Battery replacement compatibility test method and system for battery replacement battery system

Abstract

The invention relates to the technical field of battery replacement compatibility testing, in particular to a battery replacement compatibility testing method and system oriented to a battery replacement battery system. The method comprises the following steps: carrying out multiple staggered releasing / locking cycles on a to-be-tested battery replacement battery system on a simulated vehicle; if the structure and the function of the battery replacement battery system are normal, the battery replacement battery system is installed on a real vehicle, and the real vehicle runs on a test site; and according to whether the communication between the battery replacement battery system and the real vehicle is normal, whether the battery replacement cooling interface leaks the cooling liquid, whether the battery replacement battery system is in an effective locking state, whether the battery replacement electrical interface is normal, and whether the battery frame is normal, performing a vehicle end cooperative function test on the battery replacement battery system. Through a simulation vehicle, a real vehicle, a battery swap station simulation system and a vehicle end simulation system, the compatibility of the battery swap battery system with the vehicle end and the battery swap station is tested from the aspects of size, structure, function, passing and the like.

Description

Technical Field

[0001] This application relates to the field of battery swapping compatibility testing technology, and more specifically, to a battery swapping compatibility testing method and system for battery swapping systems. Background Technology

[0002] The battery swapping system is a quick-replaceable assembly that integrates a battery pack, battery management system, mechanical locking mechanism, and electrical / cooling interface. Ensuring its compatibility with swapping stations and vehicles is crucial because it ensures that battery packs of different brands and models can be safely, reliably, and efficiently identified, replaced, locked, and charged / discharged in any compatible swapping station through standardized physical dimensions, electrical protocols, and communication standards.

[0003] The compatibility (also known as interchangeability or interoperability) of electric vehicle battery swapping systems refers to the ability of the battery swapping system to be installed in vehicles of different brands and manufacturers, and to be charged and discharged at battery swapping stations of different specifications.

[0004] Existing technologies lack testing schemes for compatibility between battery swapping systems and vehicles, as well as compatibility between battery swapping systems and battery swapping stations. Therefore, this application is submitted. Summary of the Invention

[0005] The purpose of this application is to provide a battery swapping compatibility testing method and system for battery swapping systems, so as to test the compatibility of the battery swapping system with both the vehicle and the battery swapping station in terms of size, structure, function and accessibility through simulated vehicles, real vehicles, battery swapping station simulation systems and vehicle-side simulation systems.

[0006] To achieve the above objectives, this application adopts the following technical solution: Firstly, this application provides a battery swapping compatibility testing method for battery swapping systems, including: The battery swapping system under test was subjected to multiple release / lock cycles in a staggered manner on a simulated vehicle. During the cycle, vibrations were transmitted to the battery swapping system through the simulated vehicle. Determine whether the structure and function of the battery swapping system are normal; If the battery swapping system is in good working order, install the battery swapping system onto a real vehicle and run the real vehicle on a test track. During operation, the vehicle-side collaborative function of the battery swapping system is tested based on whether the communication between the battery swapping system and the actual vehicle is normal, whether the battery swapping cooling interface leaks coolant, whether the battery swapping system is in an effective locked state, whether the battery swapping electrical interface is normal, and whether the battery frame is normal.

[0007] Secondly, this application provides a battery swapping compatibility testing system for battery swapping systems, comprising: The simulated vehicle is used to perform multiple release / lock cycles on the battery swapping system under test in a staggered manner, transmitting vibrations to the battery swapping system during the cycle. A battery swapping system testing device is used to determine whether the structure and function of the battery swapping system are normal. A real vehicle is used to install the battery swapping system on a real vehicle if the structure and function of the battery swapping system are normal, and to run the real vehicle on a test track. During the operation, the vehicle-side collaborative function of the battery swapping system is tested based on whether the communication between the battery swapping system and the real vehicle is normal, whether the battery swapping cooling interface leaks coolant, whether the battery swapping system is in an effective locked state, whether the battery swapping electrical interface is normal, and whether the battery frame is normal.

