-cooling battery pack testing system according to an exemplary embodiment;

[0039] Figure 2 is a block diagram of a thermal management system according to an exemplary embodiment;

[0040] Figure 3 is a block diagram showing another direct-cooling battery pack testing system according to an exemplary embodiment;

[0041] Figure 4 is a flow chart showing a method for testing a direct-cooling battery pack according to an exemplary embodiment;

[0042] Figure 5 is a block diagram of a direct-cooling battery pack testing device according to an exemplary embodiment;

[0043] Figure 6 It is a block diagram of an electronic device according to an exemplary embodiment. DETAILED DESCRIPTION

[0044] In order to enable ordinary people 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.

[0045] It should be noted that the terms "first," "second," and the like in the specification and claims of this application and the accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or precedence. It should be understood that the terms used in this manner are interchangeable where appropriate so that the embodiments of the application described herein can be implemented in an order other than those illustrated or described herein. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application. Instead, they are merely examples of apparatus and methods consistent with certain aspects of the present application, as detailed in the appended claims.

[0046] In the embodiments of the present application, the terms "comprises," "comprising," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, article, or device comprising a series of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, article, or device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not preclude the presence of other identical elements in the process, article, or device comprising the element.

[0047] In the embodiments of this application, words such as "exemplary" or "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described as "exemplary" or "for example" in the embodiments of this application should not be interpreted as being preferred or advantageous over other embodiments or designs. Rather, the use of words such as "exemplary" or "for example" is intended to present the relevant concepts in a concrete manner.

[0048] The direct-cooling battery pack testing system provided in this application is described in detail below with reference to the accompanying drawings.

[0049] In some embodiments, as Figure 1 As shown, the direct-cooled battery pack test system includes: a direct-cooled battery pack 110, a battery pack direct-cooling test bench 120, a thermal management controller 130, a thermal management system 140 and a calibration device 150; wherein, the direct-cooled battery pack 110 is respectively connected to the battery pack direct-cooling test 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.

[0050] As a feasible implementation method, the battery pack direct cooling stand 120 is used to control the charge and discharge current of the direct cooling battery pack 110 .

[0051] It should be understood that the battery pack direct cooling rack 120 is connected to the low-voltage connector of the direct-cooled battery pack 110 to achieve communication between the direct-cooled battery pack 110 and the battery pack direct cooling rack 120 .

[0052] It should be noted that the battery pack direct cooling rack 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 .

[0053] As a feasible implementation method, the battery pack direct cooling test bench 120 can be a test bench with high-precision testing capabilities and an open software architecture. For example, the battery pack direct cooling test bench 120 can be an AVL test bench.

[0054] It should be understood that the AVL test bench is equipped with a high-precision programmable DC power supply and electronic load, supporting rapid current or voltage regulation. The AVL test bench also integrates a high-sampling-rate data acquisition module, enabling real-time monitoring of parameters such as current, voltage, and temperature of the direct-cooled battery pack 110. Furthermore, the AVL test bench supports the development of custom test scripts, allowing users to control the charge and discharge currents of the direct-cooled battery pack 110.

[0055] It should be noted that the direct-cooled battery pack 110 is used to represent a battery pack that uses direct cooling technology to perform thermal management on the battery. The direct cooling technology uses the refrigerant to directly evaporate in the cooling plate or cooling channel inside the battery pack to absorb heat, thereby taking away the heat generated by the battery.

[0056] As a feasible implementation method, controlling the charge and discharge current of the direct-cooled battery pack 110 can enable the direct-cooled battery pack 110 to operate under different test conditions, wherein the test conditions may include: constant current charging conditions, constant voltage charging conditions, constant current discharging conditions, constant power discharging conditions, etc.

[0057] It should be understood that the direct-cooled battery pack 110 is controlled to operate under different test conditions through the battery pack direct-cooling test bench 120 to simulate the actual operating environment of the vehicle, thereby verifying the test results of the thermal management system 140 and improving the accuracy of the direct-cooled battery pack test system.

[0058] In some embodiments, the calibration device 150 is used to calibrate physical quantities required for configuring a target test condition for the thermal management system 140 .

[0059] It can be understood that the calibration device 150 is a device used to provide a virtual boundary for the thermal management system 140. If a calibration physical quantity is configured, the calibration device 150 is a device or apparatus capable of calibrating the physical quantity. Exemplarily, the calibration device 150 can be an interactive calibration and measurement system (INteractive Calibration and Measurement, INCA calibration system).

[0060] It should be noted that the INCA calibration system is highly flexible and scalable, and can be customized according to different project requirements.

[0061] It should be understood that the thermal management system 140 is used to regulate the temperature of the direct-cooled battery pack 110 so that the direct-cooled battery pack 110 operates within a target temperature range to improve the performance, safety, and service life of the direct-cooled battery pack 110 .

[0062] As a feasible implementation method, calibrated physical quantities are used to represent physical quantities that are essential under the target test conditions, but are not set by the battery pack direct cooling test bench. Based on the operating status of the thermal management system 140 and the fault codes of the thermal management system 140, the required physical quantities of the thermal management system 140 can be debugged to determine the physical quantities that must be calibrated. This application does not impose any restrictions on this.

