EOL test integrated system

Abstract

The invention discloses an EOL test integrated system, and belongs to the technical field of battery pack detection. Comprising a test cabinet and an instrument cluster communicating with the test cabinet. The instrument cluster is provided with a program control charging and discharging machine, a safety tester, an air tightness detector and a multi-channel CAN card. The system further comprises a test platform. The test platform automatically issues and controls various test operations through parameters; sampling and data storage are carried out through a data engine, and visualization is provided. According to the invention, integrated, automatic and datamation management of EOL testing is realized; test parameters are configured and automatically issued in a centralized manner through the test platform, test process data and result data are completely recorded and stored, and the risk of data omission caused by manual operation is effectively avoided; and based on detailed process data, tracing analysis and accurate diagnosis are carried out on the defective battery pack.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of battery pack detection, and particularly relates to an EOL test integrated system. BACKGROUND

[0002] PackEOL test is a basic electrical performance and safety detection link before a battery pack leaves the factory. Core projects include: insulation resistance test, potential equalization (ground continuity) test and air tightness test, etc. These tests are key components of battery detection business; mainly through special instruments such as air tightness detector, safety test instrument, ground continuity tester, etc. However, in the field test process, there are significant problems in manual operation directly depending on the instrument: test process data is easy to miss, and instrument parameter setting is tedious, which affects test efficiency and reliability. SUMMARY

[0003] The purpose of the present application is to provide an EOL test integrated system to solve the problems of test data missing and parameter setting being tedious in the field EOL test process.

[0004] In order to achieve the above purpose, the present application adopts the following technical scheme: An EOL test integrated system, comprising a test cabinet and an instrument cluster in communication with the test cabinet; the instrument cluster is provided with: a program-controlled charge-discharge machine, a safety test instrument, an air tightness detector, and a multi-channel CAN card; Further comprising: a test platform; the test platform controls various test operations through automatic parameter issuing; sampling and data storage are performed through a data engine, and visualization is provided.

[0005] In some embodiments, the test cabinet is an industrial control cabinet, provided with: an embedded industrial computer, an EtherCAT master controller, and a safety PLC.

[0006] In some embodiments, the control core of the control layer of the test platform is a device driver library TCP / EtherCAT and a test flow engine; The control layer realizes automatic parameter issuing and device state monitoring through TCP / IP instrument control; high-precision timing synchronization and <1ms control period are realized through an EtherCAT real-time bus.

[0007] In some embodiments, the data layer of the test platform is provided with a data engine, including: a timing database TimescaleDB and a curve analysis module; The curve analysis module is provided with a data visualization engine; the data layer realizes millisecond-level sampling and original data storage through a timing database; dynamic curve generation and abnormal point marking are realized through the data visualization engine.

[0008] In some embodiments, the data layer establishes a multi-level storage mechanism. Level 0: Memory database realizes millisecond-level raw data caching. Level 1: Time series database supports TB-level data storage and configures compression algorithms. Level 2: Blockchain storage layer.

[0009] In some embodiments, the curve analysis module establishes an LSTM neural network model to realize abnormal point prediction of the test curve; a digital twin system is established to construct a battery pack full life cycle performance prediction model.

[0010] In some embodiments, the test platform establishes a battery pack feature database; after the battery pack is put into operation, corresponding parameters are automatically issued according to the model to control the test operation; the test platform dynamically adjusts the test parameters according to the historical test data and real-time feedback.

[0011] In some embodiments, the human-computer interaction of the test platform is a Web visual interface.

[0012] In some embodiments, it further comprises a security layer. The security layer is provided with a hardware emergency stop circuit and a safety interlocking mechanism. The hardware emergency stop circuit has a one-key power-off function and a relay state feedback function. The safety interlocking mechanism has an insulation fault linkage shutdown function and an over-temperature and over-limit protection function.

[0013] In some embodiments, the hardware emergency stop circuit is provided with an emergency stop button; a redundant double-loop design is adopted, the main loop is connected to the safety PLC through the safety relay, the auxiliary loop is connected to the hardware safety button integrated module through the digital quantity input module, and the safety PLC and the hardware safety button integrated module communicate through the redundant EtherCAT bus.

[0014] Compared with the prior art, the present application provides an EOL test integrated system, which has the following beneficial effects.

[0015] 1、The present application realizes the integration, automation and data management of EOL testing; test parameters are configured and automatically issued through the test platform, test process data and result data are recorded and stored completely, data omission risks caused by manual operation are effectively avoided, and problem battery packs are traced, analyzed and accurately diagnosed based on detailed process data.

