Battery pack inspection device

Abstract

The invention provides an inspection device for a battery pack, which can carry out a plurality of inspections and can be miniaturized. In the inspection device of the battery pack, the battery pack is provided with a relay box which connects or disconnects a battery module and a positive electrode side high-voltage connector and a battery module and a negative electrode side high-voltage connector; and a case that accommodates the battery module, the battery pack inspection device being provided with: a relay box operation unit that operates the relay box; and a voltage measurement unit that measures a voltage between the positive electrode-side connection terminal and the negative electrode-side connection terminal, a voltage between the positive electrode-side connection terminal and the case connection terminal, and a voltage between the negative electrode-side connection terminal and the case connection terminal.

Description

Technical Field

[0001] This invention relates to a battery pack inspection device. Background Technology

[0002] Patent document 1 discloses a battery pack inspection device that checks the overall voltage value of the battery pack, the voltage value of each battery cell, the charge amount (remaining capacity), and other electrical characteristics of the battery pack.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2023-118374 Summary of the Invention

[0004] Battery pack inspection involves several aspects, such as confirming the operation of constituent components and verifying insulation performance. Inspection devices exist for each inspection item, thus requiring numerous installation locations.

[0005] To address this problem, the present invention provides an inspection device for a battery pack that can perform multiple inspections and can miniaturize the device.

[0006] The battery pack inspection apparatus of the present invention comprises: a battery module having a plurality of battery cells; a positive-side high-voltage connector connected to the positive terminal of the battery module; a negative-side high-voltage connector connected to the negative terminal of the battery module; a relay box for connecting or disconnecting the battery module from the positive-side high-voltage connector and the battery module from the negative-side high-voltage connector; and a housing that at least accommodates the battery module. The battery pack inspection apparatus comprises: a relay box operation unit for operating the relay box; a positive-side connection terminal connected to the positive-side high-voltage connector; a negative-side connection terminal connected to the negative-side high-voltage connector; a housing connection terminal connected to the housing; and a voltage measuring unit for measuring the voltage between the positive-side connection terminal and the negative-side connection terminal, the voltage between the positive-side connection terminal and the housing connection terminal, and the voltage between the negative-side connection terminal and the housing connection terminal.

[0007] This structure allows for multiple checks and enables the device to be miniaturized.

[0008] The relay box operating unit is operated to connect the battery module to the positive-side high-voltage connector and the battery module to the negative-side high-voltage connector. Based on the voltage between the positive-side and negative-side connection terminals measured by the voltage measuring unit, the relay box is inspected. Furthermore, based on the voltage between the positive-side and negative-side connection terminals, the voltage between the positive-side connection terminal and the housing connection terminal, and the voltage between the negative-side connection terminal and the housing connection terminal, all measured by the voltage measuring unit, the insulation performance between the battery module and the housing is inspected. This structure allows for the inspection of the relay box and the insulation performance between the battery module and the housing.

[0009] In the battery pack inspection apparatus of the present invention, the battery pack includes: a battery module having a plurality of battery cells; a cooling fan for cooling the battery module; a battery control unit for acquiring information related to the battery module and information related to the cooling fan; and a low-voltage connector connected to the battery control unit. The battery pack inspection apparatus includes: a cooling fan operation unit for operating the cooling fan; an information acquisition unit connected to the low-voltage connector for acquiring information related to the battery module and information related to the cooling fan from the battery control unit; and a display for displaying the information acquired by the information acquisition unit.

[0010] This structure allows for multiple checks and enables the device to be miniaturized.

[0011] Based on information related to the battery module obtained by the information acquisition unit from the battery control unit, the battery module is inspected, and the cooling fan is activated by the cooling fan operation unit. Based on information related to the cooling fan obtained by the information acquisition unit from the battery control unit, the cooling fan is also inspected. This structure enables the inspection of both the battery module and the cooling fan.

[0012] Invention Effects

[0013] This invention provides an inspection device for battery packs that can perform multiple inspections and can miniaturize the device. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of a vehicle equipped with a battery pack.