[0063] It should be understood that the target test condition may be any one of the at least one test condition.

[0064] Target test conditions are a set of physical quantities and operating conditions (e.g., the operating mode of a direct-cooled battery pack) calibrated to evaluate the performance, safety, and reliability of a direct-cooled battery pack during actual vehicle operation. These conditions typically simulate typical operating conditions a battery pack might encounter in actual use to verify the effectiveness of the thermal management system.

[0065] 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, shut-off valve enabled, and direct-cooling battery pack 110 charge and discharge mode.

[0066] It should be understood that the term "ambient temperature" refers to the temperature of the external environment. The direct-cooled battery pack 110 generates heat during operation, and the thermal management system 140 is responsible for dissipating this heat to prevent battery overheating. Ambient temperature significantly impacts the performance of the thermal management system 140. When the ambient temperature is too high, the temperature differential within the thermal management system 140 decreases, reducing heat transfer efficiency and, consequently, causing the direct-cooled battery pack 110 to overheat, impacting its performance and safety. Therefore, when testing the direct-cooled battery pack 110, it is necessary to calibrate the ambient temperature to facilitate reconstructing the vehicle's operating environment.

[0067] The vehicle speed is used to indicate the vehicle's driving speed. Changes in the vehicle speed will affect the flow of air. 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-cooled battery pack 110, the vehicle speed needs to be calibrated to facilitate the restoration of the vehicle's operating environment.

[0068] The thermal management function is enabled to indicate that the thermal management system 140 is in operation. When the thermal management function is enabled, the thermal management system 140 can control the direct-cooled battery pack 110 to operate within a certain range of the target temperature, effectively reducing the possibility of overheating of the direct-cooled battery pack 110. Therefore, the thermal management function must be enabled when testing the direct-cooled battery pack 110.

[0069] Compressor 141 maximum power represents the maximum energy output that compressor 141 can provide during operation. This power directly affects the flow and pressure of the liquid in thermal management system 140. A higher maximum power of compressor 141 allows thermal management system 140 to provide a higher cooling effect, thereby better controlling the actual outlet temperature of the direct-cooled battery pack 110. Therefore, when testing a direct-cooled battery pack 110, it is necessary to calibrate compressor 141 maximum power to verify the performance of thermal management system 140.

[0070] The shut-off valve is enabled to control the state of the shut-off valve. The shut-off valve is used to control the flow of liquid from the thermal management system 140 to the passenger compartment, which can indirectly affect the cooling effect of the thermal management system 140 on the direct-cooled battery pack 110. When testing the direct-cooled battery pack 110, the shut-off valve needs to be in the power-off state.

[0071] The charge and discharge mode of the direct-cooled battery pack 110 is used to indicate that the direct-cooled battery pack 110 is in the charging or discharging process. 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 of the direct-cooled battery pack 110 and the target temperature to be smaller. Therefore, when testing the direct-cooled battery pack 110, it is necessary to determine the charge and discharge mode of the direct-cooled battery pack 110.

[0072] It can be understood that the ambient temperature, vehicle speed, thermal management function activation, maximum power of the compressor 141, shut-off valve enable, and charging and discharging mode of the direct-cooled battery pack 110 are calibrated, and the actual operation data of the vehicle is calibrated to simulate the actual operation process of the vehicle and improve the accuracy of the direct-cooled battery pack test system.

[0073] 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 quantity; based on the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature corresponding to the target test conditions, the thermal management system 140 is controlled to execute the thermal management strategy of the direct-cooled battery pack 110.

[0074] It should be understood that the thermal management system 140 operates according to calibrated physical quantities to simulate 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.

[0075] As a feasible implementation method, the actual outlet temperature of the directly-cooled battery pack 110 is used as the actual outlet temperature of the liquid flowing out of the directly-cooled battery pack 110 .

[0076] As another feasible implementation, the target outlet temperature of the direct-cooled battery pack 110 is used to represent the desired outlet temperature of the direct-cooled battery pack 110 under a certain charge and discharge current, thereby ensuring that the direct-cooled battery pack 110 operates in an optimal state. It should be noted that the direct-cooled battery pack 110 generates heat at different rates when operating under different charge and discharge currents. The target outlet temperature of the direct-cooled battery pack 110 can be determined based on the principle of thermal balance. The greater the heat generation rate of the direct-cooled battery pack 110, the lower the target outlet temperature, thereby preventing overheating of the direct-cooled battery pack 110.

[0077] It should be noted that the direct-cooled battery pack 110 has a corresponding target outlet temperature under the target test conditions. When the direct-cooled battery pack 110 operates at the target outlet temperature, the performance and service life of the direct-cooled 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 of the direct-cooled battery pack 110 and the target outlet temperature, and then control the thermal management system 140 to execute the thermal management strategy of the direct-cooled battery pack 110, so that the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature is less than or equal to the preset threshold. The specific description of the preset threshold can be referred to the following steps and is not repeated here.

