Battery pack off-line test system and method

Abstract

The invention discloses a battery pack offline test system and method. The system comprises a control module; the air tightness test module is connected with the battery pack and the control module and is configured to perform air tightness detection of the battery pack; the automatic plugging module is connected with the control module and is configured to enable the battery pack located at the test station to be in butt joint with the high-voltage test plug, the low-voltage communication test plug and the airtightness test module; the offline test module is configured to execute an offline full-item test; and the control module is configured to perform an off-line full-item test through the off-line test module and perform air tightness detection of the battery pack through the air tightness test module while performing the off-line full-item test. Automatic butt joint of the battery pack and the plug is achieved through the automatic plugging module, testing automation is achieved, and testing efficiency is improved. On the same test station, off-line full-item test and airtightness detection of the battery pack are carried out at the same time, and the test efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of automotive power battery technology, and in particular to a battery pack off-line testing system and method. Background Technology

[0002] As a core power component of new energy vehicles, the power battery pack must undergo airtightness testing (to test sealing reliability) and end-of-line testing (EOL test) before leaving the factory. These tests are key steps to ensure product quality.

[0003] In the existing technology, the airtightness test and EOL test of battery packs are usually carried out in separate workstations, resulting in low testing efficiency. Summary of the Invention

[0004] This invention provides a battery pack offline testing system and method to solve the problem of low efficiency when performing airtightness testing and EOL testing on battery packs.

[0005] According to one aspect of the present invention, a battery pack off-line testing system is provided, comprising: Control module; An airtightness testing module, connected to both the battery pack and the control module, is configured to perform airtightness testing on the battery pack. An automatic plug-in / plug-out module, connected to the control module, is configured to connect the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module, respectively. The offline test module is connected to the high-voltage test plug, the low-voltage communication test plug, and the control module, and is configured to perform a full offline test. The control module is configured to perform full-item offline testing through the offline testing module, and simultaneously perform airtightness testing of the battery pack through the airtightness testing module during the full-item offline testing.

[0006] Optionally, the automatic plug-in / plug-out module includes: Mobile unit; At least one quick-connect holder is disposed on one side of the test station and is configured to hold the high-voltage test plug and the low-voltage communication test plug; The quick-change module is detachably connected at one end to the robotic arm of the mobile unit, and at the other end is detachably connected to the high-voltage test plug or the low-voltage communication test plug under the control of the control module. An image acquisition unit is fixed to one end of the robotic arm that connects the quick-change module to the mobile unit and is connected to the control module. It is configured to acquire first image information when the battery pack is docked with the high-voltage test plug, acquire second image information when the battery pack is docked with the low-voltage communication test plug, and acquire third image information when the battery pack is docked with the airtightness test module. The control module is configured to control the moving unit to move according to the first image information so that the battery pack docks with the high-voltage test plug, to control the moving unit to move according to the second image information so that the battery pack docks with the low-voltage communication test plug, and to control the moving unit to move according to the third image information so that the battery pack docks with the airtightness test module.

[0007] Optionally, the automatic plug-in / plug-out module further includes a balance hanger module corresponding to each of the quick-plug placement frames, which is installed on the crossbeam of the corresponding quick-plug placement frame. The balance hanger module includes multiple balance hangers, and the cantilever end of the balance hanger is used to pass through and support the wire harness connected to the high-voltage test plug or the wire harness connected to the low-voltage communication test plug.

