Battery pack performance testing device based on multi-field coupling

Abstract

The invention discloses a battery pack performance testing device based on multi-field coupling. According to the technical scheme, the battery pack performance testing device is characterized by comprising a quick docking mechanism, a self-adaptive adjusting module, a multi-channel electric connection assembly and a safety protection system; the rapid butt joint mechanism adopts a guiding and positioning structure, the guiding and positioning structure comprises a plurality of guiding columns and corresponding guiding grooves, the guiding columns are arranged on one side of the testing equipment, the guiding grooves are formed in the corresponding positions of the battery pack, and the guiding and positioning structure is further provided with an auxiliary positioning device. The auxiliary positioning device comprises a plurality of positioning pins and positioning holes, the positioning pins are arranged in the battery pack, the positioning holes are formed in the test equipment, and the quick docking mechanism adopts an electric driving mode. The battery pack performance testing device based on multi-field coupling can accurately control the testing temperature within the range of-40 DEG C to 0 DEG C. And a heat isolation supporting structure is arranged, so that heat loss is effectively reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of new energy vehicle power battery testing, and specifically relates to a battery pack performance testing device based on multi-field coupling, which is used to perform comprehensive and accurate performance testing of battery packs during power battery research and development, production, and quality inspection. Background Art

[0002] With the rapid development of the new energy vehicle industry, the performance of power batteries, as core components, directly impacts the vehicle's range, safety, and service life. During the R&D, production, and quality inspection processes, battery packs require rigorous performance testing to ensure product quality and reliability. However, traditional battery pack test connection devices present numerous issues.

[0003] On the one hand, traditional test connection devices have poor compatibility and are difficult to adapt to battery packs of different models and interface specifications. Due to differences in interface size, shape, and layout among battery packs produced by different manufacturers, the same test equipment cannot quickly and effectively test the connection of multiple battery packs, significantly reducing test efficiency and increasing test costs. On the other hand, traditional test connection devices are inefficient during the connection process, cumbersome manual operation, and difficult to ensure connection accuracy. Poor contact and other problems are prone to occur, affecting the accuracy and reliability of test results.

[0004] In addition, traditional testing equipment also has obvious defects when testing the discharge power of batteries in low-temperature environments. Under extremely low temperature conditions (such as -40°C to 0°C), traditional equipment has difficulty in accurately controlling the test temperature, and there are problems with large temperature fluctuations, which cannot provide a stable low-temperature testing environment for the battery. At the same time, traditional equipment has poor thermal isolation performance and severe heat loss, which not only wastes energy, but also causes uneven temperature in the test area, affecting the accuracy of the test results. In addition, the clamping mechanism of traditional equipment lacks adaptive capabilities and is not compatible with batteries of different sizes. During the clamping process, uneven mechanical stress may be applied to the battery, interfering with the normal performance of the battery, thereby affecting the authenticity of the test results.

[0005] Therefore, there is an urgent need for a battery pack performance testing device that can solve the above problems and has high reliability, high versatility and intelligent characteristics. Summary of the Invention

[0006] In view of the problems mentioned in the background technology, the purpose of the present invention is to provide a battery pack performance testing device based on multi-field coupling to solve the problems mentioned in the background technology.

[0007] The above technical objectives of the present invention are achieved through the following technical solutions:

[0008] A battery pack performance test device based on multi-field coupling, including a quick docking mechanism, an adaptive adjustment module, a multi-channel electrical connection component and a safety protection system; the quick docking mechanism adopts a guide positioning structure, the guide positioning structure includes a plurality of guide columns and corresponding guide grooves, the guide columns are arranged on one side of the test equipment, the guide grooves are arranged at the corresponding positions of the battery pack, the guide positioning structure is also equipped with an auxiliary positioning device, the auxiliary positioning device includes a plurality of positioning pins and positioning holes, the positioning pins are arranged on the battery pack, the positioning holes are arranged on the test equipment, the quick docking mechanism adopts an electric drive mode, and the quick docking mechanism is realized by a motor and a transmission mechanism Automatic connection between the battery pack and the test equipment; the adaptive adjustment module automatically adapts to the interface tolerance of different types of battery packs through the elastic compensation unit, the elastic compensation unit is composed of multiple elastic elements, and the adaptive adjustment module also includes an adjustment mechanism, which obtains battery pack information through a sensor and transmits it to the controller, and the controller controls the adjustment mechanism to adjust the working state of the elastic compensation unit; the multi-channel electrical connection component integrates high-current contacts and signal transmission terminals, and the multi-channel electrical connection component includes a signal shielding and anti-interference module; the safety protection system includes an overcurrent protection module, an overvoltage protection module, an overheating protection module and a leakage protection module.

[0009] Preferably, the number of guide columns in the quick docking mechanism is 4-8, and the guide columns are evenly distributed around the interface of the test equipment; the electric drive method uses a servo motor as a power source and converts the motor's rotational motion into linear motion through a screw-nut transmission mechanism, and a reducer is arranged between the servo motor and the screw-nut transmission mechanism.

[0010] Preferably, the elastic element of the elastic compensation unit includes a stainless steel spring and a nitrile rubber pad; the adjustment mechanism uses an electric push rod as an actuator, and the electric push rod is connected to the elastic compensation unit through a connecting rod mechanism.

[0011] Preferably, in the multi-channel electrical connection assembly, the high-current contacts are made of copper material and are silver-plated; the signal transmission terminals adopt a pinhole structure, and the pin and hole are made of gold-plated copper alloy.

[0012] Preferably, in the safety protection system, the overcurrent protection device consists of a current transformer and an overcurrent relay, and the current transformer monitors the circuit current in real time and converts it into a voltage signal and transmits it to the overcurrent relay; the overvoltage protection device consists of a voltage transformer and an overvoltage relay, and the voltage transformer monitors the circuit voltage and transmits it to the overvoltage relay; the overheating protection device consists of a temperature sensor and a cooling fan, and the temperature sensor is installed at key positions of the battery pack and the test equipment, and the controller controls the start and stop of the cooling fan according to the temperature sensor signal and issues an alarm; the leakage protection device uses a leakage circuit breaker to detect the circuit leakage current in real time.

[0013] Preferably, it also includes a detection device for detecting the battery discharge power at low temperature, the detection device is equipped with a temperature control system, the temperature control system includes a refrigeration module and a heating module, the refrigeration module adopts a refrigeration compressor and a refrigeration cycle system, the heating module adopts an electric heating wire and an intelligent temperature controller; the detection device is equipped with a thermal isolation support structure, and the thermal isolation support structure is composed of multiple layers of thermal insulation material.

[0014] Preferably, the adaptive adjustment module and the safety protection system are respectively connected to a control host, and the control host is connected to a cloud server via a wireless communication module.

[0015] Preferably, the control host is connected to a display and an alarm.

[0016] In summary, the present invention mainly has the following beneficial effects:

[0017] This multi-field coupling-based battery pack performance tester precisely controls the test temperature within a range of -40°C to 0°C. It is equipped with a thermal isolation support structure to effectively reduce heat loss. The adaptive clamping mechanism accommodates batteries of varying sizes, preventing mechanical stress from interfering with test results. This device addresses the issues of inaccurate temperature control and severe heat leakage experienced by traditional test equipment at extremely low temperatures, making it suitable for the R&D and quality testing of power batteries for new energy vehicles. The quick docking mechanism, utilizing a guide positioning structure and auxiliary positioning device, combined with an electric drive, enables fast and accurate docking of the battery pack with the tester, improving testing efficiency. The adaptive adjustment module's elastic compensation unit and adjustment mechanism automatically adapt to the interface tolerances of different battery pack models, enhancing the device's versatility and adaptability. The multi-channel electrical connection assembly integrates high-current contacts and signal transmission terminals, and is equipped with a signal shielding and anti-interference module to ensure stable electrical connections and accurate test data. The safety protection system, including overcurrent, overvoltage, overheating, and leakage protection modules, provides comprehensive safety assurance during the testing process, reducing safety risks. The detection device for detecting battery discharge power at low temperatures can simulate different temperature environments. The equipped temperature control system and thermal isolation support structure improve the accuracy and reliability of the test. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is one of the system block diagrams of the present invention;