[0015] Figure 2 This is a schematic structural diagram of the battery pack inspection device according to Embodiment 1.

[0016] Figure 3This is a schematic structural diagram showing the battery pack inspection device according to Embodiment 1, with the positive side cable connected to the positive side connection terminal and the negative side cable connected to the negative side connection terminal.

[0017] Figure 4 This is a schematic structural diagram showing the battery pack inspection device according to Embodiment 1, with the positive side cable connected to the positive side connection terminal and the negative side cable connected to the housing connection terminal.

[0018] Figure 5 This is a schematic structural diagram showing the battery pack inspection device according to Embodiment 1, with the positive side cable connected to the housing connection terminal and the negative side cable connected to the negative side connection terminal. Detailed Implementation

[0019] The following uses Figures 1-5 The embodiments of the present invention will be described. Figure 1 This is a schematic diagram of the structure of a vehicle equipped with a battery pack. Figure 2 This is a schematic structural diagram of the battery pack inspection device according to Embodiment 1. Figure 3 This is a schematic structural diagram showing the battery pack inspection device according to Embodiment 1, with the positive side cable connected to the positive side connection terminal and the negative side cable connected to the negative side connection terminal. Figure 4 This is a schematic structural diagram showing the battery pack inspection device according to Embodiment 1, with the positive side cable connected to the positive side connection terminal and the negative side cable connected to the housing connection terminal. Figure 5 This is a schematic structural diagram showing the battery pack inspection device according to Embodiment 1, with the positive side cable connected to the housing connection terminal and the negative side cable connected to the negative side connection terminal.

[0020] Implementation Method 1

[0021] use Figure 1 The battery pack 1, which is the subject of inspection, and the vehicle 20 equipped with the battery pack 1 will be described. The battery pack 1 is installed in the vehicle 20, such as an electric vehicle, a hybrid vehicle, or a fuel cell vehicle. The power supplied from the battery pack 1 drives the electric generator 22 via the power control unit 21. When the electric generator 22 is driven, the wheels 24 rotate, and the vehicle 20 moves.

[0022] The battery pack 1 includes a battery module 2, a relay box 3, a battery monitoring unit 4, a cooling fan 5, a battery control unit 6, a housing 7, a positive side high-voltage connector 11, a negative side high-voltage connector 12, and a low-voltage connector 13.

[0023] Battery module 2 supplies drive power to electric generator 22 via power control unit 21. Battery module 2 includes multiple battery cells connected in series, each battery cell consisting of a secondary battery such as a lithium-ion battery or a nickel-metal hydride battery, or a capacitor.

[0024] The relay box 3 includes a positive-side system main relay 3a and a negative-side system main relay 3b. The positive-side system main relay 3a is positioned between the battery module 2 and the positive-side high-voltage connector 11. The positive-side system main relay 3a is connected to the positive terminal of the battery module 2 and the positive-side high-voltage connector 11 via a positive-side wiring 8a. The negative-side system main relay 3b is positioned between the battery module 2 and the negative-side high-voltage connector 12. The negative-side system main relay 3b is connected to the negative terminal of the battery module 2 and the negative-side high-voltage connector 12 via a negative-side wiring 8b.

[0025] The positive-side system main relay 3a switches the electrical connection (on) and disconnect (off) between the battery module 2 and the positive-side high-voltage connector 11 according to the control command from the battery control unit 6. The negative-side system main relay 3b switches the electrical connection (on) and disconnect (off) between the battery module 2 and the negative-side high-voltage connector 12 according to the control command from the battery control unit 6.

[0026] The battery monitoring unit 4 consists of multiple sensors used to monitor the state of the battery module 2. The battery monitoring unit 4 includes a voltage sensor group 41, a current sensor 42, and a temperature sensor 43. The voltage sensor group 41 includes multiple voltage sensors that detect the voltage of each battery cell included in the battery module 2. The current sensor 42 detects the current input to and output to the battery module 2. The temperature sensor 43 detects the temperature of the battery module 2. Each sensor outputs the detection result to the battery control unit 6.