[0008] Optionally, the offline testing module includes: a multimeter unit, a capacitor unit, a battery tester, a safety tester, an equipotential tester, and a collision simulation unit; The multimeter unit is connected to the battery pack and the control module respectively, and is configured to collect the total voltage of the battery pack; The capacitor unit is connected between the positive and negative terminals of the battery pack and is also connected to the control module. The control module is used to obtain the voltage across the capacitor unit when the battery pack is pre-charged. The battery tester is connected to both the battery pack and the control module, and is configured to detect the internal resistance of the battery pack. The safety tester is connected to the battery pack and the control module respectively, and is configured to detect the insulation resistance between the positive terminal of the battery pack and the battery pack casing, and the insulation resistance between the negative terminal of the battery pack and the battery pack casing. The equipotential tester is connected to the battery pack and the control module respectively, and is configured to detect the insulation resistance of the grounding terminal of the battery pack; The collision simulation unit is connected to the battery pack and the control module respectively, and is configured to send a collision signal to the battery pack so that the battery pack responds to the collision signal and sends a collision feedback signal back to the control module.

[0009] Optionally, the battery pack offline testing system further includes a scanning module; The scanning module is configured to scan the battery pack's identifier under the control of the control module to obtain the battery pack's basic information, and transmit the basic information to the control module; the basic information includes the battery pack's identification information.

[0010] Optionally, the battery pack includes multiple individual cells and a battery management system, and the offline testing module also includes a communication unit; The control module is connected to the battery management system through the communication unit. The control module is configured to acquire the voltage and temperature of each individual battery cell through the battery management system, and is also configured to determine the module voltage difference and the module temperature difference based on the voltage of each individual battery cell. The module voltage difference is the difference between the maximum and minimum voltage values ​​of each individual battery cell, and the module temperature difference is the difference between the maximum and minimum temperature values ​​of each individual battery cell.

[0011] According to another aspect of the present invention, a battery pack offline testing method is also provided, used to control the battery pack offline testing system described in the preceding aspect, and executed by a control module; comprising: The automatic plugging and unplugging module is controlled to connect the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug and the airtightness test module respectively. The offline testing module is controlled to perform all offline tests and acquire all offline test data. At the same time, the air tightness testing module is controlled to perform air tightness testing on the battery pack and acquire air tightness testing data. A test report is generated based on the offline test data and the airtightness test data.

[0012] Optionally, the battery pack offline testing system also includes an arrival detection module and a scanning module, wherein the arrival detection module is located at the testing station; Before the automatic insertion / removal module connects the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module respectively, the following steps are included: Upon receiving the arrival detection signal, the scanning module is controlled to scan the battery pack's identifier to obtain the battery pack's basic information; wherein, the arrival detection signal is a signal generated by the arrival detection module when it detects that the battery pack is located at the test station; the basic information includes the battery pack's identification information.

[0013] Optionally, the battery pack includes a battery management system and a communication unit. The control module is connected to the battery management system through the communication unit. The offline testing module includes a multimeter unit, a capacitor unit, a battery tester, a safety tester, an equipotential bonding tester, and a collision simulation unit. The multimeter unit is connected to both the battery pack and the control module. The capacitor unit is connected between the positive and negative terminals of the battery pack and is also connected to the control module. The battery tester is connected to both the battery pack and the control module. The safety tester is connected to both the battery pack and the control module. The equipotential bonding tester is connected to both the battery pack and the control module. The collision simulation unit is connected to both the battery pack and the control module. The controlled offline test module performs full offline testing, including: The battery pack total voltage, polarity, and short circuit tests are performed using a multimeter unit. The individual cell voltage, individual cell temperature, voltage difference, and temperature difference tests are performed using the battery management system. The insulation withstand voltage test, the equipotential test, the internal resistance test, the collision simulation unit, and the pre-charge test are performed using the capacitor unit. Each test is performed sequentially.

[0014] Optionally, the battery pack includes a battery management system; and further includes the following before the control offline test module performs the full offline test: Wake up the battery management system; Obtain the current output by the battery management system; After the battery management system is woken up based on the current output by the battery management system, the step of executing the offline test module to perform the offline full-item test is executed.

[0015] In this embodiment, an automatic plug-in / plug-out module replaces manual plugging and unplugging of wiring harnesses, enabling automatic docking of the battery pack with the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module, thus automating the testing process, reducing manpower requirements, and improving testing efficiency. Simultaneously, all post-production testing and airtightness checks of the battery pack are performed at the same testing station, further improving testing efficiency and shortening the testing cycle.