[0019] Figure 2 This is the second system block diagram of the present invention. DETAILED DESCRIPTION

[0020] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0021] Example 1

[0022] refer to Figure 1-Figure 2 , a battery pack performance test device based on multi-field coupling, including a quick docking mechanism, an adaptive adjustment module, a multi-channel electrical connection component and a safety protection system; the quick docking mechanism adopts a guide positioning structure, the guide positioning structure includes a plurality of guide columns and corresponding guide grooves, the guide columns are arranged on one side of the test equipment, the guide grooves are arranged at the corresponding positions of the battery pack, the guide positioning structure is also equipped with an auxiliary positioning device, the auxiliary positioning device includes a plurality of positioning pins and positioning holes, the positioning pins are arranged on the battery pack, and the positioning holes are arranged on the test equipment. The quick docking mechanism adopts an electric drive mode, and the quick docking mechanism is realized by a motor and a transmission mechanism. The automatic connection between the battery pack and the test equipment is realized; the adaptive adjustment module automatically adapts to the interface tolerance of battery packs of different models through the elastic compensation unit, and the elastic compensation unit is composed of multiple elastic elements. The adaptive adjustment module also includes an adjustment mechanism, which obtains battery pack information through a sensor and transmits it to the controller, and the controller controls the adjustment mechanism to adjust the working state of the elastic compensation unit; the multi-channel electrical connection component integrates high-current contacts and signal transmission terminals, and the multi-channel electrical connection component includes a signal shielding and anti-interference module; the safety protection system includes an overcurrent protection module, an overvoltage protection module, an overheating protection module and a leakage protection module.

[0023] Among them, the number of guide columns in the quick docking mechanism is 4-8, and the guide columns are evenly distributed around the interface of the test equipment; the electric drive method uses a servo motor as a power source and converts the motor's rotational motion into linear motion through a screw-nut transmission mechanism, and a reducer is arranged between the servo motor and the screw-nut transmission mechanism.

[0024] The elastic element of the elastic compensation unit includes a stainless steel spring and a nitrile rubber pad; the adjustment mechanism uses an electric push rod as an actuator, and the electric push rod is connected to the elastic compensation unit through a connecting rod mechanism.

[0025] Among them, in the multi-channel electrical connection component, the high-current contacts are made of copper material and the surface is silver-plated; the signal transmission terminals adopt a pinhole structure, and the pin and hole are made of gold-plated copper alloy.

[0026] Among them, in the safety protection system, the overcurrent protection device consists of a current transformer and an overcurrent relay. The current transformer monitors the circuit current in real time and converts it into a voltage signal and transmits it to the overcurrent relay; the overvoltage protection device consists of a voltage transformer and an overvoltage relay. The voltage transformer monitors the circuit voltage and transmits it to the overvoltage relay; the overheating protection device consists of a temperature sensor and a cooling fan. The temperature sensor is installed in key parts of the battery pack and test equipment. The controller controls the start and stop of the cooling fan according to the temperature sensor signal and issues an alarm; the leakage protection device uses a leakage circuit breaker to detect the circuit leakage current in real time.

[0027] The system also includes a detection device for detecting battery discharge power at low temperatures. The detection device is equipped with a temperature control system, which includes a cooling module and a heating module. The cooling module uses a refrigeration compressor and a refrigeration cycle system, and the heating module uses an electric heating wire and an intelligent thermostat. The detection device is equipped with a thermal isolation support structure composed of multiple layers of thermal insulation material. The adaptive adjustment module and the safety protection system are respectively connected to the control host, which is connected to the cloud server via a wireless communication module.

[0028] Wherein, the control host is connected to a display and an alarm.

