Battery pack intelligent EOL test system integrated with motor controller

Abstract

The invention discloses a battery pack intelligent EOL test system integrated with a motor controller, and relates to the related technical field of EOL test of a battery pack with a motor control system, and the system comprises a main control upper computer which is internally provided with test process management software and is used for executing test logic, controlling a test process, processing data and generating a report; the battery wake-up module adopts a relay module to communicate a wake-up line with the GND so as to realize battery wake-up; the multipath CAN bus test module is connected with the main control upper computer, is used for data interaction between a motor controller of the tested battery pack and a plurality of nodes in the motor controller, and is used for executing a protection parameter monitoring module and a UDS diagnosis data detection module; according to the invention, a plurality of test processes are integrated in one test station operation table, existing four independent stations are replaced, only one operator is needed to complete all tests, the labor cost is directly reduced, and the labor cost of production line test stations can be obviously reduced.

Description

Technical Field

[0001] This invention relates to the technical field of EOL testing for battery packs with motor control systems, specifically to an intelligent EOL testing system for battery packs with integrated motor controllers. Background Technology

[0002] The battery pack with integrated motor controller is a core component that combines energy storage and power control functions. Before it leaves the factory, it must pass the EOL test to verify whether its performance meets the standards. The test items cover key aspects such as battery wake-up, sealing performance, insulation resistance, communication function, and power matching.

[0003] In existing technologies, there is a lack of dedicated systems for EOL testing of this type of integrated battery pack, and only a "decentralized manual testing" mode can be used: independent instruments are needed to test individual performance items (such as using voltmeters and ammeters to measure electrical parameters, and using separate airtightness testers to measure sealing performance), and the instruments must be switched manually, data recorded manually, and results judged separately. This mode has the following significant drawbacks: 1. Single testing method and low efficiency: It lacks integrated testing capabilities, requires four independent workstations and four sets of testing instruments, and the testing of a single battery pack takes up to 20 minutes, which cannot adapt to the pace of mass production. 2. Poor test stability and high misjudgment rate: Manual operation is prone to errors in instrument parameter settings, data omissions and misrecording, and even damage to products due to improper operation, making it impossible to guarantee test consistency; 3. Difficulty in data traceability: Test data needs to be entered manually and cannot be associated with the product serial number, making it difficult to quickly retrieve complete test information during subsequent quality traceability. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a smart EOL testing system for battery packs that integrates a motor controller.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: The present invention discloses an intelligent EOL testing system for battery packs with integrated motor controller, including a main control host computer and built-in test process management software for executing test logic, controlling the test process, processing data and generating reports; The battery wake-up module uses a relay module to connect the wake-up line to GND to achieve battery wake-up. The multi-channel CAN bus test module is connected to the host computer and is used for data interaction between the motor controller of the battery pack under test and its internal multiple nodes. It is also used to execute the protection parameter monitoring module, UDS diagnostic data detection module, firmware / hardware version detection module and serial number reading module. The impedance monitoring module includes two external resistance meters, which are used to monitor the impedance between the battery pack's P+ terminal and the casing, and between the GND terminal and the casing in real time, respectively. The airtightness testing module is used to test the airtightness of the battery pack casing. It also includes a wake-up line / P+ voltage measurement module, a lamp line / USB load detection module, a battery SOC and charging current detection module, a traction test module, and an overcurrent test and EEPROM check module; The host computer sends control commands and receives status data through the multi-channel CAN bus test module. It can control the battery wake-up module, airtightness test module, impedance monitoring module, multi-channel CAN bus test module, protection parameter monitoring module, UDS diagnostic data detection module, firmware / hardware version detection module, serial number reading module, battery SOC and charging current detection module, lamp wire / USB load detection module, wake-up line / P+ voltage measurement module, traction force test module, overcurrent test and EEPROM check module according to the preset process, and automatically determine the test results. The storage and upload module is used to save test data, test results, test time, tester and programmer information locally in Excel format and upload them to the MES system, while automatically calculating the product pass rate.

[0006] As a preferred embodiment of the present invention, the battery wake-up module is implemented through a relay module powered by 12VDC, and the trigger level of the relay module is 3.3V-9VDC; when the relay power supply voltage and the trigger voltage both meet the standard, the relay common terminal is disconnected from the normally closed terminal and connected to the normally open terminal, thereby realizing battery wake-up.