[0008] Compared with the prior art, the beneficial effects of this application are as follows: This application achieves comprehensive and efficient verification of vehicle-side battery swapping components by constructing a multi-stage collaborative testing system consisting of dimensional testing, functional testing, and communication testing. This testing method ensures that key components such as the battery swapping electrical interface socket, vehicle-side battery swapping cooling interface, and on-board battery swapping base are precisely matched in physical dimensions and are stable and reliable in basic functions. Furthermore, by simulating the power-on / off, charging, and communication behaviors of real batteries through a battery swapping simulation system, it exposes and resolves potential compatibility issues between the vehicle and the battery swapping system in terms of electrical coordination, control logic, and data interaction in advance. This significantly improves the reliability, safety, and efficiency of the battery swapping process, and reduces the risk of failure and subsequent maintenance costs due to component incompatibility. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0010] Figure 1 This is a flowchart of a battery swapping compatibility testing method for battery swapping systems provided in an embodiment of this application; Figure 2 This is a schematic diagram of the vehicle-end simulation system provided in the embodiments of this application; Figure 3 This is a schematic diagram of the structure of the battery swapping station simulation system provided in the embodiments of this application. Detailed Implementation

[0011] The following description, in conjunction with the accompanying drawings, illustrates exemplary embodiments of this application, including various details to aid understanding. These should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of this application. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0012] The present application will be further described in detail below with reference to the embodiments.

[0013] Figure 1 This is a flowchart illustrating a battery swapping compatibility testing method for battery swapping systems, provided in an embodiment of this application. This method can be executed by a battery swapping compatibility testing system for battery swapping systems. This application is applicable to scenarios involving battery swapping compatibility testing of battery swapping systems. The compatibility testing provided in this embodiment includes compatibility testing between the battery swapping system and both the vehicle and the battery swapping station.

[0014] See Figure 1 The method provided in this embodiment includes: S110. The battery swapping system to be tested is subjected to multiple release / lock cycles in a staggered manner on a simulated vehicle. During the cycle, vibration is transmitted to the battery swapping system through the simulated vehicle.

[0015] The simulated vehicle consists of longitudinal beams and a battery swapping bracket. It's clear that the "simulated vehicle" is not a complete real vehicle, but rather a specialized bench integrating the core underbody structure—the longitudinal beams (the main frame supporting the vehicle's weight)—and the battery swapping bracket (a crucial interface connecting the battery pack to the vehicle body). By assembling these two core components according to the geometry, connection methods, and tightening torque of a real vehicle, this simulated vehicle can highly replicate the actual installation environment and constraint conditions of a battery swapping system in a real vehicle.

[0016] The battery swapping system to be tested was installed on a simulated vehicle, simulating a vehicle assembly state. 10,000 battery swapping operations were performed under conditions of 5mm offset in both the lateral and longitudinal directions and a 1° vehicle body tilt angle. Specifically, the longitudinal direction (x-direction) is the vehicle's forward and backward movement, and the lateral direction (y-direction) is the vehicle's left and right movement. With 5mm offsets in both the ±x and ±y directions, and a 1° vehicle body tilt angle without offset, 2,000 battery swaps were performed in each direction. During this period, the battery swapping mechanism of the system completed 10,000 release and lock cycles.

[0017] The test system transmits vibrations to the battery swapping system via a simulated vehicle. Specifically, the battery swapping system under test is installed on the simulated vehicle in the same assembly state as the actual vehicle, and all battery swapping lock mechanisms are locked as specified. Then, a hydraulic or electric actuator (vibration exciter) is installed at each of the four support points of the simulated vehicle (corresponding to the installation positions of the vehicle's suspension). During testing, the test system injects pre-collected and edited road load spectra into these four actuators. Based on the road load spectra, the actuators accurately reproduce the multidimensional vibrations, impacts, and loads experienced during vehicle operation in six degrees of freedom, thus directly transmitting the most realistic road vibration environment to the battery swapping system through the simulated vehicle.

[0018] S120. Determine whether the structure and function of the battery swapping system are normal.

[0019] 1. Check the appearance of the battery swapping system for deformation, cracks, twisting, or other defects.

[0020] 2. Check that the battery swapping electrical interface of the battery swapping system is in a valid connection state, and that there is no dielectric breakdown or arcing between conductors, between conductors and the outer shell, or between conductors and the shielding layer of the battery swapping electrical interface.