[0029] This multi-field coupling-based battery pack performance tester precisely controls the test temperature within a range of -40°C to 0°C. It is equipped with a thermal isolation support structure to effectively reduce heat loss. Its adaptive clamping mechanism accommodates batteries of varying sizes, preventing mechanical stress from interfering with test results. This device addresses the issues of inaccurate temperature control and severe heat leakage associated with traditional test equipment at extremely low temperatures, making it suitable for the research, development, and quality testing of power batteries for new energy vehicles. The quick docking mechanism, utilizing a guide positioning structure and auxiliary positioning device, combined with an electric drive, enables fast and accurate docking of the battery pack with the tester, improving testing efficiency. The adaptive adjustment module's elastic compensation unit and adjustment mechanism automatically adapt to the interface tolerances of different battery pack models, enhancing the device's versatility and adaptability. The multi-channel electrical connection assembly integrates high-current contacts and signal transmission terminals, and is equipped with a signal shielding and anti-interference module to ensure stable electrical connections and accurate test data. The safety protection system, including overcurrent, overvoltage, overheating, and leakage protection modules, provides comprehensive safety assurance during the testing process, reducing safety risks. The detection device for detecting battery discharge power at low temperature can simulate different temperature environments. The equipped temperature control system and thermal isolation support structure improve the accuracy and reliability of the test.

[0030] Example 2

[0031] The battery pack performance testing device based on multi-field coupling provided in this embodiment includes a quick docking mechanism, an adaptive adjustment module, a multi-channel electrical connection component and a safety protection system.

[0032] Quick docking mechanism:

[0033] The guide positioning structure consists of multiple guide posts and corresponding guide slots. The posts are located on one side of the test equipment, and the guide slots are located in the corresponding positions of the battery pack. There are 4-8 guide posts, evenly distributed around the test equipment interface, ensuring accurate docking between the battery pack and the test equipment.

[0034] Equipped with auxiliary positioning devices, including multiple positioning pins and positioning holes. The positioning pins are set on the battery pack and the positioning holes are set on the test equipment to further improve the accuracy of docking.

[0035] The electric drive system automatically connects the battery pack and test equipment via a motor and transmission mechanism. Specifically, the system uses a servo motor as the power source, and a screw-nut transmission mechanism converts the motor's rotational motion into linear motion. A speed reducer is installed between the servo motor and the screw-nut transmission mechanism, enabling precise control of the docking process and improving docking efficiency.

[0036] Adaptive adjustment module:

[0037] The system automatically adapts to the interface tolerances of different battery pack models through an elastic compensation unit. The elastic compensation unit is composed of multiple elastic elements, including stainless steel springs and nitrile rubber pads, which have good elasticity and stability.

[0038] The system also includes an adjustment mechanism, which acquires battery pack information via sensors and transmits it to a controller. The controller then controls the adjustment mechanism to adjust the operating state of the elastic compensation unit. The adjustment mechanism uses an electric push rod as an actuator, connected to the elastic compensation unit via a linkage mechanism, enabling flexible adjustments based on the actual battery pack conditions.

[0039] Multi-channel electrical connection components:

[0040] Integrates high-current contacts and signal transmission terminals. The high-current contacts are made of copper and are silver-plated. They have good conductivity and corrosion resistance and can meet the needs of high-current transmission.

[0041] The signal transmission terminal adopts a pinhole structure, and the pin and hole are made of gold-plated copper alloy, which improves the stability and accuracy of signal transmission.

[0042] It includes a signal shielding and anti-interference module, which can effectively prevent external interference from affecting the test data.

[0043] Safety protection system:

[0044] It includes overcurrent protection module, overvoltage protection module, overheat protection module and leakage protection module.

[0045] The overcurrent protection device consists of a current transformer and an overcurrent relay. The current transformer monitors the circuit current in real time and converts it into a voltage signal, which is then transmitted to the overcurrent relay. When the current exceeds the set value, the overcurrent relay operates, cutting off the circuit and protecting the equipment.

