Full-link virtual-real linkage battery simulation teaching system

Abstract

The invention relates to the technical field of new energy automobile battery teaching, and discloses a full-link virtual-real linkage battery simulation teaching system, which comprises hardware simulation, 3D / VR simulation software and an algorithm verification and fault simulation module, and is characterized in that the hardware simulation module comprises a modular insulation rack, a high-precision battery simulator, a waterway heat dissipation system and VR interaction equipment; equipment interconnection is realized through the communication module; the 3D / VR module supports 3D dynamic display and immersive operation simulation of the battery pack; the fault simulation module can issue a fault signal and is linked with hardware; the algorithm verification module supports fault data injection and user-defined algorithm operation; the system collects hardware data through the BMS controller and transmits the hardware data to the software system through the communication module, virtual and real data synchronization and a whole-process teaching closed loop are achieved, practical training safety, practical operation authenticity and teaching depth are considered, and the system is suitable for multi-scene battery teaching.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy vehicle battery teaching, in particular to a full-link virtual-real linkage battery simulation teaching system. BACKGROUND

[0002] With the rapid development of the new energy vehicle industry, the market demand for professionals in battery system-related technical fields is increasingly urgent. As a core link in personnel training, battery teaching and training directly affect the quality of personnel training. However, the existing training equipment in the current new energy vehicle battery teaching field still has many technical shortcomings and application limitations, and it is difficult to meet the needs of large-scale and deep-level teaching.

[0003] Traditional training equipment highly depends on real battery packs to carry out operation training, which has significant drawbacks in the teaching scene. On the one hand, battery packs involve high-voltage electrical systems, usually hundreds of volts, and in high-voltage power-on, voltage testing, disassembly, and other training links, improper operation can easily cause electric shock accidents. Moreover, the chemical properties of real battery packs determine that they have safety risks such as thermal runaway, electrolyte leakage, and fire and explosion, which pose a serious threat to the personal safety of training personnel. On the other hand, the disassembly process of real battery packs will cause irreversible damage such as cell loss, shell deformation, and connector wear, with high maintenance and replacement costs. Moreover, battery packs have a limited cycle life, and the capacity decay after long-term use will cause training data distortion. In addition, the environmental protection treatment of scrap batteries also increases additional costs, making it difficult to meet the high-frequency use needs of large-scale classroom teaching.

[0004] Current mainstream simulation teaching equipment mostly uses single virtual or single hardware mode, both of which have functional limitations. Pure virtual simulation equipment only simulates battery structure and operation process through software, which can avoid safety risks, but lacks the real data feedback and industrial-level hardware operation touch, making it difficult for students to combine virtual operation with actual hardware characteristics and establish a complete learning cycle of theoretical cognition, virtual operation, practical verification, and result feedback, resulting in a gap between theory and practice. Pure hardware training equipment can only carry out basic wiring and simple disassembly and other surface operation training, with limited fault simulation types, usually no more than 10 types, which cannot cover the full-link fault scenarios of battery packs, making it difficult to meet the deep-level technical research and advanced teaching needs.

[0005] Most existing training equipment only focuses on structure disassembly or basic electrical operation, and cannot adapt to multi-level teaching needs from basic skills to high-level research and development. At the same time, the software and hardware architecture of existing equipment is fixed, and it is difficult to add course resource packages and fault types on the software side, making it difficult to adapt to updates with the iteration of new energy battery technology and the upgrading of teaching needs. Therefore, there is an urgent need for a battery simulation teaching solution that can break through the limitations of existing technology and achieve safe, efficient, and full-link teaching. SUMMARY

[0006] The application aims to provide a full-link virtual-real linkage battery simulation teaching system to solve the problem that the existing battery teaching equipment cannot form a complete teaching closed loop by considering safety, real operation authenticity and teaching depth.