[0021] 3. Check whether the battery swapping system is damaged such as deformation, cracking, loosening, or falling off, and whether the locking function is intact.

[0022] 4. Check if there is any coolant leakage at the battery swapping cooling interface of the battery swapping system.

[0023] 5. Check whether the battery frame of the battery swapping system has irreversible deformation, cracks or other structural damage and functional loss.

[0024] If all five inspection items are normal (no deformation in appearance, effective connection of the battery swapping electrical interface, intact locking function, no coolant leakage, and normal and undamaged battery frame), then the battery swapping system is structurally and functionally normal. If at least one inspection item is abnormal, then the battery swapping system is structurally and functionally abnormal and fails the compatibility test.

[0025] S130. If the structure and function of the battery swapping system are normal, install the battery swapping system on a real vehicle and run the real vehicle on a test track.

[0026] If the battery swapping system is structurally or functionally faulty, S150 is executed, and the compatibility test fails.

[0027] The battery swapping system was installed on a real vehicle to simulate real charging and discharging conditions. The real vehicle was driven for at least 500 meters within the test track.

[0028] S140. During operation, the vehicle-side collaborative function test is performed on the battery swapping system based on whether the communication between the battery swapping system and the real vehicle is normal, whether the battery swapping cooling interface leaks coolant, whether the battery swapping system is in an effective locked state, whether the battery swapping electrical interface is normal, and whether the battery frame is normal.

[0029] Specifically, the following implementation methods are included: 1. Collect communication signals from the battery swapping system and determine whether the content and timing of the communication signals meet the requirements.

[0030] Specifically, after the vehicle is powered on at low voltage, it should receive a message indicating that the battery swapping system has successfully completed its self-test. After the vehicle is powered on at high voltage, it sends a high-voltage power-on command to the battery swapping system. The vehicle should receive feedback from the battery swapping system regarding the relay status, and the high-voltage electrical components should be enabled. The vehicle then sends both a high-voltage power-off command and a low-voltage power-off command to the battery swapping system and disconnects the activation circuit. The vehicle should receive feedback from the battery swapping system regarding the relay status and a message indicating that low-voltage power-off is permitted, and the battery swapping system should enter a dormant state. After the vehicle performs a low-voltage power-on and starts charging, it sends a BMS high-voltage request and a charging permission command to the battery swapping system. If the vehicle receives a charging preparation not ready message from the battery swapping system first, followed by a charging preparation ready message, then the requirements are met.

[0031] 2. Collect the leaked coolant from the battery swapping cooling interface and perform a vehicle-side collaborative function test based on the amount of coolant leakage. If the leakage exceeds a set threshold, the collaborative function test will fail.

[0032] 3. Check whether the battery swapping mechanism of the battery swapping system is damaged (e.g., deformed, cracked, loose, or detached) and determine whether the battery swapping system is in an effective locking state; if it is not in an effective locking state or is damaged, it will not pass the vehicle-side collaborative function test.

[0033] 4. Check whether the battery swapping electrical interface is in a valid connection state, and whether there is any dielectric breakdown or arcing between the conductors, between the conductor and the outer shell, or between the conductor and the shielding layer of the battery swapping electrical interface; determine whether the vehicle-side coordination function test is passed based on the test results. If the battery swapping electrical interface is in a valid connection state, and no dielectric breakdown or arcing occurs between the conductors, between the conductor and the outer shell, or between the conductor and the shielding layer of the battery swapping electrical interface, then the vehicle-side coordination function test is passed.

[0034] 5. Check whether the battery frame has structural damage or functional loss; if structural damage (such as irreversible deformation, cracks, etc.) or functional loss occurs, the vehicle-side collaborative function test will not be passed.

[0035] The battery swapping compatibility testing method provided in this embodiment, through a composite stress test combining "misaligned release / locking cycle" with simulated vehicle vibration in a laboratory environment, can proactively and efficiently expose potential structural defects and functional failure risks of the battery swapping system under mechanical alignment, locking mechanism durability, and vibration conditions before actual vehicle operation. This method constructs a phased, collaborative testing system from laboratory simulation to real-world testing, enabling compatibility testing of key performance aspects of the battery swapping system, including mechanical interfaces, locking functions, electrical connections, cooling and sealing, and vehicle-side communication.