[0007] As a preferred embodiment of the present invention, the pre-compression mechanism includes two pre-compression rollers disposed at the opening, and the airtightness testing module includes a positive pressure airtightness monitoring instrument and an airtightness fixture; the upper and lower ends of the airtightness fixture are joined by sealant, and a cylinder is configured to press down and fasten the battery pack under test, and the positive pressure airtightness monitoring instrument detects the sealing performance of the battery pack by inflating and maintaining pressure.

[0008] As a preferred embodiment of the present invention, the clamping assembly further includes an inner rod slidably installed inside the outer cylinder. The multi-channel CAN bus test module is connected to the main control host computer and is used to interact with five nodes integrated inside the battery pack: HMI, LIGHTS, CHARGINGPORT, TCS Sensor, and Motor controller. The protection parameter monitoring module monitors protection parameters based on the hardware conditions of the multi-channel CAN bus test module.

[0009] As a preferred embodiment of the present invention, the UDS diagnostic data detection module reads and compares battery information based on messages sent by the multi-channel CAN bus test module; the firmware / hardware version detection module reads and compares the BMS and MCF version numbers in the battery based on messages sent by the multi-channel CAN bus test module; and the serial number reading module is used to send messages to read the serial numbers of the BMS and MCF and compare them with the QR code.

[0010] As a preferred embodiment of the present invention, the battery SOC and charging current detection module charges the battery through a programmable DC power supply and reads the battery SOC and charging current through a host computer.

[0011] As a preferred embodiment of the present invention, the lamp line / USB load detection module measures the current and voltage values ​​of the lamp line and USB line by connecting loads with different resistance values; the wake-up line / P+ voltage measurement module measures the wake-up line and P+ voltage by sequentially switching relays.

[0012] As a preferred embodiment of the present invention, the traction force testing module includes a magnetic powder brake, a torque sensor, and a motor; the magnetic powder brake is used for brake adjustment, and the torque is adjusted by adjusting the current to achieve the braking / deceleration effect; the torque sensor is used to measure the torque, speed, and power of each gear, and compare them with the torque value read from the battery pack to determine the result.

[0013] As a preferred embodiment of the present invention, the overcurrent test and EEPROM inspection module performs overcurrent testing by connecting a high-power cement resistor load to P+ / P- and switching a solid-state relay.

[0014] As a preferred technical solution of the present invention, the host computer integrates a data management module. After the test is completed, the system automatically uploads all test results, process data and operator information to the customer's MES system, and at the same time saves them as a structured Excel file on the local hard disk in the form of a combination of product model and test date. The test management software of the host computer adopts a parallel scheduling algorithm so that the total test time does not increase linearly with the increase of the number of products tested in parallel.

[0015] The beneficial effects of this invention are: 1. This intelligent EOL testing system for battery packs with integrated motor controllers can significantly reduce labor costs at production line testing stations. Traditional manual testing requires testing thirteen major items one by one, and each item requires corresponding testing equipment. To prevent testing chaos, four testing stations are needed for such a large number of items. This system integrates thirteen testing functions into a single system, requiring only one tester. After the battery harness is connected, the system scans and starts. The system automatically tests and judges each item according to the pre-set testing process. Products that pass the test are automatically printed with a pass label, and the test data is uploaded to the customer's MES system in real time.

[0016] 2. This intelligent EOL testing system for battery packs with integrated motor controllers can significantly improve the testing efficiency of the EOL testing station. Taking the example of the system before its development, four stations and four sets of testing instruments are required for testing, and it takes 20 minutes to complete the testing of a set of EOL products. This invention automatically executes all operation steps, automatically judges the test results, automatically tests thirteen test items according to the test steps, and automatically uploads and saves the test results. The entire testing time only takes about five minutes.

