Liquid cooling pipeline test system

Abstract

The invention belongs to the technical field of liquid cooling system detection, and discloses a liquid cooling pipeline test system. The liquid cooling pipeline test system comprises a test bench, a liquid cooling pipeline and a liquid cooling unit, the test bench is provided with a mounting area and a test area, the test area is used for being arranged corresponding to a battery cluster of an energy storage system, and each test area is provided with a part of the liquid cooling pipeline and a flow resistance simulation module which is arranged on the liquid cooling pipeline and is adjustable in flow resistance. Partial liquid cooling pipelines located in different test areas are arranged in parallel or in series; the liquid cooling unit is fixed to the installation area, the liquid cooling unit and the liquid cooling pipeline are connected to form a circulation loop, and the liquid cooling unit is used for providing cooling liquid and driving the cooling liquid to circularly flow in the liquid cooling pipeline. A test mode of simulating real working conditions and flow resistance is adopted, different working conditions can be flexibly simulated without installing an actual battery and adjusting the flow resistance, it is ensured that the test environment highly restores the actual operation state of the energy storage system, and the defect that pure simulation or a simplified loop cannot reflect real equipment dynamic characteristics is overcome.

Description

Technical Field

[0001] This invention relates to the field of liquid cooling system testing technology, and in particular to a liquid cooling pipeline testing system. Background Technology

[0002] Liquid-cooled energy storage systems are a thermal management technology that uses the circulation of coolant to precisely control battery temperature. They mainly include two types: large containerized designs and small-scale industrial and commercial energy storage designs. In liquid-cooled energy storage systems, the liquid cooling pipeline is the core component, and its design directly affects the cooling effect. Therefore, testing is usually required before mass production to verify the layout and performance of the liquid cooling pipeline.

[0003] In existing technologies, testing mainly includes two methods: computer simulation and actual testing of complete prototypes. If computer simulation is used to simulate the flow of coolant in the pipeline, it is fast and low-cost, but the results are not realistic and reliable due to the influence of the model. If a complete energy storage prototype is made and a corresponding liquid cooling pipeline prototype is made separately for actual testing and verification, the test results are realistic and reliable, but the cycle is long and the cost is high, and it cannot be compatible with testing different types of energy storage systems.

[0004] Therefore, there is an urgent need to provide a liquid-cooled pipeline testing system to simulate real operating conditions and flow resistance for testing. It is suitable for containerized and commercial energy storage systems, does not require the installation of actual batteries, and uses flow resistance adjustment to flexibly simulate different operating conditions. It can overcome the shortcomings of pure simulation or simplified circuits that cannot reflect the dynamic characteristics of real equipment, and can also solve the problems of long test cycles and high costs for the whole machine. Summary of the Invention

[0005] The purpose of this invention is to provide a liquid-cooled pipeline testing system to simulate real working conditions and flow resistance for testing. It is suitable for containerized and industrial and commercial energy storage systems. It does not require the installation of actual batteries and uses flow resistance adjustment to flexibly simulate different working conditions. It can overcome the shortcomings of pure simulation or simplified circuits that cannot reflect the dynamic characteristics of real equipment, and also solve the problems of long test cycles and high costs for the whole machine.

[0006] To achieve this objective, the present invention adopts the following technical solution: This invention provides a liquid-cooled pipeline testing system, including a test bench, liquid-cooled pipelines, and a liquid-cooled unit. The test bench has an installation area and a testing area. The testing area is configured to correspond to the battery clusters of an energy storage system. Each testing area is provided with a portion of the liquid-cooled pipelines and a flow resistance simulation module provided in the liquid-cooled pipelines with adjustable flow resistance. The liquid-cooled pipelines located in different testing areas are connected in parallel or in series. The liquid cooling unit is fixed in the installation area. The liquid cooling unit is connected to the liquid cooling pipeline to form a circulation loop. The liquid cooling unit is used to provide coolant and drive the coolant to circulate in the liquid cooling pipeline.

[0007] As an optional technical solution for a liquid cooling pipeline testing system, the flow resistance simulation module includes a flow meter and a throttle valve; both the flow meter and the throttle valve are installed on a branch of the liquid cooling pipeline or on a resistance pipe connected to a branch of the liquid cooling pipeline.