[0046] The overvoltage protection device consists of a voltage transformer and an overvoltage relay. The voltage transformer monitors the circuit voltage and transmits it to the overvoltage relay. When the voltage exceeds the set value, the overvoltage relay operates and cuts off the circuit.

[0047] The overheat protection device consists of a temperature sensor and a cooling fan. The temperature sensor is installed in key positions of the battery pack and the test equipment. The controller starts and stops the cooling fan and issues an alarm based on the temperature sensor signal to prevent the equipment from being damaged by overheating.

[0048] The leakage protection device uses a leakage circuit breaker to detect circuit leakage current in real time. When leakage is detected, the circuit is cut off in time to ensure the safety of personnel and equipment.

[0049] Detection device for detecting battery discharge power at low temperature:

[0050] Equipped with a temperature control system, including a cooling module and a heating module. The cooling module uses a refrigeration compressor and refrigeration cycle system to simulate low-temperature environments; the heating module uses electric heating wires and an intelligent thermostat to precisely control the temperature. Equipped with a thermal isolation support structure composed of multiple layers of insulation material, it reduces heat transfer and improves test accuracy.

[0051] Example 3

[0052] This embodiment provides a workflow of a battery pack performance testing device based on multi-field coupling.

[0053] Working process of quick docking mechanism:

[0054] When the battery pack needs to be tested, it is moved near the test equipment. At this point, the guide post and guide slot are initially aligned. Driven by the servo motor, the screw-nut transmission mechanism converts the motor's rotational motion into linear motion, bringing the test equipment closer to the battery pack. During this approach, the locating pins gradually insert into the positioning holes, further improving docking accuracy. When docking is complete, the servo motor stops, completing the automatic connection between the battery pack and the test equipment.

[0055] The working process of the adaptive adjustment module:

[0056] The sensor acquires the battery pack interface information and transmits it to the controller. Based on this information, the controller controls the actuator's movements. The actuator adjusts the operating state of the elastic compensation unit through a linkage mechanism, causing the elastic element (stainless steel spring and nitrile rubber pad) to produce appropriate elastic deformation to accommodate the tolerances of the battery pack interface and ensure a stable electrical connection.

[0057] Working process of multi-channel electrical connection components:

[0058] High-current contacts are made of silver-plated copper and are capable of carrying high currents. The signal transmission terminals utilize a pinhole-type structure and gold-plated copper alloy to ensure stable signal transmission. The signal shielding and anti-interference module effectively blocks external interference, ensuring accurate transmission of test data.

[0059] Working process of the safety protection system:

[0060] Overcurrent protection module: The current transformer monitors the circuit current in real time and converts it into a voltage signal, which is then transmitted to the overcurrent relay. When the current exceeds the set value, the overcurrent relay activates, disconnecting the circuit and preventing damage to the equipment due to overcurrent.

[0061] Overvoltage protection module: The voltage transformer monitors the circuit voltage and transmits it to the overvoltage relay. When the voltage exceeds the set value, the overvoltage relay activates, disconnecting the circuit and protecting the equipment.

[0062] Overheat protection module: Temperature sensors are installed in key locations of the battery pack and test equipment to monitor temperature in real time. When the temperature exceeds a set value, the controller activates the cooling fan to dissipate heat and issues an alarm.

[0063] Leakage protection module: The leakage circuit breaker detects the circuit leakage current in real time. When leakage is detected, it cuts off the circuit in time to ensure the safety of personnel and equipment.

[0064] Working process of battery discharge power detection device at low temperature:

[0065] The test environment temperature is adjusted using a temperature control system based on test requirements. The refrigeration module's compressor and refrigeration cycle simulate low-temperature environments, while the heating module's electric heating wire and intelligent thermostat precisely control the temperature. The thermal isolation support structure reduces heat transfer and improves test accuracy. In low-temperature environments, the battery pack's discharge power is measured and relevant data is obtained.