[0036] Optionally, before performing staggered release / lock cycles on a simulated vehicle, the battery swapping system to be tested may also include dimensional testing of the battery swapping electrical interface, battery swapping cooling interface, bottom structure, and shape of the battery swapping system to be tested.

[0037] Use a vernier caliper with a graduation of 0.01 mm or a similar measuring instrument to check the critical dimensions of the battery swapping electrical interface; use a coordinate measuring machine or a similar measuring instrument to check the external contour of the battery swapping electrical interface. If the structure and spatial dimensions of the battery swapping electrical interface comply with the relevant standards and regulations, proceed to the next step of the test. Use a vernier caliper with a graduation of 0.01 mm or a similar measuring instrument to check the critical structural dimensions of the battery swapping cooling interface; use a coordinate measuring machine or a similar measuring instrument to check the external contour spatial dimensions of the battery swapping cooling interface. If the structure and spatial dimensions of the battery swapping cooling interface comply with the relevant standards and regulations, proceed to the next step of the test. Use a vernier caliper with a graduation of 0.01 mm or a similar measuring instrument to check the positions of the guides, locking mechanisms, bearing surfaces, electrical interfaces, and cooling interfaces at the bottom of the battery swapping system. If the bottom structure and spatial dimensions comply with the relevant standards and regulations, proceed to the next step of the test. Use a measuring tape with a graduation of 1 mm or a similar measuring instrument to check the external dimensions of the battery swapping system. If its dimensions comply with the relevant standards and regulations, proceed to the following testing steps.

[0038] To facilitate testing, this embodiment innovatively employs a test vehicle-side simulation system to mimic the vehicle's capabilities. (See also...) Figure 2 The vehicle-side simulation system includes: an on-board battery swapping base simulation unit, an on-board control simulation unit, a battery swapping electrical interface simulation socket, a vehicle-side battery swapping cooling simulation interface, and an industrial control computer.

[0039] Among them, the vehicle-mounted battery swapping base simulation unit meets the battery swapping standard requirements in terms of size, and fixes the battery swapping electrical interface simulation socket, vehicle-end battery swapping cooling simulation interface, coarse guide device, fine guide device and locking mechanism in accordance with the standard requirements.

[0040] The battery swapping electrical interface simulation socket can be plugged into the battery swapping electrical interface of the battery swapping system to establish an electrical connection. It integrates the vehicle-side charging control guidance circuit for transmitting electrical energy and electrical signals. It may have a guiding and floating mechanism (used to absorb the relative displacement between the battery swapping system and the vehicle and maintain the pre-tightening force of the plug-in, which may be composed of a floating bracket, floating plate, positioning rod, positioning sleeve and support spring, etc.).

[0041] The vehicle-side battery swapping cooling simulation interface can be plugged into the battery swapping cooling interface of the battery swapping system to transmit the cooling medium. It can have a guiding and floating mechanism (used to absorb the relative displacement between the battery swapping system and the vehicle and maintain the pre-tightening force of the plugging, which can be composed of a floating bracket, a floating plate, a positioning rod, a positioning sleeve and a support spring, etc.).

[0042] The vehicle control simulation unit includes a high-voltage electrical device simulation unit, a vehicle switch, and a CAN communication simulation unit.

[0043] The high-voltage electrical component simulation unit can simulate high-voltage electrical components in a vehicle, such as motors, air conditioners, and PTCs. It works in conjunction with the CAN communication simulation unit, vehicle switch, and battery swapping electrical interface simulation socket to test the low-voltage power-on, high-voltage power-on, high-low voltage power-off, and charging steps in the battery swapping communication process. The vehicle switch can connect or disconnect the battery swapping electrical interface simulation socket from the high-voltage electrical component simulation unit, used to connect or disconnect power from the battery swapping system. The CAN communication simulation unit can simulate the vehicle controller or T-Box, simulating the vehicle's needs and communication.