[0078] It can be understood that a direct-cooled battery pack test system is constructed by using the direct-cooled battery pack 110, the battery pack direct-cooling test bench 120, the thermal management controller 130, the thermal management system 140 and the calibration equipment 150. The battery pack direct-cooling test bench 120 controls the charge and discharge current of the direct-cooled battery pack 110, and the calibration equipment 150 configures the calibration physical quantities required for the target test conditions, which can achieve normal operation of the test bench, so that the direct-cooled battery pack test system can simulate the actual operating environment of the vehicle to the greatest extent, thereby improving 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 condition 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-cooled battery pack 110 to simulate the operation process of the thermal management system 140 in the vehicle. The performance of the thermal management system 140 can be verified through the direct-cooled battery pack test system, thereby reducing the cost of actual vehicle testing. In this way, the direct-cooling battery pack testing system provided in this application can more completely simulate the environment of the entire vehicle and the working process of the battery pack, thereby improving the accuracy of the battery pack testing.

[0079] In some embodiments, as Figure 1 As shown, the thermal management system 140 includes a compressor 141 and an expansion valve 142 .

[0080] Exemplarily, the compressor 141 is used to provide power flow for the liquid in the thermal management system 140. The compressor 141 compresses the low-temperature, low-pressure liquid refrigerant into a high-temperature, high-pressure liquid refrigerant through mechanical work, 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-cooled battery pack 110.

[0081] Exemplarily, the expansion valve 142 is used to control the flow of the liquid refrigerant in the thermal management system 140 to adjust the actual outlet temperature of the direct-cooled battery pack 110 .

[0082] As a feasible implementation method, the thermal management controller 130 is configured to control the thermal management system 140 to execute the thermal management strategy of the direct-cooled battery pack 110 based on the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature corresponding to the target test condition, including: when the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature is greater than or equal to a preset threshold, gradually adjusting the speed of the compressor 141 and the opening of the expansion valve 142 until the set conditions are met.

[0083] It should be understood that the preset threshold is the maximum difference between the outlet temperature and the target outlet temperature that can maintain optimal operation of the direct-cooled battery pack 110. It should be noted that the preset threshold can be determined based on factors such as the characteristics of the direct-cooled battery pack 110 and the control accuracy of the thermal management system 140, and this application does not limit this.

[0084] As a feasible implementation method, increasing the speed of the compressor 141 can compress the liquid, thereby increasing the flow rate of the liquid to directly cool the battery pack 110. Therefore, there is a negative correlation between the speed of the compressor 141 and the actual outlet temperature. The higher the speed of the compressor 141, the lower the actual outlet temperature.

[0085] As another feasible implementation method, the opening of the expansion valve 142 can directly determine the liquid flow flowing to the direct-cooled battery pack 110. The opening of the expansion valve 142 is negatively correlated with the actual outlet temperature. As the opening of the expansion valve 142 increases, the liquid flow flowing to the direct-cooled battery pack 110 increases, thereby reducing the actual outlet temperature of the direct-cooled battery pack 110.

[0086] It should be understood that as the direct-cooled battery pack 110 operates, heat is continuously generated, and the actual outlet temperature of the direct-cooled battery pack 110 is too high, resulting in the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature being greater than or equal to the preset threshold. It is necessary to gradually increase the speed of the compressor 141 and the opening of the expansion valve 142 to increase the flow rate and flow velocity of the liquid coolant through the direct-cooled battery pack 110, thereby reducing the actual outlet temperature of the direct-cooled battery pack 110.

[0087] As a feasible implementation method, the setting conditions include at least one of the following:

[0088] 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.

[0089] It should be understood that the purpose of adjusting the opening of the expansion valve 142 and the 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 of the direct-cooled battery pack 110 and the target outlet temperature is less than the preset threshold value, and the direct-cooled battery pack 110 can operate in the best working state. Therefore, after the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature is less than the preset threshold value, it means that the thermal management system 140 can quickly and effectively adjust the temperature of the direct-cooled battery pack 110.

[0090] Condition 2: The number of adjustments is greater than or equal to the preset number.

[0091] It should be understood that the preset number of times is the maximum number of times to prevent the direct-cooled battery pack 110 from being damaged due to changes in outlet temperature.

[0092] It should be noted that when the actual outlet temperature of the direct-cooled battery pack 110 is greater than or equal to a preset threshold, the thermal management system 140 can quickly respond and adjust the speed of the compressor 141 and the opening of the expansion valve 142 so that the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature is less than the preset threshold, thereby preventing the direct-cooled battery pack 110 from being damaged by multiple adjustments and the constant fluctuation of the outlet temperature. After the number of adjustments exceeds the preset number, the thermal management system 140 may malfunction, resulting in the inability to timely adjust the actual outlet temperature of the direct-cooled battery pack 110. The malfunction may be caused by insufficient cooling or heating capacity, a blockage in the liquid circulation pipe, or other reasons.