[0008] As an optional technical solution for a liquid-cooled pipeline testing system, the test bench also includes a mobile frame, and the liquid-cooled pipeline testing system also includes a control unit placed on the mobile frame, the control unit being signal-connected to both the flow meter and the throttle valve.

[0009] As an optional technical solution for a liquid-cooled pipeline testing system, the resistance tube is equipped with a pressure sensor interface and a temperature sensor interface; And / or, the flow resistance simulation module further includes a pipe support, through which the resistance pipe is fixed to the test bench.

[0010] As an optional technical solution for a liquid cooling pipeline testing system, the test bench includes a base plate and cluster supports fixed to the base plate. The base plate is provided with an installation area and a test area. Each test area is provided with a cluster support. The liquid cooling pipeline and the flow resistance simulation module are fixed to the cluster supports. All the cluster supports are arranged side by side.

[0011] As an optional technical solution for a liquid-cooled pipeline testing system, the test bench also includes a frame, which is fixed to the installation area, and the liquid-cooled unit is fixed to the frame.

[0012] As an optional technical solution for a liquid-cooled pipeline testing system, the test bench includes a vibration damping pad located between the frame and the liquid-cooled unit.

[0013] As an optional technical solution for a liquid-cooled piping testing system, the test area is provided with at least two sections, and the liquid-cooled piping includes: There are at least two main pipelines, and all of the main pipelines are connected to the liquid cooling unit; Branch paths are connected to the main road and extend to the test area, and each main road is connected to multiple branch paths. A connecting pipe is provided, and the branch is connected to the flow resistance simulation module through the connecting pipe.

[0014] As an optional technical solution for a liquid cooling pipeline testing system, the test area is provided, and the liquid cooling pipeline includes two branches and multiple connecting pipelines. One end of each branch is connected to the liquid cooling unit, and the other end of each branch is connected to the flow resistance simulation module through the connecting pipelines.

[0015] As an optional technical solution for a liquid cooling pipeline testing system, quick-connect couplings are used at the connection points of the liquid cooling pipeline itself, the connection points between the liquid cooling pipeline and the flow resistance simulation module, and the connection points between the liquid cooling pipeline and the liquid cooling unit.

[0016] Beneficial effects: This invention provides a liquid-cooled pipeline testing system, including a test bench, liquid-cooled pipelines, and a liquid-cooling unit. The test bench has an installation area and a testing area. The testing area is set up to correspond to the battery clusters of an energy storage system. Each testing area is equipped with a portion of liquid-cooled pipelines and a flow resistance simulation module with adjustable flow resistance located on the liquid-cooled pipelines. The liquid-cooled pipelines located in different testing areas are connected in parallel or in series. The liquid-cooling unit is fixed in the installation area and is connected to the liquid-cooled pipelines to form a circulation loop. The liquid-cooling unit is used to provide coolant and drive the coolant to circulate in the liquid-cooled pipelines. A liquid-cooled unit is installed in the mounting area of ​​the test bench, and liquid-cooled piping is installed in the test area. A flow resistance simulation module is set on the liquid-cooled piping to simulate real operating conditions and flow resistance for testing. There is no need to install actual batteries. By adjusting the flow resistance, different operating conditions can be flexibly simulated, thereby reproducing a variety of real or extreme flow resistance scenarios. This ensures that the test environment highly replicates the actual operating state of the energy storage system, overcoming the shortcomings of pure simulation or simplified circuits that cannot reflect the dynamic characteristics of real equipment. The test area is designed to correspond to the battery clusters of the energy storage system, which can be used for testing containerized and industrial and commercial energy storage systems. There is no need to remake the entire unit and piping, which saves more time and costs compared to actual testing of the entire unit. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the liquid cooling pipeline testing system provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the test bench and flow resistance simulation module provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the liquid cooling pipeline and flow resistance simulation module provided in an embodiment of the present invention; Figure 4 yes Figure 1 A magnified view of a section at point A in the middle; Figure 5 This is a schematic diagram of the flow resistance simulation module provided in an embodiment of the present invention; Figure 6 yes Figure 1 A magnified view of a section at point B.