[0007] To achieve the above-mentioned purpose, the application adopts the following technical solutions: A full-link virtual-real linkage battery simulation teaching system comprises a hardware simulation module, a 3D / VR simulation software module, an algorithm verification module and a fault simulation module. The hardware simulation module comprises a battery simulation rack main body, a battery simulator, a water cooling system, a VR interactive device and a BMS controller. The battery simulation rack main body adopts a modular assembly structure, and the surface is subjected to insulation treatment and is additionally provided with universal casters and adjusting legs. The voltage range of the battery simulator is 0V-6V, the accuracy is ≤±1mV, and active / passive balancing is supported. The water cooling system has a temperature control range of-40℃-150℃, and comprises a water pump, a heating rod, a temperature sensor and a pressure sensor. The VR interactive device comprises a VR headset, a handle, a double display, a matching software and a mobile fault setting device. The BMS controller is connected with the battery simulator, the software and the water cooling system through a communication module. An industrial computer is connected with the VR headset and the mobile fault setting device through a communication module. The 3D / VR simulation software module is developed based on a Unity engine and comprises a 3D simulation module and a VR practical training module. The 3D simulation module is used for realizing 3D dynamic display of a battery pack / module / single cell, supporting zooming, exploding, rotating and part disassembly operations. The VR practical training module is used for operation process simulation and realizes 360° dead angle-free observation through compatible VR devices. The fault simulation module sends a fault signal through the mobile fault setting device, is in real-time linkage with the hardware simulation module, and triggers the battery simulator to output corresponding fault parameters. The algorithm verification module comprises a fault data template and is used for fault data injection and operation display. The data link of each module is that the BMS controller collects simulation data of the hardware simulation module, transmits the data to the 3D / VR simulation software module through a communication module, the algorithm verification module runs a self-defined algorithm based on the injected data, outputs a result and feeds back the result to a double display. The virtual-real linkage logic is that the mobile fault setting device sends a fault instruction, the battery simulator and the BMS controller simulate a corresponding fault state, and the 3D / VR simulation software module synchronously presents a fault phenomenon and data.

[0008] The principle and advantages of the present scheme are: in actual application, through VR simulation of high-voltage high-risk operation and hardware insulation anti-short circuit design, the safety hazards of traditional real battery pack practical training are completely solved; through the virtual-real linkage mode, the defects of pure virtual equipment without real operation feedback and pure hardware equipment without virtual guidance are made up, helping students to establish a complete learning cycle of "theory-virtual-real operation-feedback"; through the full-link coverage structure disassembly, electrical principle, thermal management, algorithm development teaching content, the problem of insufficient teaching depth of existing equipment is solved; through rich fault simulation types and algorithm verification functions, the multi-level teaching needs from basic skills to high-level research and development are met; through modular design and standardized interface, the maintenance cost is reduced and the teaching application in multiple scenes is adapted.

[0009] Preferably, as an improvement, the communication module includes a CAN 2.0 bus and a WiFi module; the BMS controller connects the battery simulator, software and water cooling system through the CAN 2.0 bus, and adopts shielded twisted pair to transmit signals; the industrial computer connects the VR headset and the mobile fault setting device through the WiFi module.

[0010] Technical effects: the CAN 2.0 bus ensures the stability and real-time performance of data transmission between hardware modules, the shielded twisted pair reduces signal interference, and ensures accurate synchronization of fault parameters and simulation data; the WiFi module realizes wireless communication, breaks the bondage of wired connection, improves the operation convenience of VR interaction and fault setting, and adapts to the flexible layout requirements of practical training scenes.

[0011] Preferably, as an improvement, the algorithm verification module integrates Python 3.9 running environment, supports PyTorch / TensorFlow framework, and the fault data template is in CSV format. The algorithm running result is visualized in the form of curve, table and error analysis.

[0012] Technical effects: it is convenient to reduce the threshold of algorithm development and verification, adapt to different levels of teaching needs, intuitively compare the differences between algorithm output and hardware simulation data, and realize the whole process of algorithm writing, verification and optimization.

[0013] Preferably, as an improvement, it also includes middleware developed based on Node.js, which realizes protocol conversion between hardware data and software system through standardized API interface, and ensures the compatibility between modules.

[0014] Technical effects: it solves the industry pain points of incompatible protocols between hardware devices, software systems and algorithm tools, at the same time, provides an extension basis for subsequent addition of course resources, replacement of hardware modules and connection of third-party tools, and improves long-term adaptability.

[0015] Preferably, as an improvement, the algorithm verification module includes SOH calculation algorithm, sampling accuracy algorithm and grade discrimination algorithm. The SOH calculation algorithm is based on a second-order equivalent circuit to simulate a battery model, generate pseudo-labels, and then input them into a deep learning model. The sampling accuracy algorithm filters data points with current / voltage variance <0.1 and absolute value of variation difference <5, calculates the relative deviation ratio between BMS current / voltage and equipment, and takes the average of the 20th to 70th percentiles of data with ratio ≤1 multiplied by 100% as the consistency evaluation index. The fault level discrimination algorithm is obtained based on historical big data clustering analysis.

[0016] Technical benefits: It is easy to adapt to the needs of explaining principles and verifying practical operations in teaching.

[0017] Preferably, as an improvement, the power supply link of the hardware simulation module is as follows: the main power line of the battery simulation test bench is connected to a 220VAC socket, and the power supply is distributed to the industrial control computer, the battery simulator, and the water cooling system. The power supply link is connected in series with an emergency stop switch.

