High-power battery charging module power supply inspection system and method

Abstract

The invention discloses an inspection system and method, belongs to the technical field of high-power battery charging module power supplies, and particularly relates to a high-power battery charging module power supply inspection system and method. The detection unit comprises a sampling unit, a data acquisition unit, a controller, a data transmission unit, a temperature control unit and a power supply unit; the power supply of the battery charging module is inspected through the inspection plate and the detection unit, and meanwhile, the data correction module and the service life prediction module are arranged in the detection unit; the data correction module verifies and compensates data signals collected by the sampling unit, and the service life prediction module predicts the service life of the battery charging module power supply according to the data compensated by the data correction module, so that the accuracy of power supply inspection of the battery charging module can be ensured, the service life of the battery charging module power supply is prolonged, and the service life of the battery charging module power supply is prolonged. And meanwhile, the upper computer performs data storage and analysis, so that the inspection system can be further optimized.

Description

TECHNICAL FIELD

[0001] The application discloses a kind of inspection system and method, belong to high-power battery charging module power supply technical field, specifically related to a kind of high-power battery charging module power supply inspection system and method. BACKGROUND

[0002] High-power battery charging module power supply (usually referred to as "high-power charging module" or "DC fast charging module") is the core component of modern high-efficiency battery system (especially electric vehicles and energy storage systems) to achieve fast charging. High-power battery charging module power supply is a kind of input alternating current (AC, usually from power grid) is efficiently, stably and controllably converted into high-power direct current (DC), which is specially used for fast charging of high-voltage and large-capacity battery pack (such as lithium battery pack). It is usually used as the core power unit of DC charging pile, charging cabinet or large-scale charging system.

[0003] High-power battery charging module power supply needs to be inspected before leaving the factory. The traditional inspection objects include input characteristic detection, output characteristic detection, protection characteristic, insulation characteristic, electromagnetic compatibility characteristic and life prediction. However, due to the existence of offset error, gain error and temperature drift of chips and other devices, the performance will be reduced, which will cause errors in the collected data, resulting in inaccurate life prediction and inspection data, and thus leading to the performance reduction of high-power battery charging module power supply. SUMMARY

[0004] The application aims to provide a high-power battery charging module power supply inspection system and method to solve the above-mentioned problems.

[0005] Technical scheme: a high-power battery charging module power supply inspection system, comprising:

[0006] An inspection board for placing battery charging module power supply for inspection work

[0007] A detection unit for collecting data of battery charging module power supply on the inspection board, and performing data processing and analysis, and packaging and transmitting data information to an upper computer;

[0008] An upper computer connected with the detection unit and receiving data information of the detection unit, and performing data analysis, arrangement, storage and display.

[0009] The detection unit comprises a sampling unit, a data acquisition unit, a controller, a data transmission unit, a temperature control unit and a power supply unit.

[0010] The input end of the sampling unit is connected with the output end of the test board, the output end is connected with the input end of the data acquisition unit and the controller respectively, the output end of the data acquisition unit is connected with the controller, the temperature control unit is connected with the controller, the input end of the data transmission unit is connected with the controller, and the output end is connected with the host computer

[0011] In further embodiments, the sampling unit includes a voltage sampling module, a current sampling module, a temperature sampling module, and an isolation module; the input end of the voltage sampling module and the input end of the voltage sampling module are connected with the output end of the test board, and the output end is connected with the input end of the isolation module at the same time, the output end of the isolation module is connected with the data acquisition unit, and the input end of the temperature sampling module is connected with the controller.

[0012] In further embodiments, the controller is provided with a data correction module and a life prediction module; the data correction module verifies and compensates the data signal collected by the sampling unit, and the life prediction module predicts the life of the battery charging module power supply according to the compensated data of the data correction module.

[0013] In further embodiments, the host computer runs an operating system environment, an instrument driver environment, an application software environment, a database environment, and an auxiliary tool software environment on the host computer, and is responsible for the logical control, data processing, data acquisition control, data storage, test report generation, and data interpretation of the entire system.

[0014] The host computer is used for information interaction and control between the test personnel and the test system, mainly including power supply control and monitoring on the workbench, and cantilever display on the cabinet side plate, wherein a video switching matrix is configured inside the cabinet.