[0018] In the picture: 1. Test bench; 1a. Installation area; 1b. Test area; 11. Base plate; 12. Cluster bracket; 13. Frame; 14. Mobile frame; 2. Liquid cooling piping; 20. Flow resistance simulation module; 200. Resistance tube; 201. Flow meter; 202. Pressure sensor interface; 203. Temperature sensor interface; 204. Throttling valve; 205. Pipe support; 21. Main pipe; 22. Branch pipe; 23. Connecting pipe; 3. Liquid cooling unit; 4. Control unit. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0020] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0022] In the description of this embodiment, the terms "upper," "lower," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0023] In the design and development of small-scale (industrial and commercial) and large-scale (containerized) liquid-cooled energy storage systems, the layout and performance verification of liquid-cooled pipelines mainly rely on simulation analysis and engineering experience. Current testing methods for liquid-cooled pipelines primarily include computer simulation and full-scale prototype testing, but these still have many shortcomings, specifically: First, in actual operation, the start-up and shutdown characteristics, frequency conversion response, and cooling / heating switching of the unit will significantly affect the flow and pressure build-up process in the pipeline. However, existing tests mostly use simplified circuits (such as only water pump + water tank) or pure simulations, lacking the participation of real liquid-cooled units (including compressors, condensers, evaporators, etc.), making it difficult to expose problems such as uneven flow, air blockage, and surge under real operating conditions.

[0024] Secondly, the test piping is usually directly connected and fixed to the simulated load or the real cold plate. Once the piping scheme is changed or the compatibility of different cold plates needs to be evaluated, physical components must be replaced. There is a lack of a means to adjust online and accurately reproduce multiple flow resistance characteristics, resulting in incomplete design verification coverage and difficulty in dealing with scenarios such as cold plate aging, manufacturing deviations, or the introduction of new cold plates.

[0025] Third, during actual testing of the whole machine, due to the limitations of space and wiring on the prototype, sensors are often only placed at the main inlet / outlet, making it impossible to obtain independent flow, pressure and temperature data of each branch. This means that whether the pipeline design achieves "uniform distribution" can only be estimated or simulated, and the actual test basis is seriously insufficient, which may lead to the risk of local overheating or wasted power consumption.

[0026] Fourth, the testing platform is highly tied to the product form. Commercial and industrial storage prototypes cannot be used for container testing, and vice versa. The testing environment must be built almost from scratch each time, making it impossible to reuse existing resources or compare the pipeline performance of different product specifications on the same platform. At the same time, the platform does not have modular expansion capabilities, making it difficult to adapt to the development needs of future multi-cluster parallel or larger-scale systems.

[0027] like Figures 1 to 3 As shown, to address the problems of relying on complete prototypes, high cost, low efficiency, and disconnect between simulation and reality in liquid cooling pipeline testing, this embodiment provides a liquid cooling pipeline testing system, including a test bench 1, liquid cooling pipelines 2, and a liquid cooling unit 3. The test bench 1 has an installation area 1a and a test area 1b. The test area 1b is set up to correspond to the battery clusters of the energy storage system. Each test area 1b is equipped with a portion of the liquid cooling pipelines 2 and a flow resistance simulation module 20 with adjustable flow resistance located on the liquid cooling pipelines 2. The portions of the liquid cooling pipelines 2 located in different test areas 1b are connected in parallel or in series. The liquid cooling unit 3 is fixed to the installation area 1a. The liquid cooling unit 3 is connected to the liquid cooling pipelines 2 to form a circulation loop. The liquid cooling unit 3 is used to provide coolant and drive the coolant to circulate in the liquid cooling pipelines 2.

[0028] A liquid-cooled unit 3 is installed in installation area 1a of test bench 1, and a liquid-cooled pipeline 2 is installed in test area 1b. A flow resistance simulation module 20 is set on the liquid-cooled pipeline 2 to simulate real operating conditions and flow resistance for testing. There is no need to install actual batteries. Different operating conditions are flexibly simulated by adjusting the flow resistance, thereby reproducing a variety of real or extreme flow resistance scenarios. This ensures that the test environment highly replicates the actual operating state of the energy storage system and overcomes the shortcomings of pure simulation or simplified circuits that cannot reflect the dynamic characteristics of real equipment. By designing test area 1b to correspond to the battery cluster of the energy storage system, it can be applied to the testing of containerized and industrial and commercial energy storage systems. There is no need to remake the entire unit and pipelines, which saves more time and costs compared to actual testing of the entire unit.