[0093] It can be understood that the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature can be used to automatically adjust the speed of the compressor 141 and the opening of the expansion valve 142, achieving the greatest possible reproduction of the vehicle's actual operating environment and improving the accuracy of the testing method. If the difference between the actual outlet temperature of the direct-cooled battery pack 110 and the target outlet temperature is less than a preset threshold, it indicates that the thermal management system 140 is capable of controlling the direct-cooled battery pack 110 to maintain the target outlet temperature. Alternatively, if the direct-cooled battery pack 110 still does not reach the target outlet temperature after a preset number of adjustments, it can reflect the performance of the thermal management system 140 and improve the applicability of the testing method.

[0094] As another feasible implementation method, the thermal management controller 130 is configured to gradually adjust the speed of the compressor 141 and the opening 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 speed of the compressor 141 and the opening of the expansion valve 142 based on the difference between the actual outlet temperature of the direct-cooled battery pack 110 at the current moment and the target outlet temperature.

[0095] 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 speed of the compressor 141 and the opening 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 at the current moment and the target outlet temperature is greater than or equal to the preset threshold, the speed of the compressor 141 and the opening of the expansion valve 142 are increased 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 at the current moment and the target outlet temperature is greater than or equal to the preset threshold, the speed of the compressor 141 and the opening of the expansion valve 142 are reduced to increase the actual outlet temperature.

[0096] It can be understood that based on the difference between the actual outlet temperature of the direct-cooled battery pack 110 at the current moment and the target outlet temperature, the speed of the compressor 141 and the opening of the expansion valve 142 are adjusted in real time, which can restore the operating status of the direct-cooled battery pack 110 and the thermal management system 140 during the actual operation of the vehicle to the greatest extent, and improve the accuracy of the direct-cooled battery pack test system.

[0097] In some embodiments, sensor groups are provided at the inlet and outlet of the direct-cooling battery pack 110 .

[0098] As a feasible implementation manner, the sensor group includes a pressure sensor and a temperature sensor.

[0099] It should be noted that in order to obtain the inlet and outlet temperatures and pressures of the direct-cooled battery pack 110 in real time, sensor groups are set at the inlet and outlet of the direct-cooled battery pack 110 to facilitate determining the thermal management strategy.

[0100] It should be understood that since the direct-cooled battery pack test system is a high-voltage system, and the direct-cooled battery pack 110 and expansion valve 142 can be integrated into a single assembly without any intervening piping, installing sensor groups at the inlet and outlet of the direct-cooled battery pack 110 requires customized piping and corresponding tooling. Furthermore, since the pressure sensor and temperature sensor are newly added equipment, their data can be collected by an enthalpy difference test bench. It should be noted that the customized piping and corresponding tooling are determined based on the structure of the thermal management system 140 and are not limited in this application.

[0101] In some embodiments, the pressure sensor and the temperature sensor are newly added devices, and newly added devices are required to collect data from the pressure sensor and the temperature sensor. The newly added devices may be conventional enthalpy difference test benches.

[0102] It can be understood that by using sensors to monitor the inlet and outlet temperatures and pressures of the direct-cooled 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-cooled battery pack test system.

[0103] In some embodiments, as Figure 1 As shown, the thermal management system 140 also includes a condenser 143 .

[0104] As a feasible implementation method, a liquid flow meter is provided at the outlet of the condenser 143 to detect the liquid flow of the condenser 143 .

[0105] It should be understood that the liquid flow rate of condenser 143 represents the volume or mass of refrigerant liquid passing through condenser 143 per unit time. The liquid flow rate of condenser 143 can directly affect the pressure of thermal management system 140. If the liquid flow rate of condenser 143 is too low, the preheat in condenser 143 cannot be cooled in time, resulting in an increase in the pressure of thermal management system 140. If the liquid flow rate of condenser 143 is too high, the pressure of thermal management system 140 may be too low, resulting in unstable pressure of thermal management system 140, which may affect the normal operation of equipment such as compressor 141 and, in turn, the normal operation of thermal management system 140.

[0106] It is understandable that setting a liquid flow meter at the outlet of the condenser 143 to detect the liquid flow of the condenser 143 can more accurately control the liquid flow of the direct-cooled battery pack 110, thereby more accurately controlling the thermal management system 140 to execute the thermal management strategy.

[0107] As a feasible implementation method, Figure 2As shown, the compressor 141 is connected to the expansion valve 142 through the condenser 143, and the expansion valve 142 is connected to the direct-cooled battery pack 110 to control the flow of liquid entering the direct-cooled battery pack 110. A sensor group is set at the inlet and outlet of the direct-cooled battery pack 110 to detect the inlet and outlet temperatures and pressures of the direct-cooled battery pack 110. A liquid flow meter and a liquid storage tank are set at the outlet of the condenser 143. The liquid flow meter is used to detect the liquid flow of the condenser 143. When the direct-cooled battery pack 110 is in low-load operation or a large amount of liquid refrigerant is not needed, 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.

[0108] In some embodiments, as Figure 3 As shown, the direct-cooling battery pack testing system further includes a display device 160 .