[0016] Additional advantages, objects, and features of the application will be apparent from the following description; BRIEF DESCRIPTION OF DRAWINGS

[0017] Fig. 1 is a platform architecture diagram of the present application.

[0018] Fig. 2 is a schematic diagram of the software layer.

[0019] Fig. 3 is a schematic diagram of the hardware layer. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application.

[0021] Referring to Figs. 1-3 An EOL test integrated system includes a test cabinet and an instrument cluster in communication with the test cabinet; the instrument cluster is provided with components such as a program-controlled charge-discharge machine, a safety test instrument, a gas tightness detector, and a multi-channel CAN card (different instruments can be added according to test requirements).

[0022] Further, the system includes a test platform; the test platform automatically issues parameters to control various test operations; sampling and data storage are performed through a data engine, and visualization is provided.

[0023] It can be understood that the test cabinet and the instrument cluster are hardware parts, and the test platform is a software system.

[0024] The test cabinet is an industrial control cabinet, which is provided with an embedded industrial computer, an EtherCAT master controller, and a safety PLC. As the core operation and control unit of the system, the test cabinet is responsible for coordinating the operation of various devices and processing data; the EtherCAT master controller realizes high-precision real-time communication and device control, ensuring the collaborative work of various devices in the system; and the safety PLC ensures the safety of the entire test process, and can take safety measures such as emergency stop of device operation when an abnormal situation is detected.

[0025] The program-controlled charge-discharge machine can accurately control the charging and discharging process of the battery pack according to test requirements, simulate different working scenarios, and detect performance indicators of the battery pack in the charging and discharging process, such as capacity and charging and discharging efficiency.

[0026] Safety test instrument: used for safety performance test of battery pack, including insulation resistance test, ground resistance test, voltage resistance test, etc., to ensure the safety of battery pack during use and prevent safety hazards such as electric leakage.

[0027] Air tightness detector: through air tightness detection of battery pack, to judge whether the sealing performance of battery pack is good, to prevent external gas or liquid from entering the inside of battery pack and affecting the performance and life of battery pack.

[0028] Multi-channel CAN card: realizes communication between test system and BMS (battery management system) of battery pack and other CAN bus devices, can quickly and accurately transmit test instructions and collect data feedback from BMS, and provides data support for comprehensive evaluation of performance of battery pack.

[0029] The control core of the control layer of the test platform is the device driver library TCP / EtherCAT and the test process engine; the control layer realizes automatic parameter distribution and device state monitoring through TCP / IP instrument control; high-precision timing synchronization and <1ms control cycle are realized through EtherCAT real-time bus. In complex test scenarios, each test device can work cooperatively according to precise time sequence, improving test accuracy and reliability.

[0030] The data layer of the test platform sets up a data engine, including a timing database TimescaleDB and a curve analysis module; at the same time, the curve analysis module is provided with a data visualization engine; the data layer realizes millisecond-level sampling and raw data storage through the timing database; dynamic curve generation and abnormal point marking are realized through the data visualization engine.

[0031] The curve analysis module realizes dynamic curve generation according to collected data, and intuitively displays the performance change trend of battery pack during the test process; at the same time, it can intelligently mark abnormal points, facilitating test personnel to quickly find and analyze problems.

[0032] It can be understood that the test platform establishes a battery pack characteristic database (basically covering the model parameters to be detected); after the battery pack goes online, the corresponding parameters are automatically distributed according to its model to control the test operation; the collected data are compared with the preset data to monitor abnormalities.

[0033] Further, the battery pack characteristic database is automatically optimized; the test platform dynamically adjusts the test parameters according to historical test data and real-time feedback. For example, according to the performance of the battery pack in the early stage of charging and discharging, the subsequent charging and discharging test curve is automatically optimized, so that the test is more in line with the actual characteristics of the battery pack, and the test accuracy and efficiency are improved.

[0034] In some embodiments, to improve storage performance, a multi-level storage mechanism is established in the data layer.

[0035] Level0: Memory database (Redis) implements millisecond-level raw data cache; Level1: Time series database (TimescaleDB) supports TB-level data storage and configures compression algorithms.

[0036] Optionally, to ensure data reliability, a secure storage mechanism is established.

[0037] Level2: Blockchain storage layer; if Hyperledger Fabric architecture is used, test data cannot be tampered with.