[0029] Specifically, the test bench 1 includes a base plate 11 and cluster supports 12 fixed to the base plate 11. The base plate 11 is provided with an installation area 1a and a test area 1b. Each test area 1b is provided with a cluster support 12. The liquid cooling pipeline 2 and the flow resistance simulation module 20 are fixed to the cluster support 12. All cluster supports 12 are arranged side by side.

[0030] Cluster brackets 12 are installed on the base plate 11. The cluster brackets 12 provide a stable and reliable installation foundation for the liquid cooling pipeline 2 and the flow resistance simulation module 20, preventing displacement or vibration and ensuring the safe operation of the liquid cooling pipeline test system. The test area 1b is set up corresponding to the battery clusters of the energy storage system. Therefore, one cluster bracket 12 is set up in each test area 1b. One cluster bracket 12 can meet the testing requirements of a single battery cluster. Multiple cluster brackets 12 arranged side by side can meet the testing requirements of multiple battery clusters and facilitate modular maintenance of a single cluster.

[0031] The test area 1b has one unit, which can be used for single-cluster testing of commercial and industrial energy storage systems. Multiple test areas 1b can be used for multi-cluster testing of containerized energy storage systems. It is understood that large containerized energy storage systems typically have 2 to 6 battery clusters, while small commercial and industrial energy storage systems typically have 1 or 2 battery clusters. Because the cluster support 12 of the liquid-cooled pipeline test system in this embodiment is expandable, it can cover both commercial and industrial storage and containerized energy storage application scenarios, improving utilization.

[0032] In this embodiment, the base plate 11 is made of steel; the base plate 11 and the cluster support 12 are detachably connected; the cluster support 12 is an integral structure; there are 6 test areas 1b, and there are also 6 cluster supports 12, which correspond to 6 "cluster positions". The 6 cluster supports 12 are arranged side by side, and adjacent cluster supports 12 are detachably fixed and have equal spacing.

[0033] The cluster support 12 adopts an integrated structure to prevent tipping due to instability. The base plate 11 and the cluster support 12, as well as adjacent cluster supports 12, can be detachably connected using quick-connect, snap-fit, or fastener methods for easy expansion. In other embodiments, the number, arrangement, and corresponding pipeline connection methods of the cluster supports 12 can be varied. For example, the number of cluster supports 12 can be expanded to eight or reduced to two. The cluster supports 12 can be dynamically reconfigured via sliding rails or flexible hose jumpers; even multiple clusters of pipelines can be connected in series to simulate long-flow pressure drops.

[0034] Furthermore, the test bench 1 also includes a frame 13, which is fixed to the mounting area 1a of the base plate 11, and the liquid cooling unit 3 is fixed on the frame 13. The frame 13 is designed on the base plate 11, which can raise the liquid cooling unit 3 and reserve sufficient operating space at the bottom of the liquid cooling unit 3 to facilitate the connection of the bottom of the liquid cooling unit 3 to the liquid cooling pipeline 2, which helps to ensure efficient maintenance and safe operation.

[0035] In this embodiment, the rack 13 is arranged adjacent to the cluster support 12 and is used to place the actual liquid-cooled unit 3. The actual liquid-cooled unit 3 can reproduce the dynamic characteristics of the liquid-cooled unit in the actual energy storage system (such as start-stop impact, frequency response, and cooling / heating switching), avoiding the distortion caused by the simplified circuit. The size and load-bearing capacity of the rack 13 are designed according to the maximum 60kW liquid-cooled unit 3, and the top of the rack 13 is provided with mounting holes for fixing the liquid-cooled unit 3. The liquid-cooled unit 3 can be quickly loaded and unloaded by forklift.

[0036] Optionally, the test bench 1 includes a vibration damping pad located between the frame 13 and the liquid cooling unit 3. The vibration damping pad, placed between the frame 13 and the liquid cooling unit 3, absorbs and attenuates vibration energy through its elastic deformation, blocking vibration transmission and preventing resonance. The vibration damping pad is located on the top of the frame 13 and may be made of materials including, but not limited to, rubber.

