Test device for collision of power battery pack

Abstract

The invention provides a test device for power battery pack collision, and belongs to the technical field of new energy automobile testing, the test device comprises a tractor, an adjustable fixing mechanism, a pitch angle adjusting mechanism and a brake system, the adjustable fixing mechanism is installed on the tractor, the adjustable fixing mechanism is used for fixing battery packs of different scales, and the pitch angle adjusting mechanism is used for adjusting the pitch angle of the battery packs. The pitch angle adjusting mechanism is installed on the front portion of the tractor to adjust the pitch angle of the front portion of the tractor, the braking system is installed on the tractor and used for braking the tractor, the braking system is remotely connected with the control terminal, and through the adjustable fixing mechanism, the tractor can adapt to the power battery pack with the wide-range size and the installation requirement. And moreover, the pitch angle adjusting function of the pitch angle adjusting mechanism is introduced, and the real working condition of the vehicle in real driving is simulated, so that the test condition is closer to the actual road scene.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle testing technology, and specifically to a test device for power battery pack collisions. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the power battery pack mounted on the bottom of the vehicle has become a core safety component. However, in actual road driving, the battery pack is highly susceptible to bottom-scraping collisions caused by road bumps, speed bumps, or falling objects. Such bottom impacts can cause the battery pack casing to tear or deform under pressure, thereby damaging the internal cells, modules, and their connection structures, leading to short circuits, leaks, thermal runaway, and even catastrophic consequences such as fires and explosions, seriously threatening the lives of passengers.

[0003] To scientifically evaluate the mechanical safety performance of power battery packs, authoritative domestic and international standards such as the China New Car Assessment Program (C-NCAP) have clearly stipulated the requirement for electric vehicle undercarriage scraping tests. This test requires the use of a movable obstacle course trolley to simulate the vehicle chassis, impacting a fixed simulated road obstacle at a specified speed. This assesses the structural integrity and system safety of the battery pack mounted on the trolley during the collision.

[0004] Currently, mobile barrier devices used in such tests still face numerous technical bottlenecks in practice. Firstly, poor versatility and adaptability: battery packs from different vehicle models vary significantly in size, weight, and mounting points (wheelbase), while many existing trolley structures are fixed, making it difficult to quickly and accurately adapt to diverse test samples, resulting in high testing costs and cumbersome procedures. Secondly, insufficient rigidity of key structures: under the instantaneous impact load of a high-speed collision, if the trolley's main frame undergoes plastic deformation, weld cracking, or mounting point misalignment, it will severely interfere with the true and effective transfer of collision energy, leading to distorted test data and failing to accurately reflect the battery pack's impact resistance. Thirdly, low precision in motion trajectory control: after the trolley is disengaged from the traction device, if there is a lack of effective and synchronized braking measures, it is prone to significant deviation, causing the collision center point to deviate from the preset position, severely affecting the repeatability of the test and the comparability of the results. Fourth, the realism of the simulation of working conditions needs to be improved: In real driving, vehicles exhibit pitch dynamics such as acceleration and nose-up, and braking and nose-down. A horizontally fixed trolley cannot simulate this posture, which makes the test conditions different from real accident conditions, reducing the rigor and effectiveness of the assessment. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of the aforementioned technologies by proposing a test device for power battery pack collisions, thereby solving the problems described above.

[0006] This invention provides a test device for a power battery pack collision, comprising a tractor, an adjustable fixing mechanism, a pitch angle adjustment mechanism, and a braking system. The adjustable fixing mechanism is mounted on the tractor and is used to fix battery packs of different sizes. The pitch angle adjustment mechanism is mounted on the front of the tractor to adjust the pitch angle of the front of the tractor. The braking system is mounted on the tractor and is used to brake the tractor. The braking system is remotely connected to a control terminal.

[0007] Preferably, the adjustable fixing mechanism includes a platform, a driver, and two fixing frames. The platform is mounted on the tractor, and the two fixing frames are slidably connected to both sides of the platform. The driver is mounted on the platform and is used to drive the two fixing frames to move towards or away from each other along the platform. The two fixing frames cooperate to fix battery packs of different sizes.

[0008] Preferably, the driver includes a hand-cranked reducer and two screws. The hand-cranked reducer is mounted on the platform, one end of each of the two screws is rotatably connected to the hand-cranked reducer, and the other end of each screw is threadedly connected to the corresponding fixed frame.

[0009] Preferably, the fixing frame includes an upper bracket and a side bracket, the upper bracket is slidably connected to the platform, the upper bracket is connected to the side bracket, and the side bracket is used to fix the battery pack.