[0038] In some embodiments, the curve analysis module establishes an LSTM neural network model to predict abnormal points in the test curve; a digital twin system is established to build a battery pack life cycle performance prediction model.

[0039] Intelligent data layer fusion, data engine and neural network model deep integration; in the data sampling stage, according to the type, production batch and other information of the battery pack, dynamically adjust the sampling frequency, reduce unnecessary data storage under the premise of ensuring data integrity. After data storage, the original data is intelligently classified and labeled, which is convenient for subsequent retrieval and analysis. The data visualization engine in the curve analysis module realizes dynamic curve generation and abnormal point marking under the support of intelligence; according to historical data and industry standards, etc., the abnormal points are intelligently diagnosed, and possible fault reasons and solution suggestions are given.

[0040] Intelligent analysis and prediction through neural network model; deep analysis of a large amount of test data, through the establishment of battery pack performance model to predict key performance indicators such as capacity attenuation and internal resistance change of battery pack, to find potential problem battery pack in advance. At the same time, real-time analysis of data during the test; when detecting abnormal data trend, timely warning and automatic adjustment of test process to increase related test items or prolong test time to more accurately judge the performance and quality of battery pack.

[0041] Self-learning and optimization ability; according to the actual test results and production feedback, continuously optimize its own algorithm and model; with the continuous accumulation of test data, the accuracy of analysis and prediction will continue to improve, so that the system can better adapt to different production environments and battery pack model test requirements.

[0042] In some embodiments, the human-computer interaction of the test platform is a Web visual interface; convenient for personnel to operate, adjust, and intuitively view various data.

[0043] Further, the structure stress, temperature distribution, current flow direction and other multi-dimensional information of the battery pack are visually displayed in the form of a three-dimensional model; the tester can rotate and scale the model in real time to view detailed data of each part, facilitating in-depth analysis of the complex physical and chemical changes inside the battery pack and assisting in optimizing the design and production process of the battery pack.

[0044] In some embodiments, further comprising: a safety layer.

[0045] The safety layer is provided with: a hardware emergency stop circuit and a safety interlocking mechanism; The hardware emergency stop circuit has: a one-key power-off function and a relay state feedback function; The safety interlocking mechanism has: an insulation fault linkage shutdown function and an over-temperature and over-limit protection function.

[0046] The hardware emergency stop circuit is provided with an emergency stop button; preferably, a red mushroom head emergency stop button with a diameter of not less than 40 mm is adopted, the surface of which is provided with anti-slip texture; the emergency stop button has a manual reset function and needs to be rotated to unlock after being pressed; the protection level reaches IP67 and is suitable for industrial environments.

[0047] Further, a redundant dual-loop design is adopted; the main loop is connected to the safety PLC through a safety relay, the auxiliary loop is connected to the hardware safety button integrated module through a digital quantity input module, and the safety PLC and the hardware safety button integrated module communicate through a redundant EtherCAT bus.

[0048] It can be understood that an emergency stop button is arranged near each detection device of the test cabinet and the instrument cluster, which can be triggered quickly and conveniently.

[0049] Trigger state: when any emergency stop button is pressed, the safety PLC triggers a safety output immediately to cut off the main power supply loop of all detection devices; the hardware safety button integrated module sends an emergency stop command to the test platform and all instrument cluster devices through the EtherCAT bus; the test platform terminates all ongoing test processes, saves the current test data to a time sequence database, triggers an audible and visual alarm system, and records event logs (including time stamp, trigger button ID, etc.). Recovery state: manually reset all pressed emergency stop buttons, remove the emergency stop state through permission verification (password / fingerprint / IC card, etc.), the system automatically performs a safety self-check to confirm that all devices are in a safe state, and the test can be resumed from the breakpoint or the test process can be restarted.

[0050] The implementation process of the system is as follows.

[0051] System construction.

[0052] Firstly, the embedded industrial computer, EtherCAT master controller and safety PLC components are installed in the industrial control cabinet; hardware connection and debugging are performed to ensure that the components in the test cabinet can communicate and work cooperatively.

[0053] Then, the program-controlled charge-discharge machine, safety testing instrument, air tightness detector and multi-channel CAN card are connected to form an instrument cluster, which is connected to the test cabinet through a communication cable to complete the communication setting of the instrument cluster and the test cabinet, ensuring that the test cabinet can effectively control each device in the instrument cluster.