[0037] See Figure 1 , Figure 3 and Figure 4 The liquid cooling pipeline 2 includes a main pipeline 21, branch pipelines 22, and connecting pipelines 23. There are at least two main pipelines 21, all of which are connected to the liquid cooling unit 3. Branch pipelines 22 connect to the main pipelines 21 and extend to the test area 1b. Each main pipeline 21 connects to multiple branch pipelines 22, and the branch pipelines 22 are connected to the flow resistance simulation module 20 via the connecting pipelines 23. By placing the flow resistance simulation module 20 on the branch pipelines 22, different flow resistances can be dynamically simulated, supporting rapid switching and parallel comparison of multiple scenarios, resulting in higher testing efficiency.

[0038] Among them, the main pipeline 21 is a primary pipeline, the branch pipeline 22 is a secondary pipeline, and the connecting pipeline 23 is a tertiary pipeline. The main pipeline 21 is responsible for the main circulation, the connecting pipeline 23 is the terminal connection, the main pipeline 21 is connected to the branch pipeline 22, and then connected to the flow resistance simulation module 20 through the connecting pipeline 23.

[0039] In this embodiment, there are two main pipelines 21. One main pipeline 21 is used to distribute the coolant from the liquid-cooled unit 3 to the pipelines of each test area 1b, and the other main pipeline 21 is used to collect and return the coolant to simulate the cluster operation of a containerized energy storage system (e.g., 6 clusters in parallel correspond to a typical 5MWh container). The main pipeline 21 is a stainless steel pipe or an engineering plastic pipe, and each main pipeline 21 is connected to 6 parallel branches 22. The branches 22 located in different test areas 1b are arranged in parallel. The liquid-cooled unit 3 provides coolant. For each test area 1b, the coolant flows into one end of the flow resistance simulation module 20 through one main pipeline 21, one branch 22 and one connecting pipeline 23 in sequence. The coolant flows out from the other end of the flow resistance simulation module 20 and then flows back to the liquid-cooled unit 3 through another connecting pipeline 23, another branch 22 and another main pipeline 21 in sequence.

[0040] In this embodiment, the cluster support 12 includes a bottom frame and a main frame. The bottom frame is fixed to the base plate 11, and the main frame is fixed to the bottom frame. The main pipeline 21 is arranged horizontally along the bottom frame, and the branch pipelines 22 and connecting pipelines 23 are arranged on the main frame. The branch pipelines 22 extend vertically upward, and the connecting pipelines 23 extend horizontally. Arranging the main pipeline 21 within the bottom frame ensures that the pipelines are neatly organized, avoiding pipe collapse caused by accidental stepping, which would affect the test results.

[0041] In some cases, test area 1b is provided with one liquid cooling pipeline 2, which includes two branches 22 and multiple connecting pipelines 23. One end of all branches 22 is connected to the liquid cooling unit 3, and the other end of the branches 22 is connected to the flow resistance simulation module 20 through the connecting pipelines 23. If test area 1b is provided with only one main pipeline 21, then there is no need to provide a main pipeline 21. The branches 22 can be directly connected to the liquid cooling unit 3. The liquid cooling unit 3 provides coolant, which flows into one end of the flow resistance simulation module 20 through one branch 22 and one connecting pipeline 23 in sequence. The coolant flows out from the other end of the flow resistance simulation module 20 and then flows back to the liquid cooling unit 3 through another connecting pipeline 23 and another branch 22 in sequence.

[0042] Optionally, quick-connect fittings are used at the connections of the liquid cooling pipeline 2 itself, the connection between the liquid cooling pipeline 2 and the flow resistance simulation module 20, and the connection between the liquid cooling pipeline 2 and the liquid cooling unit 3. The connections of the liquid cooling pipeline 2 itself include the connection points between the main pipeline 21, the branch pipeline 22, and the connecting pipeline 23. By using quick-connect fittings at the connections of the liquid cooling pipeline 2 itself, the connection between the liquid cooling pipeline 2 and the flow resistance simulation module 20, and the liquid cooling unit 3, only a portion of the pipeline needs to be replaced via the quick-connect interface each time the pipeline is adjusted or modified. The remaining portion can still be reused, significantly reducing costs and enabling rapid replacement of different solutions, effectively saving testing time.