[0066] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A battery pack performance testing device based on multi-field coupling, characterized by: The invention comprises a quick docking mechanism, an adaptive adjustment module, a multi-channel electrical connection assembly and a safety protection system; the quick docking mechanism adopts a guide positioning structure, which comprises a plurality of guide posts and corresponding guide slots, the guide posts are arranged on one side of the test equipment, and the guide slots are arranged at the corresponding positions of the battery pack. The guide positioning structure is also equipped with an auxiliary positioning device, which comprises a plurality of positioning pins and positioning holes, the positioning pins are arranged on the battery pack, and the positioning holes are arranged on the test equipment. The quick docking mechanism adopts an electric drive mode, and the quick docking mechanism realizes automatic plugging of the battery pack and the test equipment through a motor and a transmission mechanism; the adaptive adjustment module automatically adapts to the interface tolerance of battery packs of different models through an elastic compensation unit, the elastic compensation unit is composed of a plurality of elastic elements, the adaptive adjustment module also includes an adjustment mechanism, the adjustment mechanism obtains battery pack information through a sensor and transmits it to a controller, and the controller controls the adjustment mechanism to adjust the working state of the elastic compensation unit; the multi-channel electrical connection assembly integrates high-current contacts and signal transmission terminals, and the multi-channel electrical connection assembly includes a signal shielding and anti-interference module; the safety protection system includes an overcurrent protection module, an overvoltage protection module, an overheating protection module and a leakage protection module.

2. The battery pack performance testing device based on multi-field coupling according to claim 1, characterized in that: The number of guide columns in the quick docking mechanism is 4-8, and the guide columns are evenly distributed around the interface of the test equipment; the electric drive method uses a servo motor as a power source and converts the motor's rotational motion into linear motion through a screw-nut transmission mechanism, and a reducer is provided between the servo motor and the screw-nut transmission mechanism.

3. The battery pack performance testing device based on multi-field coupling according to claim 1, characterized in that: The elastic element of the elastic compensation unit includes a stainless steel spring and a nitrile rubber pad; the adjustment mechanism uses an electric push rod as an actuator, and the electric push rod is connected to the elastic compensation unit through a connecting rod mechanism.

4. The battery pack performance testing device based on multi-field coupling according to claim 1, characterized in that: In the multi-channel electrical connection assembly, the high-current contacts are made of copper and silver-plated; the signal transmission terminals adopt a pinhole structure, and the pins and holes are made of gold-plated copper alloy.

5. The battery pack performance testing device based on multi-field coupling according to claim 1, characterized in that: In the safety protection system, the overcurrent protection device consists of a current transformer and an overcurrent relay. The current transformer monitors the circuit current in real time and converts it into a voltage signal for transmission to the overcurrent relay. The overvoltage protection device consists of a voltage transformer and an overvoltage relay. The voltage transformer monitors the circuit voltage and transmits it to the overvoltage relay. The overheating protection device consists of a temperature sensor and a cooling fan. The temperature sensor is installed in key positions of the battery pack and the test equipment. The controller controls the start and stop of the cooling fan and issues an alarm according to the temperature sensor signal. The leakage protection device uses a leakage circuit breaker to detect the circuit leakage current in real time.

6. The battery pack performance testing device based on multi-field coupling according to claim 5, characterized in that: It also includes a detection device for detecting the battery discharge power at low temperatures. The detection device is equipped with a temperature control system. The temperature control system includes a refrigeration module and a heating module. The refrigeration module uses a refrigeration compressor and a refrigeration cycle system, and the heating module uses an electric heating wire and an intelligent temperature controller. The detection device is equipped with a thermal isolation support structure, which is composed of multiple layers of thermal insulation material.

7. The battery pack performance testing device based on multi-field coupling according to claim 6, characterized in that: The adaptive adjustment module and the safety protection system are respectively connected to the control host, and the control host is connected to the cloud server via a wireless communication module.

8. The battery pack performance testing device based on multi-field coupling according to claim 1, characterized in that: The control host is connected with a display and an alarm.

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