[0044] The industrial control computer integrates communication protocol testing software, which controls the CAN communication simulation unit to conduct communication process tests.

[0045] Optionally, an electrical load test can be performed on the battery swapping electrical interface using a simulated socket. Specifically, the battery swapping electrical interface of the battery swapping system is installed on the simulated socket of the vehicle-side simulation system to form the electrical interface assembly under test. An AC test voltage of 50Hz~60Hz is applied to the electrical interface assembly for 1 minute. If basic insulation is used, an AC voltage of 2U + 1000V (rms) is applied; if double insulation and reinforced insulation are used, an AC voltage of 2U + 3250V (rms) is applied, where U is the maximum operating voltage of the circuit connected to the assembly, in volts (V). The equivalent DC test voltage is 1.41 times the AC voltage. If the electrical interface assembly can withstand the specified voltage between conductors, between conductors and the shell, between conductors and the shielding layer, and between the shielding layer and the shell, without dielectric breakdown or arcing, and the leakage current during the test is ≤5mA, then the electrical load test is passed.

[0046] The battery swapping cooling interface was tested for sealing using a vehicle-side battery swapping cooling simulation interface. Specifically, the battery swapping cooling interface was plugged into the vehicle-side battery swapping cooling simulation interface of the vehicle-side simulation system to form the cooling interface assembly under test. Differential pressure transmitters were connected to the inlet and outlet sides of the cooling interface assembly, and a cooling medium of 50% ethylene glycol and 50% water at a temperature of 25 ℃ was introduced. If the measurement result (pressure drop across the cooling interface assembly under test) met the pressure difference corresponding to the flow rate, the following test steps were performed.

[0047] Apply 0.25 MPa compressed air to the cooling interface assembly under test, maintain the pressure for 2 minutes, and measure the gas leakage. If the gas leakage is less than 0.5 cc / min, continue with the following test steps. Apply a suitable liquid (50% ethylene glycol and 50% water) at 0.1 MPa pressure to the cooling interface assembly under test, and perform insertion and removal cycles at a speed of 10 mm / s. After 1000 cycles, measure the coolant loss. Calculate the average leakage per insertion and removal cycle. If the average leakage is less than or equal to 0.5 mL / cycle, the sealing test is passed.

[0048] Similar to the driving tests on a real vehicle, a vehicle-side simulation system is used to conduct communication tests on the battery swapping system. Specifically, after the vehicle-side simulation system powers on at low voltage, it should receive a message indicating that the battery swapping system has successfully completed its self-test. After the vehicle-side simulation system powers on at high voltage, it sends a high-voltage power-on command to the battery swapping system, and it should receive a relay status feedback from the battery swapping system. The vehicle-side simulation system then sends both a high-voltage power-off command and a low-voltage power-off command to the battery swapping system and disconnects the activation circuit. The vehicle-side simulation system should receive a relay status feedback from the battery swapping system, a message indicating that low-voltage power-off is permitted, and the battery swapping system enters a sleep state. After the vehicle-side simulation system powers on at low voltage and starts charging, it sends a BMS high-voltage request and a charging permission command to the battery swapping system. The vehicle-side simulation system first receives a charging preparation not-ready message from the battery swapping system, and then receives a charging preparation ready message. After the vehicle-side simulation system stops charging, it should receive a charging stop message. The battery swapping system will then enter a low-voltage power-off or sleep state. If the vehicle-side simulation system receives the status of the battery swapping system's relay (or battery switch), the communication test will be passed.

[0049] This embodiment, in addition to vehicle-side testing, also conducted collaborative function testing between the battery swapping system and the charging station. This embodiment innovatively provides a test battery swapping station simulation system. See [link / reference] Figure 3 The battery swapping station simulation system includes: battery swapping electrical interface simulation socket, battery swapping cooling interface simulation socket, in-station communication control simulation unit, battery swapping replacement simulation equipment, battery rack simulation unit, and industrial control computer.

[0050] The battery swapping electrical interface simulates a socket, integrating the charging control guidance circuit at the battery swapping station. It has a guiding and floating mechanism (used to absorb the relative displacement between the battery swapping system and the battery rack equipment at the battery swapping station, and to maintain the pre-tightening force of the connection, which can be composed of a floating bracket, a floating plate, a positioning rod, a positioning sleeve, and a support spring, etc.) to establish an electrical connection with the battery swapping electrical interface and transmit electrical energy and electrical signals.