[0054] Finally, the test platform is built, the device driver library TCP / EtherCAT and test process engine are installed, the timing database TimescaleDB and the data visualization engine of the curve analysis module are configured, the initialization setting of the test platform is completed, and the data communication between the test platform and the test cabinet and the instrument cluster is ensured to be normal.

[0055] Test process.

[0056] Automatic parameter issuance: the test system issues corresponding test configuration parameters according to the battery pack model, batch information (automatic identification, scanning, manual selection, etc.), etc.

[0057] If there is no preset parameter for the battery pack, manual parameter setting is required.

[0058] Manual parameter setting: the operator sets various test parameters through the human-machine interface of the test platform according to the type of the battery pack and the test requirements; for example, the charge-discharge current, voltage, time and other parameters of the program-controlled charge-discharge machine, the test standard of the safety testing instrument, the detection pressure of the air tightness detector; the test platform automatically issues these parameters to the corresponding test equipment through TCP / IP instrument control.

[0059] Test execution: after starting the test, the test platform coordinates each test equipment to test according to the predetermined test order and time through the test process engine. For example, first, the multi-channel CAN card establishes communication with the BMS of the battery pack to obtain the basic information of the battery pack; then, the program-controlled charge-discharge machine performs charge-discharge test on the battery pack, while the safety testing instrument performs safety performance test on the battery pack, and the air tightness detector performs air tightness test on the battery pack. During the test, each test equipment transmits test data to the test platform in real time.

[0060] Data acquisition and storage: the data engine of the test platform performs millisecond-level sampling on the data transmitted by each test equipment through the timing database TimescaleDB, and stores the raw data in the database.

[0061] Data visualization and analysis: According to the collected data, dynamic curves are generated to show the performance change trend of the battery pack during the test process, such as voltage change curve, current change curve, temperature change curve, etc. At the same time, abnormal points in the curve are marked, such as voltage mutation point, current abnormal fluctuation point, etc. Test personnel can view these curves and abnormal point information through the human-computer interface of the test platform to evaluate and analyze the performance of the battery pack. In addition, intelligent analysis and prediction are realized through LSTM neural network model and battery pack full life cycle performance prediction model.

[0062] Test result judgment: The test platform determines whether the battery pack is qualified according to the preset test standard and analysis and prediction results. If the test data of the battery pack meets the preset standard, it is determined to be qualified; if one or more data does not meet the standard, it is determined to be unqualified, and the unqualified items and data are listed in detail in the test report.

[0063] Test report generation: After the test is completed, the test platform automatically generates a test report, which includes the basic information of the battery pack, test parameters, test data, test results, dynamic curves and abnormal point analysis, etc. The test report can be stored in the test platform in the form of electronic document, or printed out by the printer for easy archiving and checking.

[0064] The EOL test integrated system provided by the application realizes the integration, automation and data management of EOL test; through the centralized configuration and automatic distribution of test parameters by the test platform, the test process data and result data are recorded and stored completely, effectively avoiding the data omission risk caused by manual operation; based on detailed process data, the problem battery pack is analyzed and accurately diagnosed.

[0065] The application has at least the following advantages.

[0066] Integrated design improves test efficiency: By integrating various test instruments such as program-controlled charge-discharge machine, safety test instrument, air tightness detector, etc. in the instrument cluster, and working with the test cabinet and test platform, one-stop completion of various test items of the battery pack is realized, avoiding the cumbersome process of switching between different devices and stations in traditional test method, greatly improving the test efficiency.

[0067] High-reliability communication interface: The communication between the test instrument and the test platform adopts the communication mode based on TCP / IP protocol, ensuring stable and reliable data transmission and strong anti-interference ability.

[0068] Parameter automatic distribution and optimization: The test platform automatically distributes parameters and dynamically adjusts test parameters according to historical test data and real-time feedback.

[0069] High-precision control and synchronization improve test accuracy: The high-precision timing synchronization and less than 1ms control cycle realized by the EtherCAT master controller enable the test equipment to work accurately and cooperatively, reduce errors in the test process, and improve the accuracy of test results. The test process is fine-tuned by the device driver library TCP / EtherCAT and the control core of the test flow engine, ensuring the stability and reliability of the test process.