[0015] A high-power battery charging module power supply testing method is realized by a testing system, and the testing method comprises the following steps:

[0016] Step 1, place the battery charging module power supply on the test board, and power on the detection unit and the host computer and establish communication with the test board;

[0017] Step 2, the voltage and current signals in the test board are sampled by the voltage sampling module and the current sampling module in the sampling unit, and then sent to the data acquisition unit through the isolation module;

[0018] Step 3, the data acquisition unit sends the signal to the controller for analysis and processing after conditioning and quantization, and the temperature signal is sent to the controller for analysis and processing through the temperature sensor;

[0019] Step 4, the controller corrects and predicts the life according to the data signal;

[0020] Step 5, the results of the last processing and the life prediction information are transmitted to the host computer through the data transmission unit, and the controller controls the temperature control unit to collect the temperature in the system equipment through the sensor, and controls the equipment to refrigerate or heat according to the temperature.

[0021] In further embodiments, the specific steps in step 4 are as follows:

[0022] Step 40, correcting the data output by the data acquisition unit;

[0023] Step 41, obtaining data required for life prediction;

[0024] Step 42, data preprocessing is performed through data filtering, outlier rejection and signal denoising to obtain useful data and further feature extraction, and a data set for life prediction is obtained;

[0025] Step 43, dividing the data set into a training data set and a prediction data set, optimizing the prediction model on the training set, and using the prediction model on the test set for sequence prediction;

[0026] Step 44, outputting the prediction result.

[0027] In further embodiments, in step 40, due to the existence of offset error, gain error and temperature drift in the data acquisition unit, the performance will be degraded, so error correction and compensation are needed. Assuming that the data acquisition unit is a linear system, the input value x and the output value y have a relationship:

[0028] y=k0x

[0029] Where k0 represents the nominal sensitivity of the measurement channel, i.e. the nominal gain;

[0030] Zero error and gain error correction of the linear system are performed. The zero error refers to the output value y being non-zero when the input value x is zero. The gain error refers to the deviation of the actual gain k1 from the nominal gain k, i.e.

[0031] k=k0+Δk

[0032] Under these two errors, the relationship between the measured input value x and the actual output value y is:

[0033] y=kx+x0

[0034] Divide the output value by the nominal gain k0, so the value determined is no longer the true value x of the measured value, but:

[0035]

[0036] x 1 The deviation of x from x is the measurement error:

[0037]

[0038] In order to correct zero error and gain error, the input-output relationship after error correction is obtained and an error correction model is established, and the input true value x obtained from the measured value y is solved:

[0039]

[0040] In the formula, m1 and m2 are correction coefficients, the measured value is corrected according to the correction coefficients, and finally the accurate input value is obtained, and the correction and compensation of the data are completed.

[0041] Beneficial effects: the battery charging module power supply inspection work is carried out through the test plate and the detection unit, and the data correction module and the life prediction module are arranged in the detection unit; the data correction module verifies and compensates the data signal collected by the sampling unit, and the life prediction module predicts the life of the battery charging module power supply according to the data compensated by the data correction module, so that the accuracy of the battery charging module power supply inspection can be ensured, the life of the battery charging module power supply is improved, and the data storage and analysis of the upper computer can further optimize the inspection system. BRIEF DESCRIPTION OF DRAWINGS

[0042] Figure 1 It is a system schematic diagram of the application.

[0043] Figure 2 It is a detection unit schematic diagram of the application.

[0044] Figure 3 It is a method schematic diagram of the application.

[0045] Figure 4 It is a method step 4 schematic diagram of the application. DETAILED DESCRIPTION

[0046] The technical solutions of the application will be described clearly and completely in combination with the drawings. Obviously, the described embodiments are part of the embodiments of the application, rather than all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor belong to the protection scope of the application.

[0047] Embodiment 1:

[0048] As shown in Figure 1 and Figure 2 , a high-power battery charging module power supply inspection system comprises:

[0049] The test plate is used for placing the battery charging module power supply and performing inspection work

[0050] a detection unit for collecting data of the battery charging module power supply on the test board, and performing data processing and analysis, and packaging and transmitting data information to an upper computer;

[0051] The upper computer is connected with the detection unit and receives data information of the detection unit, and performs data analysis, arrangement, storage and display.

[0052] The detection unit comprises a sampling unit, a data collection unit, a controller, a data transmission unit, a temperature control unit and a power supply unit.

[0053] The input end of the sampling unit is connected with the output end of the test board, the output end is connected with the input end of the controller and the data collection unit respectively, the output end of the data collection unit is connected with the controller, the temperature control unit is connected with the controller, and the input end of the data transmission unit is connected with the controller and the output end is connected with the upper computer.