[0017] 3. This intelligent EOL testing system for battery packs with an integrated motor controller improves production stability and the traceability of testing procedures and data by incorporating storage and loading modules. Traditional testing methods are prone to errors, misjudgments, and product damage. With this invention, employees only need to connect the product under test according to the corresponding plug and scan the code to start the test. This intelligent EOL testing system for battery packs with an integrated motor controller is simple and convenient to operate. This system significantly reduces manual processes such as personnel inspection, test result judgment, and test data storage, greatly saving labor costs and quality costs caused by operator fatigue and errors. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a circuit block diagram of an intelligent EOL testing system for battery packs with an integrated motor controller, according to the present invention. Figure 2 This is a schematic diagram of the circuit principle for battery wake-up testing in a battery pack intelligent EOL testing system with an integrated motor controller, according to the present invention. Figure 3 This is a test flowchart of impedance monitoring in an intelligent EOL test system for battery packs with an integrated motor controller, according to the present invention. Figure 4This is a schematic diagram of the CAN bus test connection of a battery pack intelligent EOL test system with integrated motor controller according to the present invention; Figure 5 This is a flowchart of the CAN bus test of a battery pack intelligent EOL test system with integrated motor controller according to the present invention; Figure 6 This is a flowchart of the protection parameter monitoring of a battery pack intelligent EOL test system with integrated motor controller according to the present invention; Figure 7 This is a schematic diagram of the interface for UDS diagnostic data detection in a battery pack intelligent EOL testing system with an integrated motor controller, according to the present invention. Figure 8 This is a software flowchart of UDS diagnostic data detection for a battery pack intelligent EOL testing system with an integrated motor controller, according to the present invention. Figure 9 This is a schematic diagram of the firmware / hardware version detection interface of the intelligent EOL testing system for battery packs with integrated motor controller according to the present invention. Figure 10 This is a schematic diagram of the serial number reading interface of a battery pack intelligent EOL testing system with integrated motor controller according to the present invention. Figure 11 This is a wiring diagram for detecting battery SOC and charging current in a battery pack intelligent EOL testing system with integrated motor controller according to the present invention. Figure 12 This is a flowchart of the battery SOC and charging current detection of a battery pack intelligent EOL testing system with integrated motor controller according to the present invention. Figure 13 This is a hardware wiring diagram for detecting the load current and voltage of a lamp wire / USB cable in a smart EOL testing system for a battery pack with an integrated motor controller, according to the present invention. Figure 14 This is a flowchart of the lamp wire / USB cable load current and voltage detection of a battery pack intelligent EOL test system with integrated motor controller according to the present invention; Figure 15 This is one of the circuit diagrams for measuring the wake-up line and P+ voltage in a battery pack intelligent EOL test system with an integrated motor controller according to the present invention. Figure 16 This is the second circuit diagram of the wake-up line and P+ voltage measurement of the intelligent EOL test system for battery packs with integrated motor controller of the present invention. Figure 17 This is a hardware wiring diagram of an intelligent EOL testing system for battery packs with an integrated motor controller, according to the present invention, for overcurrent testing and EEPROM inspection. Figure 18This is a flowchart of the overcurrent test and EEPROM check of a battery pack intelligent EOL test system with integrated motor controller according to the present invention.

[0019] In the diagram: 1. Battery wake-up module; 2. Air tightness test module; 3. Impedance monitoring module; 4. Multi-channel CAN bus test module; 5. Protection parameter monitoring module; 6. UDS diagnostic data detection module; 7. Firmware / hardware version detection module; 8. Serial number reading module; 9. Battery SOC and charging current detection module; 10. Lamp wire / USB load detection module; 11. Wake-up line / P+ voltage measurement module; 12. Traction test module; 13. Overcurrent test and EEPROM check module. Detailed Implementation