[0010] Preferably, the platform includes a mounting platform and two guide platforms. The two ends of the two guide platforms are respectively connected to the tractor. Each of the two guide platforms is provided with two guide rails. The fixed frame is slidably connected to the two guide rails. The two ends of the mounting platform are respectively connected to the two guide platforms. The driver is mounted on the mounting platform.

[0011] Preferably, the upper support includes a connecting frame and a sliding seat, the connecting frame is connected to the side support, the connecting frame is connected to the sliding seat, and the sliding seat is slidably connected to the platform.

[0012] Preferably, the tractor includes a frame, a running gear, and two sets of wheelbase adjustment mechanisms. The frame is connected to the running gear, and a set of wheelbase adjustment mechanisms is installed at each of the front and rear ends of the frame.

[0013] Preferably, the wheelbase adjustment mechanism includes a crank handle, a transmission screw, and a bridge arm shaft. The two ends of the bridge arm shaft are slidably connected to the vehicle frame. The vehicle frame is provided with a first support. The crank handle is rotatably connected to the support. The bridge arm shaft is provided with a second support. The other end of the crank handle is threadedly connected to the second support.

[0014] Preferably, the pitch angle adjustment mechanism includes two lifts, which are respectively installed on the tractor vehicle, and the movable end of the lift is connected to the front wheel suspension frame of the tractor vehicle.

[0015] Preferably, the tractor is equipped with a mounting plate for mounting the braking system.

[0016] Compared with the prior art, the present invention has the following advantages: 1. Enhanced versatility: The adjustable fixing mechanism allows it to adapt to a wide range of power battery packs with varying sizes and installation requirements, thus improving the applicability of this equipment.

[0017] 2. Ensure structural stability: Through optimized design and manufacturing processes of the tractor and adjustable fixing mechanism, the trolley body is guaranteed not to deform or be damaged under harsh collision conditions.

[0018] 3. Ensure operational accuracy: A reliable braking system ensures that the tractor can travel stably along the predetermined trajectory after uncoupling, with accurate collision point.

[0019] 4. Simulate real working conditions: The pitch angle adjustment function of the pitch angle adjustment mechanism is introduced to make the test conditions closer to the actual road scene. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only preferred embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a three-dimensional structural schematic diagram of a test device for a power battery pack collision according to the present invention; Figure 2 This is a side view of a test device for a power battery pack collision according to the present invention. Figure 3 This is a bottom view of the test device for a power battery pack collision according to the present invention. Figure 4 This is a schematic diagram of the connection structure between the tractor and the pitch angle adjustment mechanism of the present invention; Figure 5 This is a schematic diagram of the connection structure between the battery pack and the adjustable fixing mechanism of the present invention; Figure 6 This is a schematic diagram of the connection structure between the battery pack and the adjustable fixing mechanism of the present invention; In the diagram, 1. Tractor; 2. Adjustable fixing mechanism; 3. Pitch angle adjustment mechanism; 4. Braking system; 5. Battery pack; 6. Platform; 7. Driver; 8. Hand-cranked reducer; 9. Screw; 10. Fixing frame; 11. Upper bracket; 12. Side bracket; 13. Mounting platform; 14. Guide platform; 15. Guide rail; 16. Connecting frame; 17. Sliding seat; 18. Frame; 19. Traveling mechanism; 20. Wheelbase adjustment mechanism; 21. Hand crank; 22. Drive screw; 23. Axle arm shaft; 24. First support; 25. Second support; 26. Lifting platform; 27. Mounting plate. Detailed Implementation

[0022] Example Reference Figures 1 to 6 This invention provides a test device for power battery pack collisions, including a tractor 1, an adjustable fixing mechanism 2, a pitch angle adjustment mechanism 3, and a braking system 4. The adjustable fixing mechanism 2 is installed on the tractor 1 and is used to fix battery packs 5 of different sizes and widths. The pitch angle adjustment mechanism 3 is installed at the front of the tractor 1 to adjust the pitch angle of the front of the tractor 1, simulating the pitch dynamics of acceleration and braking during actual driving, reducing the gap between the test conditions and real accident conditions, and improving the rigor and effectiveness of the assessment. The braking system 4 is installed on the tractor 1 and is used to brake the tractor 1. The braking system 4 is remotely connected to a control terminal, which is a remote controller.

[0023] The braking system 4 is existing technology; it is an independent, hydraulically driven, four-wheel synchronous braking system 4 with remote triggering capability. The test operator can remotely activate the brakes from a safe distance after the towing vehicle 1 has disengaged. The system ensures that the braking torque of all four wheels is applied synchronously, effectively preventing deviation caused by uneven braking force.