[0018] Technical benefits: Facilitates stable power supply, fault diagnosis, and power adaptation for each module.

[0019] Preferably, as an improvement, the types of fault signals include low SOH, abnormal temperature, poor voltage consistency, thermal runaway, abnormal system insulation resistance, and excessive individual voltage deviation.

[0020] Technical benefits: Facilitates comprehensive coverage of the fault range. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the architecture of a battery simulation teaching system that integrates virtual and real-world elements across the entire process. Detailed Implementation

[0022] The following detailed description illustrates the specific implementation method: The basic implementation examples are as follows: Figure 1 As shown: A battery simulation teaching system with full-link virtual and real linkage, including a hardware simulation module, a 3D / VR simulation software module, an algorithm verification module and a fault simulation module. The modules work together to build a full-process teaching system of "theoretical learning, virtual operation, hardware verification and algorithm optimization".

[0023] The hardware simulation module includes a battery simulation test bench, a battery simulator, a water cooling system, VR interactive equipment, and a BMS controller.

[0024] The main body of the battery simulation platform measures 2200*1200*1900mm. It adopts a modular assembly structure, is made of Q235 cold-rolled steel plate, and has an electrostatic powder coating insulation treatment on the surface. The bottom is equipped with universal casters and adjustable feet to support movement and fixation, solving the problem of balancing ease of movement and stability. The connectors have a foolproof design and are waterproof, eliminating the risk of abnormal detachment and short circuit.

[0025] The battery simulator is a 96-cell high-precision battery simulator with dimensions of 200*150*100mm, a voltage range of 0V~6V, an accuracy of ≤±1mV, and supports active / passive balancing.

[0026] The water cooling system has a temperature control range of -40℃ to 150℃ and includes a 24VDC 60W water pump (13m head), a 220VAC 500W heating rod, and a 50~300KpaA pressure sensor; it is used to solve the problem of realistic simulation of battery thermal management scenarios.

[0027] The VR interactive device includes a VR headset, controllers, dual displays, supporting software, and a mobile fault setter; the dual displays include a ≥23-inch operating screen and a ≥60-inch display screen; in this embodiment, the mobile fault setter is a tablet computer.

[0028] The battery simulator, BMS controller, and water cooling system are fixed to the main body of the battery simulation platform with M8 bolts, and the distance between adjacent modules is ≥5cm. The dual monitors are fixed to the front of the platform back panel with a rotatable bracket (rotation angle 0~180°). The VR headset is stored in the drawer on the left side of the platform and is worn during use.

[0029] The power supply link for the hardware simulation module is as follows: the main power line of the battery simulation test bench is connected to a 220VAC socket, and the branch circuits supply power to the industrial control computer (DC12V / 10A), the battery simulator (DC24V / 5A), and the cooling system (water pump DC24V / 3A, heating rod AC220V / 2.5A). The emergency stop switch is connected in series in the power supply link.

[0030] The communication module includes a CAN 2.0 bus and a WiFi module. The BMS controller connects to the battery simulator, software, and water cooling system via the CAN 2.0 bus (500kbps baud rate). The CAN 2.0 bus uses shielded twisted-pair cable with a cross-sectional area of ​​1 square millimeter. The industrial control computer connects to the VR headset and mobile fault setter via the WiFi module to achieve wireless communication and ensure ease of use. It also includes middleware developed based on Node.js, which uses a standardized API interface (supporting RESTful protocol) to achieve protocol conversion between hardware data and the software system, ensuring compatibility between modules.

[0031] The 3D / VR simulation software module is developed based on the Unity engine and includes a 3D simulation module and a VR training module.

[0032] The 3D simulation module is used to realize the 3D dynamic display of battery packs / modules / cells. The 3D model accuracy is 0.1mm, and it supports 1:1~1:10 scaling, 360° rotation, explosion (disassembly levels ≥3: battery pack, module, cell) and component disassembly and assembly operations (15 components can be disassembled, including pre-charge resistor, BMU, water cooling plate, etc.), to solve the problems of low model accuracy and limited interactive functions. When using it, open the battery pack software in the mobile fault setter, select the function buttons such as appearance structure, BMS system, thermal management, and charging principle, and the software will automatically synchronize to the supporting software. By clicking on components such as pre-charge resistor, BMU, and water cooling plate in the 3D model, the software will pop up the component parameters (such as pre-charge resistor resistance value 5Ω, BMU operating voltage 12V) and principle explanation (such as pre-charge resistor suppressing the initial charging surge current).