[0020] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0021] Example: Figures 1 to 18As shown in the figure, an intelligent EOL test system for a battery pack integrated with a motor controller of the present invention includes a main control host computer with built-in test process management software, which is used to execute test logic, control the test process, process data, and generate reports; a battery wake-up module 1 that uses a relay module to connect the wake-up line and GND to wake up the battery; a multi-channel CAN bus test module 4, connected to the main control host computer, which is used for data interaction with the motor controller of the battery pack to be tested and its multiple internal nodes, and is also used to execute the protection parameter monitoring module 5, the UDS diagnostic data detection module 6, the firmware / hardware version detection module 7, and the serial number reading module 8; an impedance monitoring module 3, which includes two external resistance meters, and the two resistance meters are respectively used to monitor the impedance between the P+ pole of the battery pack and the shell, and the GND pole and the shell in real time; an airtightness test module 2, which is used to detect the airtightness of the battery pack shell; it also includes a wake-up line / P+ voltage measurement module 11, a lamp line / USB load detection module 10, a battery SOC and charging current detection module 9, a traction force test module 12, and an overcurrent test and EEPROM check module 13; among them, the main control host computer sends control instructions and receives status data through the multi-channel CAN bus test module 4, and can control the battery wake-up module 1, the airtightness test module 2, the impedance monitoring module 3, the multi-channel CAN bus test module 4, the protection parameter monitoring module 5, the UDS diagnostic data detection module 6, the firmware / hardware version detection module 7, the serial number reading module 8, the battery SOC and charging current detection module 9, the lamp line / USB load detection module 10, the wake-up line / P+ voltage measurement module 11, the traction force test module 12, and the overcurrent test and EEPROM check module 13 according to a preset process, and automatically determines the test result; a storage and upload module, which is used to locally save the test data, test results, test time, tester and programmer information in Excel format, and upload them to the MES system, and automatically calculates the product qualification rate. The impedance monitoring module 3 uses two external resistance meters to respectively monitor the resistance values between P+ and GND and the product shell in real time, and a resistance value ≥ 5MΩ is qualified.In addition, the outer shell is coated with an insulating material, and theoretically the impedance to be measured is infinite, which the impedance meter cannot measure (over-range). The existing fixture holds the ejector pin against the battery shell. When the ejector pin is against the shell and the impedance meter is connected to P+ and GND, it is a closed circuit. At this time, the impedance is infinite, the impedance meter is over-range, and the test standard is met (measured value ≥ 5 Mohm). Subsequent verification will be conducted to see if the measured value is less than 5 Mohm when the battery leaks or the coating peels off. This avoids the "false pass" problem caused by uneven contact of the manual probe. At the same time, it realizes automatic recording of impedance data, eliminating the need for manual copying, improving data accuracy and test efficiency. By integrating multiple test processes into a test station operating table, replacing the existing four independent workstations, only one operator is needed to complete all tests, directly reducing labor costs. It can significantly reduce the labor costs of the production line test station. Traditional manual testing requires testing thirteen major items one by one, and each item requires corresponding test equipment. To prevent test confusion, four workstations are needed to test so many items. With this invention, only one tester is needed. After the battery harness is connected, scanning and starting the system allows for automatic testing and judgment according to the pre-set test procedure. Products that pass the test automatically print a pass label, and test data is uploaded to the customer's MES system in real time. This significantly improves the testing efficiency of the EOL (End-of-Life) testing station. Without this testing system, four stations and four sets of testing instruments are required, and testing a set of EOLs takes twenty minutes. This invention automatically executes all steps, automatically judges test results, automatically tests thirteen items according to the test procedure, and automatically uploads and saves the test results. The entire testing process takes only about five minutes.

[0022] The battery wake-up module 1 is implemented through a 12VDC powered relay module with a trigger level of 3.3V-9VDC. When the relay power supply voltage and trigger voltage meet the requirements, the relay common terminal is disconnected from the normally closed terminal and connected to the normally open terminal, thus waking up the battery. By using a 12VDC powered relay module to replace the manual connection of the Wakeup line to GND in the existing technology, the relay trigger level is set to 3.3V-9VDC (to adapt to the wake-up voltage requirements of most batteries). When the system issues a wake-up command through software, the relay power supply voltage and trigger voltage automatically meet the requirements, and its common terminal (COM) is disconnected from the normally closed terminal (NC) and connected to the normally open terminal (NO), so that the battery Wakeup pin is automatically connected to GND. This design eliminates the need for manual plugging and unplugging of the circuit, avoiding the risk of reversed wiring during manual operation (reducing product damage rate), and shortening the wake-up operation time from 1-2 minutes in the existing technology to within 10 seconds, directly improving testing efficiency.

[0023] The airtightness testing module 2 includes a positive pressure airtightness monitor and an airtightness fixture. The upper and lower ends of the airtightness fixture are joined by sealant and equipped with a cylinder for pressing down and securing the battery pack under test. The positive pressure airtightness monitor detects the sealing performance of the battery pack by inflating and holding pressure. During the test, the monitor automatically inflates to the preset pressure and holds the pressure for 10 seconds. The software automatically determines whether the pressure drop is ≤0.05kPa, eliminating the need for manual observation of the pressure gauge reading. This solves the problem of "poor sealing due to manual fixing and large reading errors" in the existing technology, improves the accuracy of airtightness test pass rate determination, and significantly shortens the time required for simultaneous testing.

[0024] The multi-channel CAN bus test module 4 connects to the main control computer and is used to interact with the five nodes integrated inside the battery pack: HMI, LIGHTS, CHARGINGPORT, TCSSensor, and Motor controller. The protection parameter monitoring module 5 monitors protection parameters based on the hardware conditions of the multi-channel CAN bus test module 4. It uses five independent CAN channels to synchronously monitor the communication data of HMI, LIGHTS, CHARGINGPORT, TCSSensor, and Motor, replacing the existing "single-channel sequential switching test" mode: the software automatically opens all CAN channels and reads data with IDs 0x602 and 0x510 in a loop within 1 second. If a channel fails to receive any ID data, the software automatically adds the channel number (e.g., CAN3) to the error list and prompts a message. Existing technology requires connecting each channel one by one and waiting for data reception, with a single-channel test taking 1 minute and a total of 5 minutes for five channels. This principle, through parallel monitoring, requires only 1 second for five-channel testing, significantly shortening the communication test time and avoiding parameter setting errors when manually switching channels.