[0024] The performance indicators of the braking system 4 are: to ensure that the straight-line travel trajectory error of the traction trolley is no greater than ±25mm during the inertial sliding phase before braking after uncoupling.

[0025] The adjustable fixing mechanism 2 includes a platform 6, a driver 7, and two fixing frames 10. The platform 6 is mounted on the tractor 1 and is positioned above the tractor 1. The two fixing frames 10 are slidably connected to both sides of the platform 6. The driver 7 is mounted on the platform 6 and is used to drive the two fixing frames 10 to move towards or away from each other along the platform 6. The two fixing frames 10 cooperate to fix battery packs 5 of different sizes. The distance between the left and right fixing frames 10 can be adjusted by the driver 7 to accommodate battery packs 5 of different widths.

[0026] The driver 7 includes a hand-cranked reducer 8 and two screw rods 9. The hand-cranked reducer 8 is mounted on the platform 6. One end of each of the two screw rods 9 is rotatably connected to the hand-cranked reducer 8, and the other end of each screw rod 9 is threadedly connected to the corresponding fixed frame 10.

[0027] A pair of left and right rotating screws 9 are driven by a hand-cranked reducer 8. The screws 9 have an accuracy of 0.02 mm and a pitch of 10 mm. When the hand-cranked reducer 8 rotates, the left and right rotating screws 9 rotate synchronously, driving the fixed frames 10 that mesh with the screws 9 to move in opposite directions or in a straight line, thereby adjusting the distance between the two fixed frames 10.

[0028] The fixed frame 10 includes an upper bracket 11 and a side bracket 12. The upper bracket 11 is slidably connected to the platform 6. The upper bracket 11 is connected to the side bracket 12. The side bracket 12 is used to fix the battery pack 5. The sliding of the upper bracket 11 can drive the sliding of the side bracket 12.

[0029] The platform 6 includes a mounting platform 13 and two guide platforms 14. The two ends of the two guide platforms 14 are respectively connected to the tractor 1. The two guide platforms 14 are respectively provided with two guide rails 15. The fixed frame 10 is slidably connected to the two guide rails 15. The two ends of the mounting platform 13 are respectively connected to the two guide platforms 14. The driver 7 is mounted on the mounting platform 13.

[0030] The upper support 11 includes a connecting frame 16 and a sliding seat 17. The connecting frame 16 is connected to the side support 12, and the connecting frame 16 is connected to the sliding seat 17. The sliding seat 17 is slidably connected to the platform 6.

[0031] A double row of linear guide rails 15 are mounted parallel to each other on the platform 6. The guide rails 15 have a precision of 0.02mm. A sliding seat 17 contains 24 ball-bearing sliders (not shown) distributed on each guide rail 15. The sliding seat 17 slides on the guide rails 15, providing high-precision, low-friction linear guidance. Rotating the hand-cranked reducer 8 allows the two fixed frames 10 to move synchronously along the guide rails 15, achieving stepless adjustment of the battery pack 5's installation width within the range of 1250mm to 2200mm. The battery pack 5 is connected to the mounting holes on the fixed frames 10 via bolts, with the mounting hole position precision of 0.2mm. The tractor 1 includes a frame 18, a running mechanism 19, and two sets of wheelbase adjustment mechanisms 20. The frame 18 is connected to the running mechanism 19, and a set of wheelbase adjustment mechanisms 20 is installed at the front and rear ends of the frame 18, respectively.

[0032] The wheelbase adjustment mechanism 20 includes a crank handle 21, a transmission screw 22, and a bridge arm shaft 23. Both ends of the bridge arm shaft 23 are slidably connected to the frame 18. The frame 18 is provided with a first support 24. The crank handle 21 is rotatably connected to the support. The bridge arm shaft 23 is provided with a second support 25. The other end of the crank handle 21 is threadedly connected to the second support 25.

[0033] The pitch angle adjustment mechanism 3 includes two lifting platforms 26, which are respectively installed on the tractor vehicle 1. The movable end of the lifting platform 26 is connected to the front wheel suspension frame of the tractor vehicle 1.

[0034] To simulate the dynamic driving posture of a vehicle, the tractor 1 is equipped with a pitch angle adjustment mechanism 3 at the front. The pitch angle adjustment mechanism 3 consists of two synchronously operating lifts 26 (such as electric or manual screw lifts 26), which together raise or lower the suspension support point of the front wheel of the trolley, so that the entire trolley platform can achieve precise setting of pitch angle within the range of 0° to 3.5°. After the adjustment is completed, the locking mechanism (such as bolts) is used to ensure that its posture remains unchanged during a collision.