[0033] The VR training module is used for immersive simulation of high-voltage operation processes (power-on / voltage testing / disassembly, etc.), and is compatible with VR devices to achieve 360° observation without blind spots. In use, press the power button on the VR headset to turn it on, and insert 1.5V AA batteries into both controllers. Select the battery pack software on the industrial control computer (e.g., package name: com.www.BatteryBenchVR) to display the virtual training scene on the VR headset. The virtual disassembly and assembly process of the battery module is as follows: In the virtual tool table, use the left controller's side button to grab the hex wrench (M5); the controller vibrates to indicate a successful grab. Move the left controller's joystick to the battery pack cover, aim the right controller at the 32 M5×20 high-gloss bolts, and press the trigger button to loosen them; the bolts automatically fall into the tool table's storage box. After all bolts are removed, use the left controller's side button to grab the cover and move it upwards to remove it, exposing the internal module. Use the hex socket (M6) to remove the 16 M8 module bolts, grab the module and remove it to complete the disassembly. Click the reset button in the scene, and the components automatically return to their positions for repeated training.

[0034] The fault simulation module sends out fault signals through the mobile fault setter. The types of fault signals include low SOH, abnormal temperature, poor voltage consistency, thermal runaway, abnormal system insulation resistance, and excessive single-cell voltage deviation. The mobile fault setter and the hardware simulation module are linked in real time, triggering the battery simulator to output corresponding fault parameters (such as a 10% voltage drop) to solve the problem of inaccurate linkage between fault simulation and hardware.

[0035] The prerequisite for fault setting is that the start-web program on the industrial control computer has been started and the algorithm service is running; otherwise, fault commands cannot be issued.

[0036] The fault setting process is as follows: Set the fault in the mobile fault setter, select the target fault from the fault signals, click confirm and issue, and the BMS interface on the display screen will update the fault data synchronously (e.g., when the single cell temperature is ≥60℃, the bench buzzer sounds and the red light flashes as an alarm). Use a multimeter to measure the output voltage of the battery simulator on the hardware side and the BMS temperature sampling signal, and compare the virtual and actual measured data to locate the fault (e.g., the temperature sensor wiring is loose). Click on fault clear in the mobile fault setter to restore the equipment to normal status.

[0037] The algorithm verification module is used for fault data injection and computation display.

[0038] The algorithm verification module integrates a Python 3.9 runtime environment, supports the PyTorch / TensorFlow framework, includes several fault data templates in CSV format, and has a standardized API interface to connect to MATLAB / Simulink to visualize algorithm execution results, which are presented in the form of curves, tables, and error analysis.

[0039] The algorithm verification module includes a SOH calculation algorithm, a sampling accuracy algorithm, and a fault level discrimination algorithm. The SOH calculation algorithm generates pseudo-labels based on battery model simulation using a second-order equivalent circuit, which are then input into a deep learning model. The sampling accuracy algorithm selects data points with stable current / voltage (variance < 0.1) and slow changes (absolute difference < 5), calculates the relative deviation ratio between the BMS current / voltage and the equipment, and takes the average of the 20th to 70th percentiles of data with a ratio ≤ 1, multiplied by 100%, as the consistency evaluation index. The fault level discrimination algorithm is obtained based on historical big data cluster analysis.

[0040] The data injection flow and calculation process are as follows: In the industrial control computer's algorithm verification module, select fault data injection, choose target data from preset fault data (such as SOH≤70%, capacity consistency deviation≥10%), and inject and transmit it to the BMS controller. Write the SOC / SOH algorithm (such as ampere-hour integration method + open-circuit voltage correction) in the Python editor; click "run algorithm," and the software compares the algorithm output with the hardware simulation data. The error threshold is ≤3%. If the error exceeds the limit, adjust the parameters to optimize the algorithm, such as the capacity attenuation coefficient.

[0041] The data links for each module are as follows: the BMS controller collects the simulation data from the hardware simulation module, transmits it to the 3D / VR simulation software module via the communication module, and the algorithm verification module runs a custom algorithm based on the injected data, outputs SOC / SOH / SOP results, and feeds them back to the dual displays.

[0042] The virtual-real linkage logic is as follows: the mobile fault setter sends a fault command, the battery simulator and BMS controller simulate the corresponding fault state, and the 3D / VR simulation software module synchronously presents the fault phenomena and data. After planning the process through virtual operation, the practical effect is verified on a hardware bench.