[0109] As a feasible implementation method, 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 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 cause of the failure of the thermal management system 140.

[0110] Exemplarily, the operating data of the direct-cooled battery pack 110 may include: the maximum temperature of the direct-cooled battery pack 110, the minimum temperature of the direct-cooled battery pack 110, the remaining power of the direct-cooled battery pack 110, the voltage of the direct-cooled battery pack 110, the current of the direct-cooled battery pack 110, the actual outlet temperature of the direct-cooled battery pack 110, the outlet pressure of the direct-cooled battery pack 110 and the outlet overheating of the direct-cooled battery pack 110, etc.

[0111] For example, the operating 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 maximum pressure of the thermal management system 140 .

[0112] Exemplarily, the operating state of the thermal management system 140 may include: a shutoff valve state, an enable signal of the compressor 141 , and an operating mode of the thermal management system 140 . When the shutoff valve is closed, the thermal management system 140 only controls the temperature of the direct-cooled battery pack 110 .

[0113] For example, the failure cause of the thermal management system 140 may include: the compressor 141 is shut down.

[0114] It should be noted that the display device 160 is a device or equipment that can intuitively display operating data. For example, the display device 160 can be a conventional enthalpy difference test bench for displaying test results.

[0115] 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 failure principle of the thermal management system 140 through the display device 160, the performance of the thermal management system 140 can be intuitively displayed to the user, making it convenient for the user to understand the status of the thermal management system 140 in real time.

[0116] In some embodiments, as shown in Table 1, the direct-cooling battery pack testing system provided in the present application can configure the calibrated physical quantities through the calibration device 150, and can also display the test results through the display device 160.

[0117] Table 1: Calibrated physical quantities and test results

[0118]

[0119] In some embodiments, as Figure 3 As shown, the direct-cooling battery pack testing system also includes a vehicle controller 170 .

[0120] As a feasible implementation method, the twisted pair of the low-voltage communication line of the direct-cooled battery pack 110 is connected in parallel to the vehicle controller 170; and the ground wire of the vehicle controller 170 is disconnected.

[0121] It should be understood that the direct-cooled battery pack 110 is simultaneously connected and communicating with the vehicle controller 170 and the battery pack direct-cooling test bench 120. When the vehicle controller 170 and the battery pack direct-cooling test bench 120 simultaneously communicate to the direct-cooled battery pack 110, the direct-cooled battery pack 110 will be unable to identify the specific signal direction, resulting in the direct-cooled battery pack 110 being unable to enter the target test conditions. To solve this problem, it is necessary to connect the twisted pair 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 dormant state and cannot send signals to the direct-cooled battery pack 110. Based on this, the battery pack direct cooling stand 120 and the direct cooling battery pack 110 can interact. At the same time, the actual outlet temperature and target outlet temperature of the direct cooling battery pack 110 can be sent to the thermal management controller 130. The thermal management controller 130 controls the thermal management system 140 to execute the thermal management strategy of the direct cooling battery pack 110, thereby realizing automatic control of the outlet temperature of the direct cooling battery pack 110.

[0122] It can be understood that the twisted pair of the low-voltage communication line of the direct-cooled battery pack 110 is connected in parallel to the vehicle controller 170, and the ground wire of the vehicle controller 170 is disconnected, so that the vehicle controller 170 is in a dormant state, reducing the possibility of failure of the direct-cooled battery pack 110 when the battery pack direct-cooling stand 120 and the vehicle controller 170 send signals to the direct-cooled battery pack 110 at the same time.

[0123] In some embodiments, the direct cooling battery pack testing method provided in this application can be applied to Figure 1 The thermal management controller in the direct cooling battery pack test system shown in FIG. Figure 4 As shown, the method includes the following steps:

[0124] S401. During operation of the thermal management system according to the calibrated physical quantities required by the target test condition, obtain the actual outlet temperature of the direct-cooled battery pack under the target test condition.

[0125] Among them, the calibration physical quantities required for the target test conditions are configured by the calibration equipment for the thermal management system.

[0126] It should be understood that the target test condition may be any one of the at least one test condition.

[0127] Target test conditions are a set of physical quantities and operating conditions (e.g., the operating mode of a direct-cooled battery pack) calibrated to evaluate the performance, safety, and reliability of a direct-cooled battery pack during actual vehicle operation. These conditions typically simulate typical operating conditions a battery pack might encounter in actual use to verify the effectiveness of the thermal management system.

[0128] As another feasible implementation method, the calibrated physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function activation, compressor maximum power, shut-off valve enable, and direct-cooling battery pack charge and discharge mode.

[0129] As a feasible implementation method, the actual outlet temperature of the direct-cooled battery pack is used as the actual outlet temperature of the liquid flowing out of the direct-cooled battery pack.

[0130] S402 : Based on the actual outlet temperature of the direct-cooled 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-cooled battery pack.