[0043] The quick-connect coupling structure refers to a structure that allows for rapid connection or disconnection, enabling pipe connection and separation without tools. It ensures no leakage under pressure or liquid conditions, supports plug-and-play functionality, significantly shortens test preparation and replacement time, and improves testing efficiency. For example, quick-connect couplings. In this embodiment, a forklift is used to fork the liquid cooling unit 3 onto the frame 13 and secure it. The inlet and outlet of the liquid cooling unit 3 are quickly connected to the liquid cooling pipeline 2 via flexible hoses and quick-connect couplings, achieving plug-and-play functionality. In other embodiments, in addition to quick-connect couplings, detachable structures such as clamps, flanges, and socket welding with detachable sections can also be used.

[0044] See Figure 3 and Figure 5 The flow resistance simulation module 20 includes a flow meter 201 and a throttle valve 204; both the flow meter 201 and the throttle valve 204 are installed on the resistance pipe 200 which is connected to the branch 22 of the liquid cooling pipeline 2.

[0045] In this embodiment, a flow resistance simulation module 20 is installed on the branch 22 of each test area 1b; each cluster support 12 is provided with a support beam, and the resistance tube 200 is used to fix it on the support beam of the cluster support 12 and is quickly connected to the connecting pipe 23 of the liquid cooling pipeline 2 through a quick-connect coupling structure; the flow meter 201 is an electronic flow meter or an electromagnetic flow meter, and the throttle valve 204 is an electric tubular throttle valve, including but not limited to a proportional regulating needle valve or a miniature regulating valve driven by a stepper motor. In other embodiments, the flow meter 201 and the throttle valve 204 may also be directly installed on the branch 22 of the liquid cooling pipeline 2.

[0046] By using a flow meter 201 and a throttle valve 204 together, the flow meter 201 can detect the actual flow value of the branch 22 in real time. Based on the measured flow value, the opening of the throttle valve 204 is controlled to simulate different flow resistances (such as simulating differences between new and old cold plates, blockages, manufacturing tolerances, etc.), and flexibly reproduce a variety of real or extreme flow resistance scenarios.

[0047] In other embodiments, the flow meter 201 and the throttle valve 204 may not be used in conjunction, and other flow resistance simulation methods may be used instead. For example, a set of fixed throttle orifice plates with preset orifice diameters may be used in conjunction with a multi-way switching valve to achieve discrete gear adjustment; or different actuators such as stepper motor driven ball valve, proportional solenoid valve, and pneumatic regulating valve may be used to replace the electric needle valve; or even a physical cold plate sample may be directly connected as a fixed load.

[0048] Optionally, the resistance pipe 200 is equipped with a pressure sensor interface 202 and a temperature sensor interface 203. The reserved design of the pressure sensor interface 202 and temperature sensor interface 203 allows for quick connection of the pressure and temperature sensors, enabling real-time monitoring of the pressure and temperature of the branch 22. This results in more refined and reliable test data, enabling real-time and accurate measurement of key performance indicators such as the uniformity of flow distribution, pressure drop, and temperature rise in each branch. This provides reliable experimental data for pipeline layout optimization and significantly reduces blind reliance on simulation results.

[0049] Optionally, each cluster bracket 12 is also equipped with electrical terminals for powering or communicating with the sensor and throttle valve 204, and a label marked "Cluster 1 to 6".

[0050] See Figure 5 and Figure 6 The flow resistance simulation module 20 also includes a pipe support 205, through which the resistance pipe 200 is fixed to the test bench 1. Integrating the flow meter 201 and the throttle valve 204 onto the resistance pipe 200 to form the flow resistance simulation module 20, and fixing the resistance pipe 200 to the test bench 1 via the pipe support 205, can ensure the stability of the liquid cooling pipeline test system, reduce measurement errors, obtain more accurate test data, and prevent the accuracy of test results from being affected by the positional differences of the flow resistance simulation module 20.

[0051] Optionally, the test bench 1 also includes a movable frame 14, and the liquid-cooled pipeline testing system also includes a control unit 4 placed on the movable frame 14. The control unit 4 is signal-connected to both the flow meter 201 and the throttle valve 204. Placing the control unit 4 on the movable frame 14 allows for quick adjustment of its position, ensuring flexible and safe operation. The control unit 4's signal connection to the flow meter 201 and the throttle valve 204 enables the acquisition of flow data and control of the opening degree of the throttle valve 204.