[0016] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of a battery pack offline testing system provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of an automatic plug-in / plug-out module provided in an embodiment of the present invention; Figure 3 This is a partial structural diagram of an automatic plug-in / plug-out module provided in an embodiment of the present invention; Figure 4 This is a partial structural diagram of another automatic plug-in / plug-out module provided in an embodiment of the present invention; Figure 5 This is a magnified view of a partial area of ​​an automatic plug-in / plug-out module provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of a high-voltage test plug provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of a low-voltage communication test plug provided in an embodiment of the present invention; Figure 8 This is a schematic diagram of another battery pack offline testing system provided in an embodiment of the present invention; Figure 9 A flowchart of a battery pack off-line testing method provided in an embodiment of the present invention; Figure 10 A flowchart of another battery pack offline testing method provided in an embodiment of the present invention. Detailed Implementation

[0019] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0020] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0021] Figure 1 This is a schematic diagram of a battery pack offline testing system provided in an embodiment of the present invention, with reference to... Figure 1 The system includes: Control module 10; The air tightness test module 12 is connected to the battery pack 1 and the control module 10 respectively, and is configured to perform air tightness testing on the battery pack 1. Automatic insertion and removal module 11 is connected to control module 10. Automatic insertion and removal module 11 is configured to connect the battery pack 1 located at the test station to high voltage test plug 2, low voltage communication test plug 3 and air tightness test module 12 respectively under the control of control module 10. The offline test module 13 is connected to the high voltage test plug 2, the low voltage communication test plug 3 and the control module 10 respectively, and is configured to perform offline full-item tests. The control module 10 is configured to perform full-item offline testing of the battery pack 1 through the offline testing module 13, and to perform airtightness testing of the battery pack through the airtightness testing module 12 while performing full-item offline testing.

[0022] The control module 10, which can be an industrial computer, serves as the control core. It connects to the automatic insertion / removal module 11, the airtightness testing module 12, and the offline testing module 13, respectively. It controls the testing process, processes the test data obtained after testing, and can further generate product reports based on the offline test data obtained from the full offline testing and the airtightness test data. The control module 10 also connects to the Manufacturing Execution System (MSE system) for interaction with the MES system, uploading product reports to the MES system.

[0023] The offline testing module 13 integrates multiple test units capable of performing total voltage and polarity tests, individual cell voltage tests, individual cell temperature tests, short circuit tests, insulation withstand voltage tests, temperature difference tests, voltage difference tests, equipotential tests, internal resistance tests, and hardware and software tests of the battery management system within the battery pack, in order to complete all offline testing items.

[0024] The battery pack includes a liquid cooling channel to regulate the temperature of the individual cells within the pack, primarily for cooling. Therefore, a leak detection module 12 is required to check for leaks in the liquid cooling channel. The leak detection module 12 is connected to the liquid cooling channel and can use conventional equipment. It inflates the liquid cooling channel of the battery pack 1 with gas and maintains the pressure for a preset time. The leak detection module determines whether the battery pack's airtightness is acceptable based on the pressure change. If the pressure change is less than a threshold value (e.g., 20 Pa), the battery pack's airtightness is considered acceptable; otherwise, it is considered unacceptable, indicating a leak in the liquid cooling channel.

[0025] The automatic insertion / removal module 11 may include at least a movable robotic arm, which enables the docking of the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12 with the battery pack 1. Specifically, the battery pack 1 includes a first interface, a second interface, and a third interface. The first interface is used to dock with the high-voltage test plug 2, the second interface is used to dock with the low-voltage communication test plug 3, and the third interface is used to connect to the airtightness test module 12. The third interface is the interface for the liquid cooling channels included in the battery pack. The control module 10 sequentially connects the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12 to the corresponding interfaces of the battery pack 1 via the automatic insertion / removal module 11. In this embodiment, after the battery pack 1 has been docked with the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12, the control module 10 performs airtightness testing via the airtightness test module 12 while simultaneously conducting full-item offline testing via the offline testing module 13, thereby improving work efficiency.