[0131] As another feasible implementation method, the target outlet temperature of the direct-cooled battery pack is used to indicate the desired outlet temperature of the direct-cooled battery pack under a certain charge and discharge current, which can ensure that the direct-cooled battery pack operates in an optimal state. It should be noted that the direct-cooled battery pack generates heat at different rates when operating at different charge and discharge currents. The target outlet temperature of the direct-cooled battery pack can be determined based on the principle of thermal balance. The greater the heat generation rate of the direct-cooled battery pack, the lower the target outlet temperature to prevent overheating of the direct-cooled battery pack.

[0132] It should be noted that the direct-cooled battery pack has a corresponding target outlet temperature under the target test conditions. When the direct-cooled battery pack operates at the target outlet temperature, it can effectively improve the performance and service life of the direct-cooled battery pack. Therefore, the thermal management controller can determine the thermal management strategy based on the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature, and then control the thermal management system to execute the thermal management strategy of the direct-cooled battery pack, so that the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than or equal to the preset threshold. The specific description of the preset threshold can be referred to the following steps and will not be repeated here.

[0133] It is understandable that during the operation of the thermal management system according to the calibrated physical quantities required for 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-cooled 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-cooled battery pack to simulate the operation process of the thermal management system in the vehicle. The direct-cooled battery pack test system can verify the performance of the thermal management system and reduce the cost of actual vehicle testing. In this way, the direct-cooled battery pack test system provided by this application can more completely simulate the environment of the entire vehicle and the working process of the battery pack, thereby improving the accuracy of the battery pack test.

[0134] In some embodiments, a thermal management system includes a compressor and an expansion valve.

[0135] As a feasible implementation method, the above step S402 can be specifically implemented as follows: 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 the preset threshold, gradually adjust the speed of the compressor and the opening of the expansion valve until the set conditions are met.

[0136] As a feasible implementation method, increasing the compressor speed can compress the liquid, thereby increasing the liquid flow rate to directly cool the battery pack. Therefore, there is a negative correlation between the compressor speed and the actual outlet temperature. The higher the compressor speed, the lower the actual outlet temperature.

[0137] As another feasible implementation method, the expansion valve opening can directly determine the liquid flow rate flowing to the direct-cooled battery pack. The expansion valve opening is negatively correlated with the actual outlet temperature. As the expansion valve opening increases, the liquid flow rate flowing to the direct-cooled battery pack increases, thereby reducing the actual outlet temperature of the direct-cooled battery pack.

[0138] The setting conditions include at least one of the following:

[0139] Condition a: The difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than a preset threshold.

[0140] It should be understood that the purpose of adjusting the expansion valve opening and the compressor speed is to adjust the actual outlet temperature of the direct-cooled battery pack so 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, and the direct-cooled battery pack can operate in the best working state. Therefore, after the difference between the actual outlet temperature of the direct-cooled battery pack and the target outlet temperature is less than the preset threshold, it means that the thermal management system can quickly and effectively adjust the temperature of the direct-cooled battery pack.

[0141] Condition b: The number of adjustments is greater than or equal to the preset number.

[0142] It should be understood that the preset number of times is the maximum number of times to prevent the direct-cooled battery pack from being damaged due to changes in outlet temperature.

[0143] It is understood that the difference between the actual and target outlet temperatures of the direct-cooled battery pack can automatically adjust the compressor speed and expansion valve opening, achieving the greatest possible reproduction of the vehicle's actual operating environment and improving the accuracy of the test method. If the difference between the actual and target outlet temperatures of the direct-cooled battery pack is less than a preset threshold, this indicates that the thermal management system is capable of maintaining the direct-cooled battery pack at the target outlet temperature. Alternatively, if the direct-cooled battery pack remains below the target outlet temperature after a preset number of adjustments, this indicates the performance of the thermal management system and improves the applicability of the test method.

[0144] In some embodiments, the above-mentioned "gradually adjusting the speed of the compressor and the opening of the expansion valve" can be specifically implemented as follows: during each adjustment process, the actual outlet temperature of the direct-cooled battery pack at the current moment is obtained, 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, the speed of the compressor and the opening of the expansion valve are adjusted.

[0145] 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 compressor speed and expansion valve opening. During each adjustment process, it is necessary to compare the actual outlet temperature of the direct-cooled battery pack 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 at the current moment and the target outlet temperature is greater than or equal to a preset threshold, the compressor speed and expansion valve opening are increased 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 at the current moment and the target outlet temperature is greater than or equal to a preset threshold, the compressor speed and expansion valve opening are reduced to increase the actual outlet temperature.

[0146] It can be understood that based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature, real-time adjustment of the compressor speed and the opening of the expansion valve can restore the operating status of the direct-cooled battery pack and the thermal management system during the actual operation of the vehicle to the greatest extent, thereby improving the accuracy of the direct-cooled battery pack test system.

[0147] The above mainly introduces the solution provided by the embodiment of the present application from the perspective of the method. In order to achieve the above functions, the direct-cooling battery pack testing device or electronic equipment includes hardware structures and / or software modules corresponding to the execution of each function. Those skilled in the art should easily realize that, in combination 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 function is executed in the form of hardware or computer software driving hardware depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this application.