[0027] The cooling fan 5 includes a fan motor 5a that rotates the cooling fan 5 and a fan circuit 5b that controls the rotational speed of the fan motor 5a. The cooling fan 5 operates via the fan circuit 5b and the fan motor 5a according to control commands from the battery control unit 6. When the cooling fan 5 is operating, air is supplied to the battery module 2, and the battery module 2 is cooled. The cooling fan 5 outputs the rotational speed of the fan motor 5a detected by the fan circuit 5b to the battery control unit 6.

[0028] The battery control unit 6 includes a processor such as a central processing unit (CPU), a memory such as read-only memory (ROM) and random access memory (RAM), and input / output ports for inputting and outputting various signals (none of which are shown).

[0029] The battery control unit 6 obtains information related to the battery module 2 from the battery monitoring unit 4. Based on signals received from the sensors of the battery monitoring unit 4 and programs stored in the memory, the battery control unit 6 monitors and manages the status of the battery module 2 and the battery monitoring unit 4. For example, based on signals received from the sensors of the battery monitoring unit 4, the battery control unit 6 determines whether any abnormality has occurred in any of the battery cells of the battery module 2 or any of the sensors of the battery monitoring unit 4.

[0030] The battery control unit 6 controls the rotation speed of the cooling fan 5 based on temperature information and other data detected by the current sensor 42 of the battery module 2. The battery control unit 6 obtains information such as the rotation speed of the cooling fan 5 from the cooling fan 5 and monitors its status. Based on control commands from the integrated ECU 23, the battery control unit 6 controls the on / off state of the positive-side system main relay 3a and the negative-side system main relay 3b.

[0031] The battery control unit 6 is connected to the integrated ECU 23 via the low-voltage connector 13. The battery control unit 6 and the integrated ECU 23 are connected in a manner that enables controller area network (CAN) communication, and output the monitoring results of the battery module 2 to the integrated ECU 23.

[0032] The housing 7 is made of metal such as aluminum and houses all components of the battery pack 1, including the battery module 2 and the relay box 3. A positive-side high-voltage connector 11, a negative-side high-voltage connector 12, and a low-voltage connector 13 are fixed to the housing 7. The positive-side high-voltage connector 11, the negative-side high-voltage connector 12, and the low-voltage connector 13 are electrically insulated from the housing 7.

[0033] use Figure 2 The battery pack inspection device 30 will be described. The battery pack inspection device 30 is a device that performs checks on the operation of the components and the insulation performance before the assembled battery pack 1 is mounted on the vehicle 20.

[0034] The battery pack inspection device 30 includes a connection terminal section 31, an operation section 32, an information processing section 33, a display 34, a microphone 35, and a voltage measuring section 36.

[0035] The connection terminal section 31 has a positive-side connection terminal 31a, a negative-side connection terminal 31b, and a housing connection terminal 31c. The positive-side connection terminal 31a is connected to the positive-side high-voltage connector 11 via a positive-side voltage measuring wire 37a. The negative-side connection terminal 31b is connected to the negative-side high-voltage connector 12 via a negative-side voltage measuring wire 37b. The housing connection terminal 31c is connected to the housing 7 via a housing voltage measuring wire 37c.

[0036] The voltage measuring unit 36 ​​measures the voltage between the positive side connection terminal 31a and the negative side connection terminal 31b. The voltage measuring unit 36 ​​uses a digital high-resistance meter, a digital multimeter, an analog tester, etc. The voltage measuring unit 36 ​​includes a positive side cable 36a, a negative side cable 36b, and a display unit 36c. With the positive side system main relay 3a and the negative side system main relay 3b in the ON state, the positive side cable 36a is connected to the positive side connection terminal 31a, and the negative side cable 36b is connected to the negative side connection terminal 31b, thereby measuring the overall voltage of the battery module 2. The measured voltage is displayed on the display unit 36c.