[0052] In this embodiment, the mobile frame 14 is a trolley, and the control unit 4 includes a laptop computer and related software system or an industrial touch screen controller + multi-channel data acquisition card; if the pressure sensor interface 202 is connected to the pressure sensor and the temperature sensor interface 203 is connected to the temperature sensor, the control unit 4 is signal connected to both the pressure sensor and the temperature sensor.

[0053] The flow meter 201 measures the actual flow rate of its branch pipeline in real time and transmits the signal to the control unit 4. The control unit 4 automatically adjusts the opening of the flow meter 201 according to the preset target. The pressure sensor interface 202 and temperature sensor interface 203 are reserved for data input for subsequent expansion experiments. The control unit 4 can read data such as flow rate, pressure difference, and temperature, and display the real-time curves of flow rate, pressure difference, and temperature of each branch. Through closed-loop control, the flow-pressure drop characteristic curve of the branch pipeline is made to accurately match the real resistance characteristics of the target cold plate. It supports the pre-storage of multiple cold plate models (such as cold plate A, cold plate B, aged cold plate, etc.). After setting the "target flow resistance model", automatic matching and one-click switching can be achieved. Therefore, without physically replacing the cold plate, the flow resistance of various batteries can be simulated in the same liquid-cooled pipeline test system, realizing "one machine, multiple models" verification. The data can also be exported for simulation result comparison. In this embodiment, the control unit 4 performs automatic closed-loop flow resistance control based on the received flow data to adjust the opening of the throttle valve 204; in other embodiments, the operator can also manually adjust the throttle valve 204 to the target value based on the flow rate or differential pressure reading.

[0054] The following is a detailed description of the usage process of the liquid cooling pipeline testing system: Use a forklift to install and fix the liquid cooling unit 3 on the frame 13. Install quick-connect fittings at the inlet and outlet of the liquid cooling unit 3. Install the corresponding pipelines (main pipeline 21, branch pipeline 22 and connecting pipeline 23) on the cluster support 12. Connect the main pipeline 21 to the inlet and outlet of the liquid cooling unit 3 through quick-connect fittings. After all the pipelines in each cluster are connected, select the corresponding "cold plate resistance model" in the control unit 4 according to actual needs. When the liquid cooling unit 3 is started, the coolant provided by the liquid cooling unit 3 circulates in the pipeline. The control unit 4 automatically adjusts each throttle valve 204 to match the flow rate or pressure drop of each branch pipeline with the "cold plate resistance model". The corresponding sensors connected through the reserved pressure sensor interface 202 and temperature sensor interface 203 collect temperature and pressure data in real time to observe whether the flow distribution is uniform, whether there is a dead zone, and whether the power consumption of the liquid cooling unit 3 exceeds the standard, thereby verifying whether the design of the liquid cooling pipeline 2 is reasonable. If the flow rate is found to be low at a certain point, the pipeline route can be modified on site (such as increasing the pipe diameter and reducing the number of bends). After replacing the pipeline, there is no need to rebuild the whole machine. It only takes a few minutes to disassemble and reassemble before testing. If different pipeline design schemes are used in different cluster positions, the performance differences of multiple pipeline schemes can also be compared at the same time.

[0055] The liquid-cooled pipeline testing system of this embodiment has a rack 13 arranged on the base plate 11, which can directly place the actual liquid-cooled unit 3 (including compressor, water pump, condenser, etc.) without simplification or replacement. The liquid-cooled unit 3 can be quickly loaded and unloaded by forklift, ensuring that the test environment highly replicates the actual operating state of the energy storage system, overcoming the shortcomings of pure simulation or simplified circuits that cannot reflect the dynamic characteristics of real equipment. Each branch 22 is equipped with a throttle valve 204 and a flow meter 201. By adjusting the opening of the throttle valve 204 with electronic signals, the flow resistance of various cold plates under different operating conditions (such as differences between new and old cold plates, blockage, manufacturing tolerances, etc.) can be dynamically simulated, flexibly reproducing various real or extreme flow resistance scenarios, and improving the performance of the system. Robustness of the pipeline design: Each branch 22 has a standard pipe joint reserved in the connecting pipeline 23, which can be connected to temperature sensors, pressure sensors and flow sensors at any time to realize real-time and accurate measurement of key performance indicators such as flow distribution, pressure drop and temperature rise of each branch 22, providing reliable experimental basis for pipeline layout optimization and significantly reducing blind reliance on simulation results; It is suitable for single-cluster verification of small industrial and commercial energy storage systems, and can also simulate the whole-cluster operation state of large containerized energy storage systems by connecting multiple clusters in parallel. It has high utilization rate. The cluster support 12 of the test bench 1 adopts a modular design, which can flexibly expand the number of test clusters in the future according to needs to adapt to the development and verification needs of larger scale or new energy storage products.