[0026] In other embodiments, under the control of the control module 10, the automatic insertion / removal module 11 connects the high-voltage test plug 2 and the low-voltage communication test plug 3 to the battery pack 1, enabling full-item offline testing. After all tests included in the full-item offline testing are completed, the control module 10 controls the automatic insertion / removal module 11 to grab the airtightness test module 12 and connect it to the third interface of the battery pack 1 for airtightness testing. The automatic insertion / removal module 11 achieves automatic docking of the high-voltage test plug, low-voltage communication test plug, and airtightness test module 12 with the battery pack 1, eliminating the need for manual operation. By replacing manual wiring harness insertion / removal, the testing station can operate unmanned, reducing the need for operators by more than 80%. Furthermore, airtightness testing, full-item offline testing, and docking of the battery pack 1 with the high-voltage test plug 2, low-voltage communication test plug 3, and airtightness test module 12 are all completed at the testing station, shortening the single-product testing cycle and improving efficiency by more than 50% compared to traditional solutions.

[0027] In this embodiment, an automatic plug-in / plug-out module replaces manual plugging and unplugging of wiring harnesses, enabling automatic docking of the battery pack with the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module, thus automating the testing process and reducing manpower requirements. Simultaneously, all post-production tests and airtightness checks of the battery pack are performed at the same testing station, improving testing efficiency and shortening the testing cycle.

[0028] Figure 2 This is a schematic diagram of an automatic plug-in / plug-out module provided in an embodiment of the present invention. Figure 3 This is a partial structural diagram of an automatic plug-in / plug-out module provided in an embodiment of the present invention. Figure 4 This is a partial structural diagram of another automatic plug-in / plug-out module provided in an embodiment of the present invention. Figure 5 This is a magnified view of a partial area of ​​an automatic plug-in / plug-out module provided in an embodiment of the present invention, wherein... Figure 5 To Figure 3 Enlarged view of region 4 in the first section. Figure 6 This is a schematic diagram of the structure of a high-voltage test plug provided in an embodiment of the present invention. Figure 7 This is a schematic diagram of a low-voltage communication test plug provided in an embodiment of the present invention, with reference to... Figures 1-7 Optional, automatic plug-in / plug-out modules include: Mobile unit 111; At least one quick-connect holder 112 is provided on one side of the test station and is configured to hold the high-voltage test plug 2 and the low-voltage communication test plug 3; the quick-connect holder 112 can also be used to hold the airtightness test module 12.

[0029] The quick-change module 113 has one end detachably connected to the robotic arm of the mobile unit 111, and the other end detachably connected to the high-voltage test plug 2 or the low-voltage communication test plug 3 under the control of the control module 10. The quick-change module 113 supports automatic switching of the high-voltage test plug 2 and the low-voltage communication test plug 3.

[0030] The balance hanger module, which corresponds one-to-one with the quick-connect placement rack 112, is installed on the crossbeam of the quick-connect placement rack 112. The balance hanger module includes multiple balance hangers 114. The cantilever end of the balance hanger 114 is used to pass through and support the wire harness connected to the high-voltage test plug 2 or the wire harness connected to the low-voltage communication test plug 3. Image acquisition unit 115 is fixed to one end of the robotic arm of quick-change module 113 connected to moving unit 111. Image acquisition unit 115 is connected to control module 10 and is configured to acquire first image information when battery pack 1 docks with high voltage test plug 2, second image information when battery pack 1 docks with low voltage communication test plug 3, and third image information when battery pack 1 docks with airtightness test module 12. The control module 10 is configured to control the movement of the mobile unit 10 according to the first image information so that the battery pack 1 docks with the high voltage test plug 2, control the movement of the mobile unit 111 according to the second image information so that the battery pack 1 docks with the low voltage communication test plug 3, and control the movement of the mobile unit 111 according to the third image information so that the battery pack 1 docks with the airtightness test module 12.