[0051] The battery swapping cooling interface simulates a socket with a guide and floating mechanism (used to absorb the relative displacement between the battery swapping system and the battery rack equipment in the battery swapping station, and to maintain the pre-tightening force for the insertion, which can be composed of a floating bracket, a floating plate, a positioning rod, a positioning sleeve, and a support spring, etc.) for connecting to the battery swapping cooling interface and transmitting coolant.

[0052] The station's communication control simulation unit includes a high-voltage power conversion simulation unit, an in-station switch, and a CAN communication simulation unit. The high-voltage power conversion simulation unit simulates the conversion of power between the power distribution network and the battery swapping system using a high-voltage power conversion device within the battery swapping station. It also performs communication tests with the CAN communication simulation unit, the in-station switch, and the battery swapping electrical interface simulation socket to test the battery swapping process, including BMS power-on and wake-up tests, static monitoring status tests, and charging / discharging status tests. The in-station switch connects or disconnects the battery swapping electrical interface simulation socket from the high-voltage power conversion simulation unit to connect or disconnect power from the battery swapping system. The CAN communication simulation unit simulates the control logic of the battery swapping station controller.

[0053] The battery swapping simulation equipment is used to simulate the grabbing, moving, and replacement of the battery swapping system at a battery swapping station. The battery rack simulation unit is used to load and support the battery swapping system and to fix the battery swapping electrical interface simulation socket, battery swapping cooling interface simulation socket, coarse guide device, fine guide device, and locking mechanism according to standard requirements.

[0054] The industrial control computer integrates communication protocol testing software and battery swapping simulation equipment control software. It conducts battery swapping communication process testing by controlling the CAN communication simulation unit and replaces the battery swapping system by controlling the battery swapping simulation equipment.

[0055] Optionally, the battery swapping system is installed on the battery rack simulation unit of the battery swapping station simulation system for electrical connection and communication; if the battery swapping system is connected and communicates normally, the battery swapping station collaborative function test is passed.

[0056] Specifically, the battery swapping simulation equipment picks up the battery swapping system and installs it onto the battery rack simulation unit. The battery swapping cooling interface simulation socket connects to the battery swapping cooling interface of the battery swapping system, and the battery swapping electrical interface simulation socket connects to the battery swapping electrical interface of the battery swapping system. Both parties then power on / off and charge the battery, meeting the following requirements: 1. The battery swapping electrical interface should be in an effective connection state, and there should be no dielectric breakdown or electric arc between the conductors of the battery swapping electrical interface, between the conductor and the outer shell, or between the conductor and the shielding layer.

[0057] 2. The battery swapping cooling interface should be in a valid connection state and there should be no coolant leakage.

[0058] 3. The battery swapping station simulation system should be able to communicate normally with the battery swapping system and perform normal charging and discharging. For example, during BMS power-on and wake-up tests, static monitoring status tests, and charging and discharging status tests, the battery swapping station simulation system should be able to receive relevant messages sent by the battery swapping system, and the battery swapping system should be able to correctly respond to the instructions issued by the battery swapping station simulation system.

[0059] 4. The battery swapping mechanism of the battery swapping system should not be deformed, cracked, loosened, or detached, and the locking function should remain intact.

[0060] 5. The battery frame of the battery swapping system should not have irreversible deformation, cracks, or other structural damage or functional loss.

[0061] This application also provides a battery swapping compatibility testing system for battery swapping systems, including: The simulated vehicle is used to perform multiple release / lock cycles on the battery swapping system under test in a staggered manner, transmitting vibrations to the battery swapping system during the cycle.

[0062] A battery swapping system testing device (such as a scale and coolant collection device) is used to determine whether the structure and function of the battery swapping system are normal.

[0063] A real vehicle is used to test the battery swapping system. If the battery swapping system's structure and function are normal, the system is installed on a real vehicle and operated on a test track. During operation, the vehicle's vehicle-side collaborative functions are tested based on whether the communication between the battery swapping system and the real vehicle is normal, whether the battery swapping cooling interface leaks coolant, whether the battery swapping system is in a valid locked state, whether the battery swapping electrical interface is normal, and whether the battery frame is normal.