[0037] The operation unit 32 includes a relay box operation unit 32a and a cooling fan operation unit 32b. The operation unit 32 is connected to the low-voltage connector 13 via a communication line 39. By operating the relay box operation unit 32a, the positive-side system main relay 3a and the negative-side system main relay 3b can be switched on / off. By operating the cooling fan operation unit 32b, the operation of the cooling fan 5 can be switched off / off.

[0038] The connecting terminal 31 and the operating unit 32 are located in the box 40. Alternatively, the connecting terminal 31 and the operating unit 32 may be provided separately.

[0039] The information processing unit 33 includes an information acquisition unit 33a and an information output unit 33b. The information processing unit 33 uses a single-board computer such as a Raspberry Pi or a personal computer. The information processing unit 33 is connected to the low-voltage connector 13 via a communication line 39.

[0040] The information acquisition unit 33a acquires information related to the battery pack 1 from the battery control unit 6. Specifically, the information acquisition unit 33a acquires information related to the battery module 2 (current or temperature of the battery module 2, voltage of each battery cell, etc.), information related to the battery monitoring unit 4 (abnormalities of each sensor, etc.), and information related to the cooling fan 5 (speed of the cooling fan 5, etc.) from the battery control unit 6.

[0041] The information processing unit 33 is connected to the microphone 35 that detects sound. The information acquisition unit 33a acquires the sound detected by the microphone 35.

[0042] The information output unit 33b outputs the information related to the battery pack 1 acquired by the information acquisition unit 33a to the display 34. The display 34 displays the information related to the battery pack 1 output by the information output unit 33b.

[0043] The inspection method of the battery pack-based inspection device 30 is described. The battery pack inspection device 30 inspects (A) the relay box, (B) the insulation performance, (C) the battery module and battery monitoring unit, and (D) the cooling fan.

[0044] (A) Relay box

[0045] The inspection method for relay box 3 is explained.

[0046] Operate the relay box operation section 32a to repeatedly switch the positive-side system main relay 3a and the negative-side system main relay 3b on and off. If the positive-side system main relay 3a and the negative-side system main relay 3b are functioning normally, they will operate and produce a working sound. If the microphone 35 can detect this working sound, it can be determined that the positive-side system main relay 3a and the negative-side system main relay 3b are functioning normally. Alternatively, the microphone 35 can be omitted, and the operator's ear can be used to determine whether a working sound is produced.

[0047] If either the positive-side system main relay 3a or the negative-side system main relay 3b is functioning normally while the other is malfunctioning, the malfunction cannot be detected solely by the operating sound. Therefore, with both the positive-side system main relay 3a and the negative-side system main relay 3b in the ON state, the overall voltage of the battery module 2 is measured to determine the malfunction.

[0048] Specifically, such as Figure 3 As shown, the positive side cable 36a of the voltage measuring unit 36 ​​is connected to the positive side connection terminal 31a, and the negative side cable 36b is connected to the negative side connection terminal 31b. Then, the relay box operation unit 32a is operated to turn on the positive side system main relay 3a and the negative side system main relay 3b. Then, the voltage between the positive side connection terminal 31a and the negative side connection terminal 31b, that is, the voltage of the entire battery module 2, is measured by the voltage measuring unit 36. If the measured voltage exceeds the specified voltage, it is determined that the positive side system main relay 3a and the negative side system main relay 3b are working normally. If the measured voltage does not exceed the specified voltage, it is determined that either or both of the positive side system main relay 3a and the negative side system main relay 3b are abnormal.

[0049] Next, operate the relay box operation unit 32a to disconnect the positive-side system main relay 3a and the negative-side system main relay 3b. Then, if the voltage measured by the voltage measuring unit 36 ​​does not exceed the specified voltage, it is determined that the positive-side system main relay 3a and the negative-side system main relay 3b are working normally. If the measured voltage exceeds the specified voltage, it is determined that the abnormality is caused by the positive-side system main relay 3a and the negative-side system main relay 3b being stuck due to a connection failure.

[0050] (B) Insulation performance

[0051] Next, the method for checking the insulation performance of battery pack 1 will be explained.