[0031] Optionally, the automatic insertion / removal module also includes a ground rail 116 for providing a track for the movement of the mobile unit 111. The mobile unit 111 can be a six-axis robot, which includes a robotic arm and a base. The base is used to move along the ground rail, and the robotic arm is connected to the base. The end of the robotic arm is detachably connected to one end of the quick-change module 113. After the quick-change module 113 is connected to the robotic arm, the other end of the quick-change module 113 is used to connect sequentially to the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12, so that the battery pack 1 can be docked sequentially with the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12 through the movement of the robotic arm.

[0032] In one optional embodiment, the battery pack offline testing system includes a testing station with one quick-connect rack 112 corresponding to the testing station, or two quick-connect racks 112 corresponding to the testing station. The testing station is located on one side of the ground rail, and the placement direction of the quick-connect racks 112 is perpendicular to the extension direction of the ground rail. When two quick-connect racks 112 are set for one testing station, the two quick-connect racks 112 are positioned opposite each other on both sides of the testing station. The quick-connect racks 112 and the battery pack 1 are arranged sequentially along the extension direction of the ground rail 116. Each battery pack 1 includes a first interface 101 and a second interface 102 located on opposite sides of the battery pack 1, with the first interface 101 facing the nearest quick-connect rack 112 and the second interface 102 facing the nearest quick-connect rack 112. Alternatively, as... Figure 2 As shown, the battery pack off-line testing system includes multiple testing stations, each with two oppositely positioned quick-connect racks 112. The multiple testing stations are arranged sequentially along the extension direction of the ground rail. The moving unit 112 moves along the ground rail to sequentially perform all off-line tests and airtightness checks on the battery packs at each testing station. Optionally, a quick-connect rack 112 can hold multiple different types of high-voltage test plugs 2 and low-voltage communication test plugs 3 to match different models of power batteries, improving the compatibility of the off-line testing system. The quick-change module 113 and the quick-connect rack 112 adapt to the testing requirements of different battery pack models, supporting rapid model changeover on the production line.

[0033] Each quick-connect mounting bracket 112 has multiple balance hangers 114 on its top crossbeam. Each balance hanger 114 can correspond to one high-voltage test plug 2 or one low-voltage communication test plug 3, so that the wiring harness of each high-voltage test plug 2 is suspended by a balance hanger 114 to reduce the load on the high-voltage test plug 2, and the wiring harness of each low-voltage communication test plug 3 is suspended by a balance hanger 114 to reduce the load on the low-voltage communication test plug 3.

[0034] The image acquisition unit 115 can be a 3D camera to acquire image information in real time during the docking process of the battery pack 1 with the high voltage test plug 2, the low voltage communication test plug 3 and the airtightness test module 12, so that the moving unit 111 can achieve precise docking of the battery pack with each component through the movement of its own base or its own robotic arm, ensuring docking accuracy.

[0035] Among them, the quick-swap module 113 connects the airtightness test module 12 to the battery pack 1 through the airtight quick-swap tooling.

[0036] Figure 8 This is a schematic diagram of another battery pack offline testing system provided in an embodiment of the present invention, with reference to... Figure 8Optionally, the offline test module 13 includes: a multimeter unit 131, a capacitor unit 132, a battery tester 133, a safety tester 134, an equipotential tester 135, and a collision simulation unit 136. Multimeter unit 131 is connected to both battery pack 1 and control module 10, and is configured to collect the total voltage of battery pack 1. Multimeter unit 131 has electrical isolation and channel expansion functions. The multimeter unit includes a positive detection terminal and a negative detection terminal. The positive detection terminal is connected to the positive terminal of battery pack 1, and the negative detection terminal is connected to the negative terminal of battery pack 1, thereby detecting the total voltage of battery pack 1 and determining whether the total voltage of battery pack 1 meets specifications. Control module 10 determines whether the polarity of battery pack 1 is normal based on the total voltage of battery pack 1. If the total voltage of battery pack 1 is positive, the polarity is normal; if the total voltage of battery pack 1 is negative, the polarity of battery pack 1 is reversed; if the total voltage of battery pack 1 is 0, the relay inside battery pack 1 cannot engage properly, and battery pack 1 cannot output voltage normally.