[0025] Among them, the UDS diagnostic data detection module 6 reads and compares battery information by sending messages based on the multi-channel CAN bus test module 4; the firmware / hardware version detection module 7 reads and compares the BMS and MCF version numbers in the battery by sending messages based on the multi-channel CAN bus test module 4; the serial number reading module 8 is used to send messages to read the serial numbers of BMS and MCF and compare them with the QR code; and it reads key battery information (lamp line voltage, USB status, etc.) by sending UDS messages based on the CAN bus. It replaces the existing "single reading judgment" with "three-read verification": the software sends three messages continuously for each monitoring information (such as lamp line voltage, corresponding to UDSID0x7F5, address 0xFE01), and judges "qualified" only when the three received data are consistent. This solves the problem of misjudgment caused by interference in the existing single reading, improves the accuracy of UDS diagnosis, and automatically compares the data with the qualification standard without the need for manual calculation and judgment.

[0026] The battery SOC and charging current detection module 9 charges the battery via a programmable DC power supply and reads the battery SOC and charging current via a host computer. The module charges the battery sample via the programmable DC power supply, and simultaneously reads the battery SOC and charging current via the host computer software. The acceptable SOC standards are: sea freight: 50-80%; air freight: 20-30%. The error between the charging current read by the host computer and the DC power supply current is within 5%.

[0027] The system includes a lamp line / USB load detection module 10, which measures the current and voltage values ​​of the lamp line and USB cable by connecting loads with different resistance values; and a wake-up line / P+ voltage measurement module 11, which measures the wake-up line and P+ voltage by sequentially switching relays. Two loads with different resistance values ​​are connected to the lamp line as needed, and another load is connected to the USB cable. The host computer sends a CAN command to turn on and adjust the lamp line and USB cable, and then measures the current and voltage values ​​of the USB and lamp line loads to ensure they are correct. A current and voltage acquisition module replaces the current and voltage meters, directly communicating with the host computer to display the required measured current and voltage values. The implementation scheme is as follows: LIGHTS (6V), 3Ω load resistor, 2A current, 12W±5% power; LIGHTS (12V), 6Ω load resistor, 2A current, 24W±5% power; USB (5V), 2Ω load resistor, 2.5A current, 12.5W±5% power.

[0028] The traction test module 12 includes a magnetic powder brake, a torque sensor, and a motor. The magnetic powder brake is used for brake adjustment. By adjusting the current, the torque is adjusted to achieve the braking / deceleration effect. The torque sensor is used to measure the torque, speed, and power of each gear and compare them with the torque value read from the battery pack to determine the result. The overcurrent test and EEPROM check module 13 performs overcurrent testing by connecting a high-power cement resistor load to P+ / P- and switching a solid-state relay. This achieves discharge overcurrent protection by connecting the high-power cement resistor as a load to P+ / P- and performing overcurrent testing via a solid-state relay. The discharge current is required to be ≥40A. The existing method of "manual temporary connection of the resistor load" is replaced by "0.9Ω / 2000W cement resistor + solid-state relay": software controls the solid-state relay to automatically close, allowing the battery to discharge through the cement resistor (discharge current ≥...). 40A (meets overcurrent protection testing requirements), eliminating the need for manual resistor insertion / removal (avoiding the risk of electric shock); after the overcurrent test, the software automatically sends a CAN message (ID0x0A6401F0) to read the EEPROM history, determining that "the fault type is overcurrent protection" and "the date is consistent with the current date"—this principle automates overcurrent testing and history checking, avoiding the operational risks of manually connecting resistors (such as burns from overheating). At the same time, the history data is automatically uploaded, solving the cumbersome problem of "removing the battery to read the history," reducing the test time from five minutes to one minute.

[0029] The main control computer integrates a data management module. After the test is completed, the system automatically uploads all test results, process data and operator information to the customer's MES system. At the same time, it saves the data as a structured Excel file on the local hard drive, named by the product model and test date. The test management software of the main control computer adopts a parallel scheduling algorithm, which ensures that the total test time does not increase linearly with the increase of the number of products tested in parallel. This avoids data omissions and errors. Moreover, the complete test data can be quickly retrieved by the product serial number during subsequent quality traceability without having to look through paper records, which greatly improves traceability efficiency.