[0070] Efficient data processing and visualization: The test platform realizes millisecond-level sampling and raw data storage through the timing database TimescaleDB, which can quickly and comprehensively record data in the test process; the hybrid storage architecture of the in-memory database and TimescaleDB is adopted, with high-frequency real-time sampling data temporarily stored in the in-memory database to ensure data read-write speed, and periodically archived to TimescaleDB for long-term storage and analysis. The data visualization engine converts data into intuitive dynamic curves (such as dynamically converting key test parameters such as "voltage, current, temperature, etc." into trend curves) for process monitoring and result analysis; abnormal points are marked, and test personnel can quickly understand the performance status of the battery pack and timely find problems.

[0071] Emergency safety mechanism: Real-time monitoring of system operation status, immediate safety measures when abnormal conditions are detected, such as overcurrent, overvoltage, equipment failure, etc., to stop equipment operation and prevent safety accidents; integrated hardware-level emergency stop function, supports one-key triggering, can immediately interrupt all test processes and cut off related power supply in emergency situations, ensuring the safety of test personnel and equipment.

[0072] The above is only the preferred specific implementation of the present application, but the protection scope of the present application is not limited thereto, any person skilled in the art can make equivalent substitutions or changes within the technical scope disclosed by the present application according to the technical solution and inventive concept of the present application, which should be covered within the protection scope of the present application.

[0073] In the description of the present application, the description of the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In the present application, the illustrative description of the above terms is not necessarily for the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any suitable manner in any one or more embodiments or examples. In addition, the skilled in the art can combine and combine the different embodiments or examples described in the present application and the features of the different embodiments or examples without contradiction.

[0074] Although the embodiments of the present application have been shown and described above, it is understood that the above-described embodiments are exemplary and are not to be construed as limiting the present application, and that changes, modifications, substitutions and variations can be made by those skilled in the art without departing from the scope of the present application.

Claims

1. An EOL test integration system, comprising: The test cabinet and the instrument cluster in communication with the test cabinet are included; The instrument cluster is provided with a program-controlled charge-discharge machine, a safety test instrument, a gas tightness detector, and a multi-channel CAN card; It also includes a test platform; the test platform controls various test operations through automatic parameter issuance; sampling and data storage are performed through a data engine, and visualization is provided.

2. The EOL test integration system of claim 1, wherein, The test cabinet is an industrial control cabinet, which is provided with an embedded industrial computer, an EtherCAT master controller, and a safety PLC.

3. The EOL test integration system of claim 1, wherein, The control core of the control layer of the test platform is a device driver library TCP / EtherCAT and a test process engine; The control layer realizes automatic parameter issuance and device state monitoring through TCP / IP instrument control, and realizes high-precision timing synchronization and <1ms control period through EtherCAT real-time bus.

4. The EOL test integration system of claim 1, wherein, The data layer of the test platform is provided with a data engine, including a timing database TimescaleDB and a curve analysis module; The curve analysis module is provided with a data visualization engine; the data layer realizes millisecond-level sampling and raw data storage through the timing database, and realizes dynamic curve generation and abnormal point marking through the data visualization engine.

5. The EOL test integration system of claim 4, wherein, The data layer establishes a multi-level storage mechanism; Level 0: Memory database realizes millisecond-level raw data caching; Level 1: Timing database supports TB-level data storage and configures compression algorithm; Level 2: Blockchain storage layer.

6. The EOL test integration system of claim 4, wherein, The curve analysis module establishes an LSTM neural network model to realize abnormal point prediction of test curves; a digital twin system is established to build a battery pack full-life cycle performance prediction model.

7. The EOL test integration system of claim 1, wherein, The test platform establishes a battery pack feature database; after the battery pack is put into operation, corresponding parameters are automatically issued according to its model to control test operations; the test platform dynamically adjusts test parameters according to historical test data and real-time feedback.

8. The EOL test integration system of claim 1, wherein, The human-computer interaction of the test platform is a Web visualization interface.

9. The EOL test integration system of claim 1, wherein, It also includes: A safety layer; The safety layer is provided with a hardware emergency stop circuit and a safety interlocking mechanism; The hardware emergency stop circuit has a one-key power-off function and a relay state feedback function; The safety interlocking mechanism has an insulation fault linkage shutdown function and an over-temperature and over-limit protection function.

10. The EOL test integration system of claim 9, wherein, The hardware emergency stop circuit is provided with an emergency stop button; a redundant double-circuit design is adopted, the main circuit is connected to the safety PLC through the safety relay, the auxiliary circuit is connected to the hardware safety button integrated module through the digital quantity input module, and the safety PLC and the hardware safety button integrated module communicate through the redundant EtherCAT bus.

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