[0054] In one embodiment, as shown in Figure 1 and Figure 2 The sampling unit comprises a voltage sampling module, a current sampling module, a temperature sampling module and an isolation module; the input end of the voltage sampling module and the input end of the voltage sampling module are connected with the output end of the test board, and the output end is connected with the input end of the isolation module at the same time, the output end of the isolation module is connected with the data collection unit, and the input end of the temperature sampling module is connected with the controller.

[0055] In one embodiment, as shown in Figure 1 and Figure 2 The controller is provided with a data correction module and a life prediction module; the data correction module verifies and compensates the data signal collected by the sampling unit, and the life prediction module predicts the life of the battery charging module power supply according to the compensated data of the data correction module.

[0056] In one embodiment, as shown in Figure 1 and Figure 2 The upper computer runs operating system environment, instrument driving environment, application software environment, database environment and auxiliary tool software environment on the host computer, and is responsible for the logical control, data processing, data acquisition control, data storage, test report generation and data interpretation of the whole system.

[0057] The upper computer is used for information interaction and control between the test personnel and the test system, mainly including power supply control and monitoring on the workbench, and cantilever display on the side plate of the cabinet, wherein a video switching matrix is arranged in the cabinet.

[0058] Example 2:

[0059] As shown in Figure 3 and Figure 4 A high-power battery charging module power inspection method is realized by an inspection system, and the inspection method comprises the following steps:

[0060] Step 1, place the battery charging module power on the inspection board, and power on the detection unit and the upper computer and establish communication with the inspection board;

[0061] Step 2, the voltage and current signals in the inspection board are sampled by the voltage sampling module and the current sampling module in the sampling unit, and then sent to the data acquisition unit through the isolation module;

[0062] Step 3, the data acquisition unit sends the signal to the controller for analysis and processing after conditioning and quantization, and the temperature signal is sent to the controller for analysis and processing through the temperature sensor;

[0063] Step 4, the controller corrects and predicts the life according to the data signal;

[0064] Step 5, the results of the final processing and the life prediction information are transmitted to the upper computer through the data transmission unit, and the controller controls the temperature control unit sensor acquisition system to collect the internal temperature of the device, and controls the device refrigeration or heating accordingly.

[0065] In one embodiment, as shown in Figure 3 and Figure 4 The specific steps in step 4 are as follows:

[0066] Step 40, correct the data output from the data acquisition unit;

[0067] Step 41, obtain the data required for life prediction;

[0068] Step 42, perform data preprocessing by data filtering, outlier rejection and signal denoising to obtain useful data and further feature extraction, and obtain a data set for life prediction;

[0069] Step 43, divide the data set into training data set and prediction data set, optimize the prediction model on the training set, and use the prediction model on the test set for sequence prediction;

[0070] Step 44, output the prediction result.

[0071] In one embodiment, in step 40, due to the existence of offset error, gain error and temperature drift of the data acquisition unit, the performance will be degraded, so error correction and compensation are needed. Assuming that the data acquisition unit is a linear system, there is a relationship between the input value x and the output value y:

[0072] y=k0x

[0073] wherein k0 represents the nominal sensitivity of the measurement channel, i.e. the nominal gain;

[0074] A zero error and a gain error correction of the linear system are performed, the zero error being that the output value y is not zero when the input value x is zero, and the gain error being the deviation of the actual gain k1 from the nominal gain k0, i.e.

[0075] k=k0+Δk

[0076] Under these two errors, the relationship between the measured input value x and the actual output value y is:

[0077] y=kx+x0

[0078] Dividing the output value by the nominal gain k0, the value thus determined is no longer the true value x of the measured quantity, but:

[0079]

[0080] x 1 The deviation from x, i.e. the measurement error, is:

[0081]

[0082] In order to correct the zero error and the gain error, the input-output relationship after the error correction is first derived and an error correction model is established, and the true value x of the input is obtained from the measured value y:

[0083]

[0084] wherein m1 and m2 are correction coefficients, and the measured value is corrected according to the correction coefficients, so that the accurate input value is finally obtained, and the correction and compensation of the data are completed.

[0085] Obviously, the above embodiments are merely examples for the purpose of clear illustration, and are not intended to limit the embodiments. Other different forms of changes or variations can be made by those of ordinary skill in the art on the basis of the above description. It is not necessary or possible to exhaust all the embodiments. The obvious changes or variations derived therefrom are still within the protection scope of the present application.