[0030] During operation, the hardware status at the test station must first be checked: Ensure the 12VDC-powered relay module (trigger level range 3.3V-9VDC, corresponding to battery wake-up module 1) is powered normally; the positive pressure airtightness monitor (corresponding to airtightness test module 2) is in standby mode; the wiring of the multi-channel CAN bus test module 4 is secure; the wiring of the 0.9Ω / 2000W high-power cement resistor and solid-state relay (corresponding to overcurrent test and EEPROM check module 13) for overcurrent testing is secure; and the programmable DC power supply (corresponding to battery SOC and charging current detection module 9) is in standby mode. Regarding the software environment, start the "SYD-8900 Battery Product Automatic Testing System" software, confirming no hardware connection abnormalities, normal permissions for the test result storage directory "D:\SYD-9000\Result\", and that the system has established communication with the MES system to ensure subsequent data can be uploaded normally. Operators log in to the system according to their permissions—the software supports three levels of user permissions (administrator, programmer, and ordinary user), with different permissions corresponding to different functional ranges to avoid unauthorized operations. After logging in, click "File → Open File" in the software menu bar and select the corresponding test configuration file according to the model of the battery pack to be tested. After clicking "OK", the software automatically loads the preset test parameters for the battery pack model, including the SOC qualification standard (50-80% for sea transport, 20-30% for air transport, corresponding to the battery SOC and charging current detection module 9), the overcurrent test current threshold (≥40A, corresponding to the overcurrent test and EEPROM check module 13), the data ID to be read from the CAN bus (0x602, 0x510, corresponding to the multi-channel CAN bus test module 4), and the message ID and address corresponding to UDS diagnosis (corresponding to the UDS diagnostic data detection module 6). There is no need to manually set the instrument parameters one by one, and no need to manually debug multiple instruments. The operation efficiency is significantly better than the existing technology. The operator connects the battery pack's Wakeup, P+, and GND lines to their respective interfaces (Battery Wake-up Module 1 and Impedance Monitoring Module 3, respectively) according to the interface labels on the control panel. Simultaneously, the CAN-H and CAN-L lines are connected to the corresponding channels of the multi-channel CAN bus module 4 (the five CAN channels monitor data from the HMI, LIGHTS, CHARGINGPORT, TCSSensor, and Motor, respectively). After wiring, the software automatically detects the product connection status without manual confirmation. Then, the operator scans the QR code on the battery pack surface with a barcode scanner. The software automatically reads the product serial number and completes the binding (corresponding to Serial Number Reading Module 8), ensuring that subsequent test data corresponds one-to-one with the product and avoiding errors from manual serial number recording. The system automatically completes thirteen tests in a preset order, with only the traction test requiring a simple manual interaction. First, the battery wake-up module 1 is executed: the software issues a command to power on the 12VDC relay module. When both the relay's power supply voltage and trigger level (3.3V-9VDC) meet the standards, the relay's common terminal (COM) disconnects from the normally closed terminal (NC) and connects to the normally open terminal (NO), thus waking the battery. The software receives the feedback and determines "wake-up qualified." Next, the airtightness test module 2 is executed: the airtight fixture uses a cylinder to press down and secure the battery pack. The upper and lower ends of the fixture are joined with sealant to ensure a seal. The positive pressure airtightness monitor completes the test by inflating and maintaining pressure, and the software automatically determines the result. Then, the impedance monitoring module 3 is activated: two external resistance meters monitor the impedance of P+, GND, and the battery casing in real time. The battery casing is coated with insulating material, theoretically with infinite impedance (resistance meters exceeding their range), or when the measured resistance is ≥5MΩ, it is determined to be "impedance qualified." The entire automatic test execution phase takes approximately five minutes, while existing technology requires twenty minutes. Then, the data of HMI, LIGHTS, CHARGINGPORT, TCSSensor, and Motor are monitored simultaneously (corresponding to the multi-channel CAN bus test module 4). The software receives data with IDs 0x602 and 0x510 in a loop within 1 second. If all channels successfully receive data with both IDs, the software determines that the CAN bus is qualified. If a channel does not receive data, the software automatically records the channel number and provides a prompt. Based on the hardware conditions of the CAN bus, the protection parameter monitoring module 5 continues to execute: the software calls the preset parameters in the Excel spreadsheet, compares the configuration parameters read from the CAN bus with the data in the spreadsheet, completes the qualification judgment, and executes the UDS diagnostic data detection module 6. The software sends the corresponding message based on the CAN bus and reads the battery pack's lamp line voltage (UDSID0x7F5, Address0xFE01), USB status (UDSID0x7F5, Address0xFDFE), backup line status (UDSID0x7F5, Address0xFDFF), charging current (UDSID0x7F5, Address0xFE02), and time (UDSID0x7F5, Address0xFD20). Each piece of information is read three times consecutively. If the three results are consistent, it is judged that "UDS diagnosis is qualified". Using the firmware / hardware version detection module 7, the software sends messages via the CAN bus to read the BMS and MCF version numbers of the battery pack. It also reads them three times consecutively. If the results are the same, it is determined to be qualified. When the serial number reading module 8 reads the serial number, the software sends messages with IDs 0xFD07, 0xFD08, and 0xFD09 via UDS respectively: The message with ID 0xFD07 is sent to read [4:8] of the received data to obtain the first 4 digits of the serial number, the message with ID 0xFD08 is sent to read [4:8] of the received data to obtain the middle 4 digits of the serial number, and the message with ID 0xFD09 is sent to read [4:6] of the received data to obtain the last 2 digits of the serial number. The complete serial number is compared with the QR code information of the battery pack. If they are the same, it is determined that the "serial number is qualified".