[0035] The tractor 1 is equipped with a mounting plate 27 for mounting the brake system 4.

[0036] The fixed frame 10 and the chassis 18 in this equipment are constructed from high-strength square steel tubing. This specification of square tubing provides excellent bending and torsional stiffness. To ensure long-term structural stability, the fixed frame 10 and chassis 18 undergo stress-relief annealing after welding to eliminate internal stress and prevent deformation during subsequent processing and use. Furthermore, key mounting and connection points are precision machined to ensure the datum accuracy of each component's installation.

[0037] During the test, the wheelbase and installation width were first adjusted according to the specifications of the battery pack 5 under test, using the wheelbase adjustment mechanism 20 and the adjustable fixing mechanism 2, respectively. The required angle was then set using the pitch angle adjustment mechanism 3. Subsequently, a counterweight was added to the trolley to ensure that its total mass met the test requirements. The tractor 1 was connected to the tractor 1 via a towing hook and accelerated to a predetermined speed before being unhooked. The operator then triggered the independent braking system 4 via a remote control, causing the traveling mechanism 19 (the four wheels of the trolley) to brake synchronously, maintaining straight-line movement until the battery pack 5 at its bottom scraped against the simulated obstacle fixed to the ground.

[0038] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention, or modify them into equivalent embodiments, without departing from the scope of the present invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technology of the present invention without departing from the scope of the present invention are within the protection scope of the present invention.

Claims

1. A test apparatus for a power battery pack collision, characterized in that; The system includes a tractor, an adjustable fixing mechanism, a pitch angle adjustment mechanism, and a braking system. The adjustable fixing mechanism is mounted on the tractor and is used to fix battery packs of different sizes. The pitch angle adjustment mechanism is mounted on the front of the tractor to adjust the pitch angle of the front of the tractor. The braking system is mounted on the tractor and is used to brake the tractor. The braking system is remotely connected to a control terminal.

2. The test apparatus for a power battery pack collision according to claim 1, characterized in that: The adjustable fixing mechanism includes a platform, a driver, and two fixing frames. The platform is mounted on the tractor, and the two fixing frames are slidably connected to both sides of the platform. The driver is mounted on the platform and is used to drive the two fixing frames to move towards or away from each other along the platform. The two fixing frames cooperate to fix battery packs of different sizes.

3. The test apparatus for a power battery pack collision according to claim 2, characterized in that; The driver includes a hand-cranked reducer and two screws. The hand-cranked reducer is mounted on the platform. One end of each of the two screws is rotatably connected to the hand-cranked reducer, and the other end of each screw is threadedly connected to the corresponding fixed frame.

4. The test apparatus for a power battery pack collision according to claim 2, characterized in that: The fixed frame includes an upper bracket and a side bracket. The upper bracket is slidably connected to the platform and is connected to the side bracket. The side bracket is used to fix the battery pack.

5. The test apparatus for a power battery pack collision according to claim 2, characterized in that: The platform includes a mounting platform and two guide platforms. The two ends of the two guide platforms are respectively connected to the tractor. Each of the two guide platforms is provided with two guide rails. The fixed frame is slidably connected to the two guide rails. The two ends of the mounting platform are respectively connected to the two guide platforms. The driver is mounted on the mounting platform.

6. The test apparatus for a power battery pack collision according to claim 4, characterized in that: The upper support includes a connecting frame and a sliding seat. The connecting frame is connected to the side support, the connecting frame is connected to the sliding seat, and the sliding seat is slidably connected to the platform.

7. The test apparatus for a power battery pack collision according to claim 1, characterized in that: The tractor unit includes a frame, a running gear, and two sets of wheelbase adjustment mechanisms. The frame is connected to the running gear, and a set of wheelbase adjustment mechanisms is installed at the front and rear ends of the frame, respectively.

8. The test apparatus for a power battery pack collision according to claim 7, characterized in that: The wheelbase adjustment mechanism includes a crank handle, a transmission screw, and a bridge arm shaft. The two ends of the bridge arm shaft are slidably connected to the frame. The frame is provided with a first support. The crank handle is rotatably connected to the support. The bridge arm shaft is provided with a second support. The other end of the crank handle is threadedly connected to the second support.

9. The test apparatus for a power battery pack collision according to claim 1, characterized in that: The pitch angle adjustment mechanism includes two lifts, which are respectively installed on the tractor vehicle. The movable end of the lift is connected to the front wheel suspension frame of the tractor vehicle.

10. The test apparatus for a power battery pack collision according to claim 1, characterized in that: The tractor is equipped with a mounting plate for installing the braking system.

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