Claims

1. A high-power battery charging module power supply inspection system, characterized in that: include: Inspection board, used to place the battery charging module power supply for inspection work; The detection unit is used to collect data from the battery charging module power supply on the inspection board, process and analyze the data, and package the data information and transmit it to the host computer; The host computer is connected to the detection unit and receives data information from the detection unit, and performs data analysis, organization, storage and display. The detection unit includes: a sampling unit, a data acquisition unit, a controller, a data transmission unit, a temperature control unit and a power supply unit; The input end of the sampling unit is connected to the output end of the inspection board, and the output end is respectively connected to the input end of the controller and the data acquisition unit. The output end of the data acquisition unit is connected to the controller, the temperature control unit is connected to the controller, the input end of the data transmission unit is connected to the controller, and the output end is connected to the host computer.

2. A high-power battery charging module power supply inspection system according to claim 1, characterized in that: The sampling unit includes a voltage sampling module, a current sampling module, a temperature sampling module and an isolation module; the input end of the voltage sampling module and the input end of the voltage sampling module are connected to the output end of the inspection board, and the output end is also connected to the input end of the isolation module, the output end of the isolation module is connected to the data acquisition unit, and the input end of the temperature sampling module is connected to the controller.

3. A high-power battery charging module power supply inspection system according to claim 1, characterized in that: The controller is provided with a data correction module and a life prediction module; the data correction module verifies and compensates the data signal collected by the sampling unit, and the life prediction module predicts the life of the battery charging module power supply based on the data compensated by the data correction module.

4. A high-power battery charging module power supply inspection system according to claim 1, characterized in that: The host computer runs the operating system environment, instrument driver environment, application software environment, database environment and auxiliary tool software environment on the main control computer, and is responsible for the logic control, data processing, data acquisition control, data storage, test report generation and data interpretation of the entire system; The host computer is used for information interaction and control between test personnel and the inspection system, mainly including power supply control and monitoring on the work surface, cantilever display on the cabinet side panel, and a video switching matrix is ​​configured inside the cabinet.

5. A high-power battery charging module power supply inspection method, implemented by a high-power battery charging module power supply inspection system according to any one of claims 1 to 4, the inspection method comprising the following steps: Step 1: Place the battery charging module power supply on the test board, and power on the detection unit and the host computer to establish communication with the test board; Step 2: The voltage and current signals in the test board are sampled by the voltage sampling module and the current sampling module in the sampling unit, and then sent to the data acquisition unit after passing through the isolation module; Step 3: The data acquisition unit conditions and quantifies the signal and sends it to the controller for analysis and processing. The temperature signal is sent to the controller for analysis and processing through the temperature sensor; Step 4: The controller performs correction and life prediction based on the data signal; Step 5: The final processing result and life prediction information are transmitted to the host computer through the data transmission unit. The controller simultaneously controls the sensor of the temperature control unit to collect the temperature inside the system equipment and controls the cooling or heating of the equipment accordingly.

6. A high-power battery charging module power supply inspection method according to claim 5, characterized in that: The specific steps in step 4 are as follows: Step 40: Correcting the data outputted from the data acquisition unit; Step 41: Obtain data required for lifespan prediction; Step 42: Preprocess the data by filtering, removing outliers, and denoising the signal to obtain useful data and perform further feature extraction to obtain a data set for lifespan prediction. Step 43: Divide the data set into a training data set and a prediction data set, optimize the prediction model on the training set, and use the prediction model to perform sequence prediction on the test set; Step 44: Output the prediction result.

7. A high-power battery charging module power supply inspection method according to claim 6, characterized in that: In step 40, since the data acquisition unit has offset error, gain error and temperature drift, which will cause performance degradation, error correction and compensation are required. Assume that the data acquisition unit is a linear system, and the input value x and the output value y have the relationship: y=k0x Where k0 represents the nominal sensitivity of the measurement channel, that is, the nominal gain; Correct the zero error and gain error of the linear system. The zero error refers to the output value y not being zero when the input value x is zero. The gain error refers to the deviation between the actual gain k1 and the nominal gain k, that is: k=k0+Δk Under these two errors, the relationship between the measured input value x and the actual output value y is: y=kx+x0 Dividing the output value by the nominal gain k0 determines that the value is no longer the true value x of the measured value, but rather: x 1 The deviation from x, i.e. the measurement error, is: In order to correct the zero error and gain error, we first derive the input-output relationship after error correction and establish an error correction model to obtain the true input value x from the measured value y: Where m1 and m2 are correction coefficients. The measured value is corrected according to the correction coefficients to finally obtain the accurate input value, thus completing the correction and compensation of the data.

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