[0031] In the battery SOC and charging current detection module 9 for detecting SOC and charging current, the programmable DC power supply charges the battery pack, and the host computer software reads the battery SOC value and charging current: When the SOC meets 50 - 80% in the sea transportation scenario or 20 - 30% in the air transportation scenario, and the charging current read by the host computer has an error of ≤ 5% compared with the DC power supply set current, it is determined that the "SOC and charging current are qualified". In the lamp wire / USB load detection module 10 for the lamp wire / USB load current and voltage detection link, different resistance loads are connected as required: A 3Ω resistor is connected to the lamp wire (6V, current 2A, power 12W ± 5%), a 6Ω resistor is connected to the lamp wire (12V, current 2A, power 24W ± 5%), and a 2Ω resistor is connected to the USB wire (5V, current 2.5A, power 12.5W ± 5%). The current and voltage acquisition module communicates directly with the host computer, and the software reads the values and compares them with the preset values. If it is qualified, it is determined that the "lamp wire / USB load is qualified".

[0032] The wake-up line / P+ voltage measurement module 11 completes the channel switching sequentially via relays. The software automatically collects and determines whether the voltage value meets the standard. During the traction force test, the magnetic powder brake adjusts the current to change the torque to achieve braking / deceleration. The torque sensor measures the torque, speed, and power at each gear. The software prompts the operator to rotate the motor until it spins and then click confirm. Subsequently, the data collected by the sensor is compared with the torque value fed back by the battery pack. If they match, the "traction force is qualified". Finally, the overcurrent test and EEPROM check module 13 perform the overcurrent test and EEPROM check. M-check: A 0.9Ω / 2000W cement resistor is connected as a load to P+ / P-. Software controls the solid-state relay to close and discharge. The overcurrent test is completed when the discharge current is ≥40A. Simultaneously, a CAN message is sent to read the battery pack's EEPROM history information. If the date recorded in the "overcurrent protection" history matches the current date, the "EEPROM check is qualified." This significantly improves the testing efficiency of the finished product EOL testing station. Without this testing system, four stations and four sets of testing instruments are required, and testing one set of finished product EOLs takes twenty minutes. This invention automatically executes all operation steps, automatically judges test results, automatically tests thirteen test items according to the test steps, and automatically uploads and saves the test results. The entire test takes only about five minutes.

[0033] The results output and data management phases are fully automated, requiring no manual intervention. After all tests are completed, the software automatically determines the overall result; a "PASS" is displayed for passing tests, and specific anomalies (corresponding to each test module) are marked for failing tests. Simultaneously, the software automatically calculates the product pass rate. Test data is saved in Excel format ("Product Model + Date") to the directory "D:\SYD-9000\Result\". The file contains test data, test results, test time, tester information, programmer information, etc. Data is also uploaded to the MES system in real time to ensure traceability. Passing products will automatically print a finished product label, which the operator can then affix to the designated location on the battery pack.

[0034] Product switchover is convenient and requires no hardware adjustments. When testing different battery pack models, the operator only needs to disconnect the current battery pack, re-call the corresponding test configuration file (adapted to the parameters of each test module) in the software, connect the new battery pack, scan the serial number (corresponding to serial number reading module 8), and start the test. Unlike existing technologies, there is no need to readjust the instrument hardware parameters, which greatly improves the flexibility of the production line.