[0056] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A liquid-cooled pipeline testing system, characterized in that, The system includes a test bench (1), liquid cooling pipelines (2), and a liquid cooling unit (3). The test bench (1) has an installation area (1a) and a test area (1b). The test area (1b) is set up to correspond to the battery clusters of the energy storage system. Each test area (1b) is provided with a portion of the liquid cooling pipelines (2) and a flow resistance simulation module (20) provided on the liquid cooling pipelines (2) with adjustable flow resistance. The portions of the liquid cooling pipelines (2) located in different test areas (1b) are connected in parallel or in series. The liquid cooling unit (3) is fixed in the installation area (1a). The liquid cooling unit (3) is connected to the liquid cooling pipeline (2) to form a circulation loop. The liquid cooling unit (3) is used to provide coolant and drive the coolant to circulate in the liquid cooling pipeline (2).

2. The liquid-cooled pipeline testing system according to claim 1, characterized in that, The flow resistance simulation module (20) includes a flow meter (201) and a throttle valve (204); the flow meter (201) and the throttle valve (204) are both installed on the branch (22) of the liquid cooling pipeline (2) or on the resistance pipe (200) connected to the branch (22) of the liquid cooling pipeline (2).

3. The liquid-cooled pipeline testing system according to claim 2, characterized in that, The test bench (1) also includes a mobile frame (14), and the liquid cooling pipeline test system also includes a control unit (4) placed on the mobile frame (14). The control unit (4) is signal connected to the flow meter (201) and the throttle valve (204).

4. The liquid-cooled pipeline testing system according to claim 2, characterized in that, The resistance tube (200) is provided with a pressure sensor interface (202) and a temperature sensor interface (203). And / or, the flow resistance simulation module (20) further includes a pipe support (205), through which the resistance tube (200) is fixed to the test bench (1).

5. The liquid-cooled pipeline testing system according to claim 1, characterized in that, The test bench (1) includes a base plate (11) and a cluster support (12) fixed to the base plate (11). The base plate (11) is provided with the installation area (1a) and the test area (1b). Each test area (1b) is provided with a cluster support (12). The liquid cooling pipeline (2) and the flow resistance simulation module (20) are fixed to the cluster support (12). All the cluster supports (12) are arranged side by side.

6. The liquid-cooled pipeline testing system according to claim 5, characterized in that, The test bench (1) also includes a frame (13), which is fixed to the installation area (1a), and the liquid cooling unit (3) is fixed to the frame (13).

7. The liquid-cooled pipeline testing system according to claim 6, characterized in that, The test bench (1) includes a shock-absorbing pad located between the frame (13) and the liquid cooling unit (3).

8. The liquid-cooled pipeline testing system according to any one of claims 1-7, characterized in that, The test area (1b) is provided with at least two, and the liquid cooling pipeline (2) includes: There are at least two main pipelines (21), and all of the main pipelines (21) are connected to the liquid cooling unit (3); Branch (22), connected to the main road (21) and extending to the test area (1b), each of the main roads (21) is connected to a plurality of the branch (22); Connecting pipe (23), the branch (22) is connected to the flow resistance simulation module (20) through the connecting pipe (23).

9. The liquid-cooled pipeline testing system according to any one of claims 1-7, characterized in that, The test area (1b) is provided, and the liquid cooling pipeline (2) includes two branches (22) and multiple connecting pipelines (23). One end of all branches (22) is connected to the liquid cooling unit (3), and the other end of the branches (22) is connected to the flow resistance simulation module (20) through the connecting pipelines (23).

10. The liquid-cooled pipeline testing system according to any one of claims 1-7, characterized in that, The connection points of the liquid cooling pipeline (2) itself, the connection points of the liquid cooling pipeline (2) and the flow resistance simulation module (20), and the connection points of the liquid cooling pipeline (2) and the liquid cooling unit (3) all adopt quick-connect couplings.

Images