[0052] like Figure 3 As shown, the positive side cable 36a of the voltage measuring unit 36 ​​is connected to the positive side connection terminal 31a, and the negative side cable 36b is connected to the negative side connection terminal 31b. Then, the relay box operation unit 32a is operated to turn on the positive side system main relay 3a and the negative side system main relay 3b. Then, the voltage V between the positive side connection terminal 31a and the negative side connection terminal 31b, that is, the voltage V of the entire battery module 2, is measured by the voltage measuring unit 36. A reference voltage V0 is set based on this measured voltage V. For example, a fraction of the measured voltage V is used as the reference voltage V0.

[0053] Next, as Figure 4 As shown, the positive side cable 36a of the voltage measuring unit 36 ​​is connected to the positive side connection terminal 31a, and the negative side cable 36b is connected to the housing connection terminal 31c. That is, the voltage V1 between the positive side connection terminal 31a and the housing connection terminal 31c is measured by the voltage measuring unit 36. If the measured voltage V1 is below the reference voltage V0, it is determined that the negative side of the battery module 2 is properly insulated from the housing 7. On the other hand, if the measured voltage V1 exceeds the reference voltage V0, it is determined that the negative side of the battery module 2 is not properly insulated from the housing 7.

[0054] Next, as Figure 5 As shown, the positive side cable 36a of the voltage measuring unit 36 ​​is connected to the housing connection terminal 31c, and the negative side cable 36b is connected to the negative side connection terminal 31b. That is, the voltage V2 between the negative side connection terminal 31b and the housing connection terminal 31c is measured by the voltage measuring unit 36. If the measured voltage V2 is below the reference voltage V0, it is determined that the positive side of the battery module 2 is properly insulated from the housing 7. On the other hand, if the measured voltage V2 exceeds the reference voltage V0, it is determined that the positive side of the battery module 2 is not properly insulated from the housing 7.

[0055] Thus, the checks on (A) the relay box and (B) the insulation performance are performed by the connection terminal section 31, the relay box operation section 32a, and the voltage measuring section 36. According to the battery pack inspection device 30 of the present invention, by including the connection terminal section 31, the relay box operation section 32a, and the voltage measuring section 36, multiple checks can be performed; specifically, the checks on (A) the relay box and (B) the insulation performance can be performed, enabling the device to be miniaturized.

[0056] (C) Battery module and battery monitoring unit

[0057] Next, the inspection methods for battery module 2 and battery monitoring unit 4 will be explained.

[0058] The information acquisition unit 33a acquires information related to the battery module 2 (current or temperature of the battery module 2, voltage of each battery cell, etc.) and information related to the battery monitoring unit 4 (abnormalities of each sensor, etc.) from the battery control unit 6. The information output unit 33b outputs the information related to the battery module 2 or battery monitoring unit 4 acquired by the information acquisition unit 33a to the display 34. The display 34 displays the information related to the battery module 2 or battery monitoring unit 4 output by the information output unit 33b. Based on the information related to the battery module 2 or battery monitoring unit 4 displayed on the display 34, it is confirmed whether an abnormality has occurred in the battery module 2 or battery monitoring unit 4.

[0059] (D) Cooling fan

[0060] Next, the inspection method for cooling fan 5 will be explained.

[0061] Operate the cooling fan control unit 32b to make the cooling fan 5 work. If the microphone 35 can detect the working sound of the cooling fan 5, it can be determined that the cooling fan 5 is working normally. Alternatively, the microphone 35 can be omitted, and the operator's ears can be used to determine whether a working sound is produced.

[0062] Even if the cooling fan 5 is operating, for example, if the speed of the cooling fan 5 is abnormally low, the abnormality cannot be detected by the operating sound alone. Therefore, the abnormality is determined based on the information related to the cooling fan 5 obtained by the battery control unit 6.