[0035] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A smart EOL testing system for battery packs with an integrated motor controller, characterized in that, include: The main control host computer has built-in test process management software, which is used to execute test logic, control the test process, process data and generate reports; The battery wake-up module (1) uses a relay module to connect the wake-up line to GND to achieve battery wake-up; The multi-channel CAN bus test module (4) is connected to the host computer and is used for data interaction between the motor controller of the battery pack under test and its internal multiple nodes. It is also used to execute the protection parameter monitoring module (5), the UDS diagnostic data detection module (6), the firmware / hardware version detection module (7), and the serial number reading module (8). Impedance monitoring module (3), which includes two external resistance meters, which are used to monitor the impedance between the P+ terminal and the casing and the GND terminal and the casing in real time, respectively. The airtightness test module (2) is used to test the airtightness of the battery pack casing; It also includes a wake-up line / P+ voltage measurement module (11), a lamp line / USB load detection module (10), a battery SOC and charging current detection module (9), a traction test module (12), and an overcurrent test and EEPROM check module (13). The host computer sends control commands and receives status data through the multi-channel CAN bus test module (4), and can control the battery wake-up module (1), airtightness test module (2), impedance monitoring module (3), multi-channel CAN bus test module (4), protection parameter monitoring module (5), UDS diagnostic data detection module (6), firmware / hardware version detection module (7), serial number reading module (8), battery SOC and charging current detection module (9), lamp wire / USB load detection module (10), wake-up line / P+ voltage measurement module (11), traction force test module (12), overcurrent test and EEPROM check module (13) according to the preset process, and automatically determine the test results; The storage and upload module is used to save test data, test results, test time, tester and programmer information locally in Excel format and upload them to the MES system, while automatically calculating the product pass rate.

2. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The battery wake-up module (1) is implemented by a relay module powered by 12VDC. The trigger level of the relay module is 3.3V-9VDC. When the relay power supply voltage and the trigger voltage are both up to standard, the common terminal of the relay is disconnected from the normally closed terminal and connected to the normally open terminal to realize battery wake-up.

3. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The air tightness test module (2) includes a positive pressure air tightness monitor and an air tightness fixture; the upper and lower ends of the air tightness fixture are joined by sealant, and a cylinder is configured to press down and tighten the battery pack under test. The positive pressure air tightness monitor detects the sealing performance of the battery pack by inflating and maintaining pressure.

4. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The multi-channel CAN bus test module (4) is connected to the host computer and is used to interact with the five nodes integrated inside the battery pack: HMI, LIGHTS, CHARGINGPORT, TCS Sensor and Motor controller. The protection parameter monitoring module (5) monitors the protection parameters based on the hardware conditions of the multi-channel CAN bus test module (4).

5. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The UDS diagnostic data detection module (6) reads and compares battery information based on the message sent by the multi-channel CAN bus test module (4). The firmware / hardware version detection module (7) reads and compares the BMS and MCF version numbers in the battery based on the message sent by the multi-channel CAN bus test module (4). The serial number reading module (8) is used to send a message to read the serial numbers of BMS and MCF and compare them with the QR code.

6. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The battery SOC and charging current detection module (9) charges the battery through a programmable DC power supply and reads the battery SOC and charging current through the host computer.

7. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The lamp line / USB load detection module (10) measures the current and voltage values ​​of the lamp line and USB line by connecting loads with different resistance values; the wake-up line / P+ voltage measurement module (11) measures the wake-up line and P+ voltage by sequentially switching relays.

8. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The traction test module (12) includes a magnetic powder brake, a torque sensor and a motor; the magnetic powder brake is used for brake adjustment, and the torque is adjusted by adjusting the current to achieve braking / deceleration; the torque sensor is used to measure the torque, speed and power of each gear, and compares them with the torque value read from the battery pack to determine the result.

9. The intelligent EOL testing system for battery packs with integrated motor controller according to claim 1, characterized in that, The overcurrent test and EEPROM inspection module (13) performs overcurrent testing by connecting a high-power cement resistor load to P+ / P- and switching a solid-state relay.

10. A battery pack intelligent EOL testing system with an integrated motor controller according to claim 1, characterized in that, The test management software of the main control host computer adopts a parallel scheduling algorithm, so that the total test time does not increase linearly with the increase of the number of products tested in parallel.

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