[0037] Capacitor unit 132 is connected between the positive and negative terminals of battery pack 1 and is also connected to control module 10. Control module 10 is used to obtain the voltage across capacitor unit 132 during pre-charging of battery pack 1. Capacitor unit 132 includes a capacitor, such as 500NF, connected between the positive and negative terminals of battery pack 1 to detect whether the pre-charging circuit is normal. Control module 10 controls the battery pack to output a pre-charging voltage and conduct the pre-charging circuit through the battery management system of battery pack 1. At this time, the voltage across the capacitor returned is the pre-charging voltage output by battery pack 1. The pre-charging function is detected based on the voltage across capacitor unit 132.

[0038] The battery tester 133 is connected to the battery pack 1 and the control module 10 respectively, and is configured to detect the internal resistance of the battery pack 1.

[0039] The safety tester 134 is connected to both the battery pack 1 and the control module 10, and is configured to detect the insulation resistance between the positive terminal and the battery pack casing of the battery pack 1, and the insulation resistance between the negative terminal and the battery pack casing. The battery pack 1 includes a casing and multiple individual cells disposed within the casing. The safety tester 134 detects the insulation resistance of the battery pack 1, that is, the insulation resistance between the positive terminal and the casing of the battery pack 1, and the insulation resistance between the negative terminal and the casing of the battery pack 1. If the impedance is greater than the impedance threshold and close to infinity, it proves that the insulation resistance of the battery pack 1 meets the requirements.

[0040] The equipotential bonding tester 135 is connected to both the battery pack 1 and the control module 10, and is configured to detect the insulation resistance of the grounding terminal of the battery pack 1. The equipotential bonding tester 135, also known as a grounding tester, is used to measure the resistance between a first point and a second point on the battery pack 1 casing. The first point is the grounding terminal, and the second point is the point on the casing furthest from the first point. If the resistance between the first and second points is less than a set resistance value, such as less than 0.1 ohms, then the battery pack 1 is confirmed to have normal grounding conductivity.

[0041] The collision simulation unit 136 is connected to both the battery pack 1 and the control module 10. It is configured to send a collision signal to the battery pack 1, causing the battery pack 1 to respond to the collision signal and send a collision feedback signal back to the control module 10. The collision simulation unit 136 provides a collision signal simulating a collision occurring in the battery pack. The collision signal can be a square wave signal. After responding to the collision signal, the battery management system in the battery pack takes a series of measures to deal with the collision and sends back a feedback signal generated in response to the collision signal. Upon receiving the feedback signal, the control module 10 determines that the battery pack 1 can respond normally to the occurrence of a collision and meets the specifications.

[0042] Among them, the multimeter unit 131, capacitor unit 132, battery tester 133, safety tester 134, and equipotential tester 135 are all connected to the high voltage test plug, and the collision simulation unit 136 is connected to the low voltage communication test plug.

[0043] Continue to refer to Figure 8 Optionally, the battery pack offline testing system also includes a scanning module 14; The scanning module 14 is configured to scan the identifier of the battery pack 1 under the control of the control module 10 to obtain the basic information of the battery pack 1, and transmit the basic information to the control module 10; the basic information includes the identification information of the battery pack 1, that is, the ID of the battery pack.