[0064] Optionally, the system also includes a battery swapping station simulation system, which is used to install the battery swapping system onto the battery rack simulation unit for electrical connection and communication; if the battery swapping system is connected and communicates normally, the system passes the battery swapping station collaborative function test.

[0065] This system performs the battery swapping compatibility testing method provided in the above embodiments and has the corresponding technical effects, which will not be elaborated here.

[0066] This application achieves comprehensive and efficient verification of vehicle-side battery swapping components by constructing a multi-stage collaborative testing system consisting of dimensional testing, functional testing, and communication testing. This testing method ensures that key components such as the battery swapping electrical interface socket, vehicle-side battery swapping cooling interface, and on-board battery swapping base are precisely matched in physical dimensions and are stable and reliable in basic functions. Furthermore, by simulating the power-on / off, charging, and communication behaviors of real batteries through a battery swapping simulation system, it exposes and resolves potential compatibility issues between the vehicle and the battery swapping system in terms of electrical coordination, control logic, and data interaction in advance. This significantly improves the reliability, safety, and efficiency of the battery swapping process, and reduces the risk of failure and subsequent maintenance costs due to component incompatibility.

[0067] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this application can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution disclosed in this application can be achieved, and this is not limited herein.

[0068] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A battery swap compatibility test method for a battery swap battery system, characterized in that, The method comprises the following steps: a battery swap system to be tested is subjected to a plurality of release / locking cycles in a staggered manner on a simulation vehicle, during which the simulation vehicle transmits vibration to the battery swap system; it is determined whether the structure and function of the battery swap system are normal; if the structure and function of the battery swap system are normal, the battery swap system is installed on a real vehicle, and the real vehicle is run on a test field; during the running, vehicle-end collaborative function testing is performed on the battery swap system according to whether communication between the battery swap system and the real vehicle is normal, whether the battery swap cooling interface leaks cooling liquid, whether the battery swap system is in an effective locking state, whether the battery swap electrical interface is normal, and whether the battery frame is normal. 2.The battery swap compatibility test method for a battery swap oriented battery system according to claim 1, characterized in that, After the vehicle-end collaborative function testing of the battery swap system, the method further comprises the following steps: the battery swap system is installed on a battery rack simulation unit of a battery swap station simulation system to perform electrical connection and communication; if the battery swap system is connected and communicates normally, battery swap station collaborative function testing is performed. 3.The battery swap compatibility test method for a battery swap oriented battery system according to claim 1, characterized in that, The method of subjecting a battery swap system to be tested to a plurality of release / locking cycles in a staggered manner on a simulation vehicle comprises the following steps: the battery swap system to be tested is installed on a simulation vehicle, and the simulation vehicle comprises longitudinal beams and a battery swap support; 10000 times of battery swap operations of the battery swap system are performed under a condition that a horizontal direction and a vertical direction are respectively offset by 5mm and a vehicle body plane is inclined by 1°, and during the 10000 times of battery swap operations, a release and locking cycle of the battery swap mechanism is completed 10000 times. 4.The battery swap compatibility test method for a battery swap oriented battery system according to claim 1, characterized in that, During the running, vehicle-end collaborative function testing is performed on the battery swap system according to whether communication between the battery swap system and the real vehicle is normal, whether the battery swap cooling interface leaks cooling liquid, whether the battery swap system is in an effective locking state, whether the battery swap electrical interface is normal, and whether the battery frame is normal, and the vehicle-end collaborative function testing comprises the following steps: communication signals of the battery swap system are collected, and it is determined whether the content and sending time of the communication signals meet the requirements; cooling liquid leaked from the battery swap cooling interface is collected, and vehicle-end collaborative function testing is performed according to the leakage amount of the cooling liquid; it is detected whether the battery swap mechanism of the battery swap system is damaged, and whether the battery swap system is in an effective locking state; if not, the vehicle-end collaborative function testing is not passed; it is detected whether the battery swap electrical interface is in an effective connection state, and whether dielectric breakdown or arc phenomenon occurs between conductors, between a conductor and a shell, and between a conductor and a shielding layer of the battery swap electrical interface; and whether the vehicle-end collaborative function testing is passed is determined according to the detection result; it is detected whether the battery frame is structurally damaged or functionally missing; if so, the vehicle-end collaborative function testing is not passed. 5.The battery swap compatibility test method for a battery swap oriented battery system according to claim 1, wherein, Before the method of subjecting a battery swap system to be tested to a plurality of release / locking cycles in a staggered manner on a simulation vehicle, the method further comprises the following step: dimensional testing is performed on a battery swap electrical interface, a battery swap cooling interface, a bottom structure and an outer shape of the battery swap system to be tested. 6.The battery swap compatibility test method for a battery swap oriented battery system according to claim 5, characterized in that, After the dimensional testing is passed, the method further comprises the following steps: electrical load testing is performed on the battery swap electrical interface by using a battery swap electrical interface simulation socket; and The vehicle end battery swap cooling simulation interface is used to test the sealing performance of the battery swap cooling interface. The vehicle end simulation system is used to test the communication of the battery swap system.