[0148] The embodiments of the present application can, according to the above method, exemplarily divide the functional modules of the direct-cooled battery pack test device or electronic equipment. For example, the direct-cooled battery pack test device or electronic equipment may include various functional modules corresponding to the various functional divisions, or two or more functions may be integrated into one processing module. The above-mentioned integrated modules can be implemented in the form of hardware or in the form of software functional modules. It should be noted that the division of modules in the embodiments of the present application is schematic and is only a logical functional division. There may be other division methods in actual implementation.

[0149] Reference Figure 5 The direct-cooled battery pack testing device 500 includes: an acquisition module 501 and a control module 502; the acquisition module 501 is used to obtain 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 calibration physical quantity required for the target test condition; the calibration physical quantity required for the target test condition is configured by the calibration equipment for the thermal management system; the control module 502 is used 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.

[0150] In one possible implementation, the thermal management system includes a compressor and an expansion valve; the control module 502 is specifically used to gradually adjust the speed of the compressor and the opening of the expansion valve until the set conditions are met 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; 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 a preset threshold; the number of adjustments is greater than or equal to a preset number.

[0151] In one possible implementation, the control module 502 is specifically used to obtain the actual outlet temperature of the direct-cooled battery pack at the current moment during each adjustment process, and adjust the speed of the compressor and the opening 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.

[0152] Figure 6 FIG. 1 is a block diagram of an electronic device according to an exemplary embodiment. Figure 6 As shown, the electronic device 600 includes but is not limited to: a processor 601 and a memory 602 .

[0153] The memory 602 is used to store executable instructions of the processor 601. It is understandable that the processor 601 is configured to execute instructions to implement the direct cooling battery pack testing method in the above embodiment.

[0154] It should be noted that those skilled in the art can understand that Figure 6 The electronic device structure shown in the figure does not limit the electronic device, and the electronic device may include Figure 6 More or fewer components may be shown, or certain components may be combined, or the components may be arranged differently.

[0155] The processor 601 is the control center of the electronic device. It connects the various parts of the entire electronic device using various interfaces and lines. By running or executing software programs and / or modules stored in the memory 602 and calling data stored in the memory 602, it performs various functions of the electronic device and processes data, thereby monitoring the electronic device as a whole. The processor 601 may include one or more processing units. Optionally, the processor 601 may integrate an application processor and a modem processor, wherein the application processor mainly processes the operating system, user interface, and application programs, and the modem processor mainly handles wireless communications. It is understood that the modem processor may not be integrated into the processor 601.

[0156] Memory 602 can be used to store software programs and various data. Memory 602 may primarily include a program storage area and a data storage area. The program storage area may store an operating system and application programs required by at least one functional module (such as a determination unit, a processing unit, etc.). Furthermore, memory 602 may include high-speed random access memory and non-volatile memory, such as at least one disk storage device, flash memory device, or other volatile solid-state storage device.

[0157] In an exemplary embodiment, a computer-readable storage medium including instructions is also provided, such as a 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 testing method in the above embodiment.

[0158] In actual implementation, Figure 5 The functions of the acquisition module 501 and the control module 502 can be obtained by Figure 6 The processor 601 in the embodiment calls the computer program stored in the memory 602. The specific execution process can be referred to the description of the method part in the above embodiment, which will not be repeated here.

[0159] Optionally, the computer-readable storage medium may be a non-transitory computer-readable storage medium, for example, the non-transitory computer-readable storage medium may be a read-only memory (ROM), a random access memory (RAM), a CD-ROM, a magnetic tape, a floppy disk, an optical data storage device, etc.

[0160] In an exemplary embodiment, the present application also provides a computer program product comprising one or more instructions, which can be executed by the processor 601 of the electronic device to complete the direct-cooling battery pack testing method in the above embodiment.

[0161] It should be noted that when the instructions in the above-mentioned computer-readable storage medium or one or more instructions in the computer program product are executed by the processor of the electronic device, the various processes of the above-mentioned method embodiment are implemented and the same technical effect as the above-mentioned method can be achieved. To avoid repetition, they will not be repeated here.

[0162] Through the description of the above implementation methods, technical personnel in the relevant field can clearly understand that for the convenience and simplicity of description, only the division of the above-mentioned functional modules is used as an example. In actual applications, the above-mentioned functions can be distributed and completed by different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete the full classification or partial functions described above.

[0163] In the several embodiments provided in this 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 schematic. For example, the division of modules or units is only a logical function division. In actual implementation, there may be other division methods, such as 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 mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms.

[0164] The units described as separate components may or may not be physically separate, and the components shown as units may be one physical unit or multiple physical units, that is, they may be located in one place or distributed in multiple places. Some or all of the units may be selected according to actual needs to achieve the purpose of the present embodiment.

[0165] In addition, the functional units in the various embodiments of the present application may be integrated into a single processing unit, or each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or software functional units.