[0044] The scanning module 14 can be a barcode scanner, and the identification of battery pack 1 can be a barcode, QR code, or RFID tag set on battery pack 1. After obtaining the identification information of battery pack 1 at the testing station through the scanning module 14, subsequent tests are performed to bind the offline test data and airtightness test data obtained from the full-item offline test to the ID of battery pack 1. With the test data bound to the ID of battery pack, the control module 10 uploads the offline test data and airtightness test data to the MES system in real time, realizing full-process quality traceability and facilitating problem troubleshooting.

[0045] Continue to refer to Figure 8 Optionally, the battery pack includes multiple individual cells and a battery management system, and the offline test module 13 also includes a communication unit 137; The control module 10 is connected to the battery management system via the communication unit 137. The control module 10 is configured to acquire the voltage and temperature of each individual cell through the battery management system, and is also configured to determine the module voltage difference based on the voltage of each individual cell and the module temperature difference based on the temperature of each individual cell. The module voltage difference is the difference between the maximum and minimum voltage values ​​of each individual cell, and the module temperature difference is the difference between the maximum and minimum temperature values ​​of each individual cell. The communication unit 137 can be a CAN communication unit, used to realize information exchange between the battery management system and the control module 10. The communication unit 137 is connected to the battery management system in the battery pack 1 through a low-voltage communication test plug. After obtaining the voltage and temperature of each individual cell through the battery management system, the control module 10 determines whether the voltage and temperature of each individual cell meet the specifications, and determines whether the voltage of each individual cell in the battery pack is balanced based on the difference between the maximum and minimum voltage values ​​of all individual cells, and determines whether the temperature of each individual cell in the battery pack is balanced based on the difference between the maximum and minimum temperature values ​​of all individual cells.

[0046] Optionally, the battery pack offline testing system also includes an arrival detection module set at the testing station. The arrival detection module is connected to the control module. The arrival detection module can be an infrared sensor or other sensor used to detect whether the battery pack has arrived at the testing station. When the arrival of the battery pack is detected, an arrival detection signal is generated. After receiving the arrival detection signal, the control module 10 controls the scanning module 14 to scan the identification of the battery pack 1 to obtain the identification information of the battery pack 1. After obtaining the identification information of the battery pack, the control module 11 controls the automatic plugging and unplugging module 11 to connect the high-voltage test plug, the low-voltage communication test plug and the airtightness test module 12 to the battery pack respectively to perform full-item offline testing and airtightness testing.

[0047] Optionally, the battery pack offline testing system also includes a power module, which is connected to both the battery pack and the control module. The power module can be a UPS (Uninterruptible Power Supply) used to power the battery management system and wake it up. The power module is also used for auxiliary performance testing of the battery pack.

[0048] This invention also provides a battery pack offline testing method, used to control the battery pack offline testing system in any of the above embodiments, and executed by the control module in the battery pack offline testing system. Figure 9 A flowchart of a battery pack off-line testing method provided in an embodiment of the present invention is shown below. Figure 1 and Figure 9 The method includes: S110: Controls the automatic plug-in / plug-out module to connect the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module, respectively.

[0049] The automatic plug-in / plug-out module 11 sequentially grabs the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12 to sequentially connect the high-voltage test plug 2, the low-voltage communication test plug 3, and the airtightness test module 12 to the corresponding interfaces of the battery pack 1.

[0050] S120: Controls the offline testing module to perform all offline tests and acquire all offline test data, while controlling the airtightness testing module to perform airtightness testing on the battery pack and acquire airtightness testing data.

[0051] The control module 10 controls the offline testing module 13 to execute the full offline test, which includes multiple tests that can be performed sequentially. Simultaneously with the offline testing module 13 executing the full offline test, the control module 12 performs airtightness testing, enabling parallel testing, shortening the testing cycle, and improving testing efficiency.

[0052] S130: Generate a test report based on the offline test data and airtightness test data.