[0063] Specifically, the information acquisition unit 33a acquires the rotational speed information of the cooling fan 5 acquired by the battery control unit 6. The information output unit 33b outputs the rotational speed information of the cooling fan 5 acquired by the information acquisition unit 33a to the display 34. The display 34 displays the rotational speed information of the cooling fan 5 output by the information output unit 33b. Based on the rotational speed information of the cooling fan 5 displayed on the display 34, it is determined whether the cooling fan 5 is malfunctioning. For example, if the rotational speed of the cooling fan 5 is lower than the specified speed, it is determined that the cooling fan 5 is malfunctioning.

[0064] Thus, the inspection of (C) the battery module and battery monitoring unit and (D) the cooling fan is performed by the information processing unit 33, the display 34, and the cooling fan operation unit 32b. According to the battery pack inspection device 30 of the present invention, by including the information processing unit 33, the display 34, and the cooling fan operation unit 32b, multiple inspections can be performed; specifically, the inspection of (C) the battery module and battery monitoring unit and (D) the cooling fan can be performed, enabling the device to be miniaturized.

[0065] Furthermore, the present invention is not limited to the above-described embodiments, and appropriate modifications can be made without departing from the spirit of the invention.

[0066] Symbol Explanation

[0067] 1-Battery pack, 2-Battery module, 3-Relay box, 4-Battery monitoring unit, 5-Cooling fan, 6-Battery control unit, 7-Housing, 11-Positive side high voltage connector, 12-Negative side high voltage connector, 13-Low voltage connector, 30-Battery pack inspection device, 31-Connection terminal section, 31a-Positive side connection terminal, 31b-Negative side connection terminal, 31c-Housing connection terminal, 32-Operating unit, 32a-Relay box operating unit, 32b-Cooling fan operating unit, 33-Information processing unit, 33a-Information acquisition unit, 33b-Information output unit, 34-Monitor, 36-Voltage measuring unit.

Claims

1. A battery pack inspection device, characterized in that, The battery pack includes: A battery module, which has multiple battery cells; A high-voltage connector on the positive side, which is connected to the positive terminal of the battery module; A negative-side high-voltage connector, which is connected to the negative terminal of the battery module; A relay box, which connects or disconnects the battery module from the positive-side high-voltage connector and from the battery module to the negative-side high-voltage connector; and A housing that at least accommodates the battery module, and an inspection device for the battery pack comprising: A relay box operating unit that operates the relay box; The positive side connection terminal is connected to the positive side high voltage connector; The negative-side connection terminal is connected to the negative-side high-voltage connector. A housing connection terminal, which is connected to the housing; and The voltage measuring unit measures the voltage between the positive terminal and the negative terminal, the voltage between the positive terminal and the housing terminal, and the voltage between the negative terminal and the housing terminal.

2. The battery pack inspection device according to claim 1, characterized in that, Operate the relay box operating unit to connect the battery module to the positive-side high-voltage connector and the battery module to the negative-side high-voltage connector. Based on the voltage between the positive and negative terminals measured by the voltage measuring unit, the relay box is inspected. Based on the voltage between the positive electrode side connection terminal and the negative electrode side connection terminal, the voltage between the positive electrode side connection terminal and the housing connection terminal, and the voltage between the negative electrode side connection terminal and the housing connection terminal measured by the voltage measuring unit, the insulation performance between the battery module and the housing is checked.

3. A battery pack inspection device, characterized in that, The battery pack includes: A battery module, which has multiple battery cells; A cooling fan that cools the battery module; The battery control unit acquires information related to the battery module and information related to the cooling fan; and A low-voltage connector, which connects to the battery control unit, and an inspection device for the battery pack, comprising: A cooling fan operating unit that enables the cooling fan to operate; An information acquisition unit, which is connected to the low-voltage connector, acquires information related to the battery module and information related to the cooling fan from the battery control unit; and A display that shows the information acquired by the information acquisition unit.

4. The battery pack inspection device according to claim 3, characterized in that, Based on the information related to the battery module obtained by the information acquisition unit from the battery control unit, the battery module is inspected. The cooling fan is operated by the cooling fan control unit. The cooling fan is inspected based on information related to the cooling fan obtained by the information acquisition unit from the battery control unit.

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