[0043] The training process includes: (1) Pre-processing: Powering on the equipment (resetting the emergency stop switch, turning on the industrial control computer, and starting the monitor), running the server and training software, and completing the VR equipment pairing; (2) Virtual training: conducting battery pack disassembly and assembly, high-voltage operation, and fault identification training through VR headsets or 3D software; (3) Hardware verification: performing real wiring, fault setting, and parameter measurement on the main body of the battery simulation bench, and comparing the results of virtual operation; (4) Algorithm iteration: injecting fault data, editing the Python algorithm, verifying the accuracy of the algorithm through hardware simulation data, and optimizing the parameters.

[0044] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A full-link virtual-real linkage battery simulation teaching system, characterized in that, The hardware simulation module, the 3D / VR simulation software module, the algorithm verification module and the fault simulation module are included. The hardware simulation module includes a battery simulation bench body, a battery simulator, a water cooling system, a VR interactive device and a BMS controller. The battery simulation bench body adopts a modular assembly structure, and the surface is insulated and provided with universal casters and adjustable legs. The voltage range of the battery simulator is 0V-6V, the accuracy is less than or equal to ±1mV, and active / passive balancing is supported. The water cooling system has a temperature control range of-40℃-150℃, and includes a water pump, a heating rod, a temperature sensor and a pressure sensor. The VR interactive device includes a VR headset, a handle, a double display, a matching software and a mobile fault setting device. The BMS controller is connected with the battery simulator, the software and the water cooling system through a communication module. The industrial computer is connected with the VR headset and the mobile fault setting device through a communication module. The 3D / VR simulation software module is developed based on a Unity engine and includes a 3D simulation module and a VR practical training module. The 3D simulation module is used for realizing 3D dynamic display of a battery pack / module / cell, supporting zooming, explosion, rotation and part disassembly operation. The VR practical training module is used for operation process simulation and realizes 360° dead angle-free observation through compatible VR equipment. The fault simulation module sends a fault signal through the mobile fault setting device, and is in real-time linkage with the hardware simulation module to trigger the battery simulator to output corresponding fault parameters. The algorithm verification module includes a fault data template and is used for fault data injection and operation display.

2. The full-link virtual-real linkage battery simulation teaching system according to claim 1, characterized in that: The data link of each module is that the BMS controller collects simulation data of the hardware simulation module, the simulation data is transmitted to the 3D / VR simulation software module through a communication module, the algorithm verification module runs a self-defined algorithm based on the injected data, and the output result is fed back to the double display. 3.The full-link virtual-real interactive battery simulation teaching system according to claim 1, characterized in that: The virtual-real linkage logic is that the mobile fault setting device sends a fault instruction, the battery simulator and the BMS controller simulate corresponding fault states, and the 3D / VR simulation software module synchronously presents fault phenomena and data.

4. The full-link virtual-real interactive battery simulation teaching system according to claim 1, characterized in that: The communication module includes a CAN 2.0 bus and a WiFi module; the BMS controller is connected with the battery simulator, the software and the water cooling system through the CAN 2.0 bus, and adopts shielded twisted pair transmission signals; and the industrial computer is connected with the VR headset and the mobile fault setting device through the WiFi module.

5. The full-link virtual-real interactive battery simulation teaching system according to claim 1, characterized in that: The algorithm verification module integrates a Python 3.9 running environment, supports PyTorch / TensorFlow frameworks, the fault data template is in CSV format, and the algorithm running result is visually presented in the form of a curve, a table and error analysis. The algorithm verification module also includes a middleware developed based on Node.js, which realizes protocol conversion of hardware data and software systems through a standardized API interface, and guarantees compatibility between modules. The algorithm verification module includes SOH calculation algorithms, sampling accuracy algorithms and grade discrimination algorithms. The SOH calculation algorithm is based on a second-order equivalent circuit to simulate a battery model, generate pseudo labels and then bring the pseudo labels into a deep learning model. The sampling accuracy algorithm calculates the relative deviation ratio of the BMS current / voltage and the device by screening data points with current / voltage variance <0.1 and change differential absolute value <5, and taking the average value of 20% to 70% quantile of the data with ratio ≤1 multiplied by 100% as the consistency evaluation index; The fault level discrimination algorithm is obtained based on historical big data clustering analysis.

6. The full-link virtual-real interactive battery simulation teaching system according to claim 1, characterized in that, The power supply link of the hardware simulation module is that the total power supply line of the battery simulation bench main body is connected to a 220VAC socket, and is branched to supply power to the industrial computer, the battery simulator and the water cooling system, and the power supply link is connected in series with an emergency stop switch.

7. The battery simulation teaching system of full-link virtual-real linkage according to claim 1, characterized in that: The types of the fault signals include SOH being too low, temperature being abnormal, voltage consistency being poor, thermal runaway, system insulation resistance being abnormal and single cell voltage deviation being out of standard.

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