[0166] 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 this understanding, the technical solution of the embodiment of the present application, or the part that contributes to the prior art, or the entire classification part or part of the technical solution can be embodied in the form of a software product. The software product is stored in a storage medium and includes a number of instructions for enabling a device (which can be a single-chip microcomputer, chip, etc.) or a processor to execute the entire classification part or part of the steps of the various embodiments of the present application. The aforementioned storage medium includes: U disk, mobile hard disk, ROM, RAM, disk or optical disk, etc., various media that can store program code.

[0167] The above are only specific embodiments of the present application, but the scope of protection of the present application is not limited thereto. Any changes or replacements within the technical scope disclosed in this application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A direct cooling battery pack testing system, characterized in that: include: A direct-cooled battery pack, a battery pack direct-cooling test bench, a thermal management controller, a thermal management system, and a calibration device; the thermal management system includes a compressor speed and an expansion valve opening; wherein the direct-cooled battery pack is connected to the battery pack direct-cooling test bench, the thermal management controller, and the thermal management system, respectively; the thermal management controller is connected to the thermal management system; and the calibration device is connected to the thermal management system; The battery pack direct cooling stand is used to control the charge and discharge current of the direct cooling battery pack; The calibration device is used to calibrate physical quantities required for configuring the target test conditions for the thermal management system; wherein the calibrated physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function activation, compressor maximum power, shutoff valve enable, and direct-cooled battery pack charge and discharge mode; The thermal management controller is configured to obtain, during operation of the thermal management system according to the calibrated physical quantity, an actual outlet temperature of the direct-cooled battery pack under the target test condition; and gradually adjust the speed of the compressor and the opening of the expansion valve until a set condition is met when a difference between the actual outlet temperature of the direct-cooled battery pack and a target outlet temperature is greater than or equal to a preset threshold. The set condition includes: 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 preset threshold is the maximum difference between the outlet temperature and the target outlet temperature that can maintain the direct-cooled battery pack operating in an optimal state; The number of adjustments is greater than or equal to a preset number; the preset number is the maximum number of times to prevent the direct-cooled battery pack from being damaged due to changes in the outlet temperature; The direct-cooled battery pack testing system also includes a vehicle controller; the twisted pair of the low-voltage communication line of the direct-cooled battery pack is connected in parallel to the vehicle controller; and the ground wire of the vehicle controller is disconnected.

2. The direct cooling battery pack testing system according to claim 1, characterized in that: The thermal management controller is configured to gradually adjust the speed of the compressor and the opening of the expansion valve, including: During each adjustment process, the actual outlet temperature of the direct-cooled battery pack at the current moment is obtained, and the speed of the compressor and the opening of the expansion valve are adjusted based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature.

3. The direct cooling battery pack testing system according to claim 1, characterized in that: A sensor group is provided at the inlet and outlet of the direct-cooling battery pack; the sensor group includes a pressure sensor and a temperature sensor.

4. The direct cooling battery pack testing system according to claim 1, characterized in that: The thermal management system includes a condenser, and a liquid flow meter is provided at the outlet of the condenser for detecting the liquid flow of the condenser.

5. The direct cooling battery pack testing system according to claim 1, characterized in that: The direct-cooling battery pack testing system further includes a display device, which is connected to the thermal management system; The display device is used to display at least one of the following: operating data of the direct-cooled battery pack, operating data of the thermal management system, working status of the thermal management system, and cause of failure of the thermal management system.

6. A direct cooling battery pack testing method, characterized in that: A thermal management controller applied to a direct-cooled battery pack test system according to any one of claims 1 to 5, wherein the thermal management system includes a compressor and an expansion valve; and the method includes: During operation of the thermal management system according to the calibration physical quantities required for the target test condition, obtaining the actual outlet temperature of the direct-cooled battery pack under the target test condition; the calibration physical quantities required for the target test condition are configured for the thermal management system by the calibration equipment; wherein the calibration physical quantities include at least one of the following: ambient temperature, vehicle speed, thermal management function enabled, maximum compressor power, shutoff valve enabled, and direct-cooled battery pack charge and discharge mode; 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, the speed of the compressor and the opening of the expansion valve are gradually adjusted until a set condition is met; wherein the set condition includes: 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 preset threshold is the maximum difference between the outlet temperature and the target outlet temperature that can maintain the direct-cooled battery pack operating in an optimal state; The number of adjustments is greater than or equal to a preset number; the preset number is the maximum number of times to prevent the direct-cooled battery pack from being damaged due to changes in the outlet temperature; The direct-cooled battery pack testing system also includes a vehicle controller; the twisted pair of the low-voltage communication line of the direct-cooled battery pack is connected in parallel to the vehicle controller; and the ground wire of the vehicle controller is disconnected.

7. The direct cooling battery pack testing method according to claim 6, characterized in that: The gradually adjusting the speed of the compressor and the opening of the expansion valve includes: During each adjustment process, the actual outlet temperature of the direct-cooled battery pack at the current moment is obtained, and the speed of the compressor and the opening of the expansion valve are adjusted based on the difference between the actual outlet temperature of the direct-cooled battery pack at the current moment and the target outlet temperature.

8. An electronic device, characterized in that: It includes a processor and a memory, 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 cooling battery pack testing method as described in any one of claims 6 to 7.

Images