7. A battery swap compatibility test system for a battery swap battery system, characterized in that, It comprises: a simulation vehicle, which is used to perform multiple release / locking cycles of the battery swap system to be tested on the simulation vehicle in a staggered manner, and to transmit vibration to the battery swap system during the cycles; a battery swap system detection device, which is used to determine whether the structure and function of the battery swap system are normal; a real vehicle, which is used to install the battery swap system on the real vehicle if the structure and function of the battery swap system are normal, and to run the real vehicle on a test field; During the running, the vehicle end cooperative function test of the battery swap system is performed according to whether the communication between the battery swap system and the real vehicle is normal, whether the battery swap cooling interface leaks cooling liquid, whether the battery swap system is in an effective locking state, whether the battery swap electrical interface is normal, and whether the battery frame is normal. 8.The battery swap compatibility test system for a battery swap oriented battery system according to claim 7, characterized in that, It further comprises: a battery swap station simulation system, which is used to install the battery swap system on a battery rack-mounted simulation unit for electrical connection and communication; if the connection and communication of the battery swap system are normal, the battery swap station cooperative function test is performed. 9.The battery swap compatibility test system for a battery swap oriented battery system according to claim 8, characterized in that, The battery swap station simulation system comprises: a battery swap electrical interface simulation socket, which integrates a battery swap station end charging control guide loop, has a guide and floating mechanism, and is used to establish electrical connection with the battery swap electrical interface, transmit electrical energy and electrical signals; a battery swap cooling interface simulation socket, which has a guide and floating mechanism, is used to connect with the battery swap cooling interface, and transmit cooling liquid; an in-station communication control simulation unit, which comprises a high-voltage power supply conversion simulation unit, an in-station switch, and a CAN communication simulation unit; a battery swap replacement simulation device, which is used to simulate the grabbing, moving, and replacing of the battery swap system by the battery swap station replacement device; a battery rack-mounted simulation unit, which is used to load and lift the battery swap system, and fix the battery swap electrical interface simulation socket, the battery swap cooling interface simulation socket, and the coarse guide device, the fine guide device, and the locking mechanism according to the standard requirements; an industrial computer, which integrates communication protocol test software and battery swap replacement simulation device control software, performs battery swap communication process test by controlling the CAN communication simulation unit, and replaces the battery swap system by controlling the battery swap replacement simulation device.

10. The battery swap compatibility test system for a battery swap system according to claim 9, wherein the high-voltage power supply conversion simulation unit is used to simulate the conversion of the high-voltage power supply conversion device in the battery swap station to convert the power of the power distribution network and the battery swap system, and to perform communication test of the battery swap process with the CAN communication simulation unit, the in-station switch, and the battery swap electrical interface simulation socket; the in-station switch is used to connect or disconnect the battery swap electrical interface simulation socket and the high-voltage power supply conversion simulation unit to connect or disconnect the electrical energy from the battery swap system; the CAN communication simulation unit is used to simulate the control logic of the battery swap station controller.

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