[0053] Control module 10 summarizes all test data, generates a test report containing product ID, test results, and environmental parameters, uploads it to the MES system in real time, and simultaneously feeds back the test status to the PLC on the production line.

[0054] In this embodiment, an automatic plug-in / plug-out module replaces manual plugging and unplugging of wiring harnesses, enabling automatic docking of the battery pack with the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module, thus automating the testing process and reducing manpower requirements. Simultaneously, all post-production tests and airtightness checks of the battery pack are performed at the same testing station, improving testing efficiency and shortening the testing cycle.

[0055] Figure 10 A flowchart of another battery pack off-line testing method provided in an embodiment of the present invention is shown below. Figures 2-10 The battery pack off-line testing system also includes an arrival detection module and a scanning module. The arrival detection module is located at the testing station, and the method includes: S111: Upon receiving the arrival detection signal, the control scanning module scans the battery pack's identifier to obtain its basic information. The arrival detection signal is generated by the arrival detection module when it detects that the battery pack is located at the test station; the basic information includes the battery pack's identification information.

[0056] After the battery pack is delivered to the test station, the arrival detection module sends an arrival detection signal to the control module 10. The scanning module 14 scans the identifier of the battery pack 1, starts the test process, and binds the ID of the battery pack.

[0057] S121: Control the automatic plug-in / plug module to connect the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module respectively.

[0058] The control module 10 controls the movement of the mobile unit 111, the image acquisition unit 115 positions the first interface, the second interface and the third interface of the battery pack, the mobile unit 111 takes the corresponding plug from the quick-connect placement rack 112 through the quick-change module 113, and completes the automatic docking of the high voltage test plug, the low voltage communication test plug and the airtightness test module in sequence, and fixes the wiring harness through the balance crane 114.

[0059] S131: The battery pack's total voltage, polarity, and short-circuit tests are performed using a multimeter unit; individual cell voltage, temperature, differential voltage, and temperature difference tests are performed using the battery management system; insulation withstand voltage, equipotential bonding, and internal resistance tests are performed using a safety tester; collision tests are performed using an equipotential bonding tester; pre-charge tests are performed using a battery tester; and all offline test data are acquired. These tests are conducted sequentially. During any test in the offline full-item testing, an airtightness test module is simultaneously used to perform airtightness checks and acquire the airtightness test data.

[0060] Control module 10 controls offline testing module 13 to perform a series of tests according to a preset process. For example, the tests are performed sequentially as follows: battery pack short circuit test (checking whether each high-voltage port and casing is energized to eliminate potential safety hazards), insulation withstand voltage test (insulation resistance and withstand voltage testing to ensure product safety), equipotential test (ensuring normal grounding of the battery pack and guaranteeing battery pack grounding safety), internal resistance test (also known as ACIR test, high-precision acquisition of battery pack internal resistance and comparison with process requirements), battery management system software version test (testing the BMS system software version via low-voltage communication), and battery management system hardware version test. Tests include: (BMS system hardware testing via low-voltage communication), total battery pack voltage and polarity testing (collecting total battery pack voltage using a multimeter unit to perform polarity testing and determine if the plug and battery pack are properly connected), individual cell voltage testing (collecting the voltage of individual cells in the battery pack via the communication unit), individual cell temperature testing (collecting the temperature of individual cells in the battery pack via the communication unit), differential voltage testing (collecting the voltage of each individual cell via the communication unit to calculate the module differential voltage), temperature difference testing (collecting the temperature of each individual cell via the communication unit to calculate the module temperature difference), impact testing, and pre-charge testing.

[0061] S141: Generate a test report based on the offline test data and airtightness test data.

[0062] Optionally, following S141, the following may also be included: The automatic plug-in / plug-out module disconnects the high-voltage test plug, low-voltage communication test plug, and airtightness test module connected to the battery pack and places them on the quick-connect rack. The battery pack leaves the test station, and the PLC on the production line receives the station's idle signal and transfers the battery pack to the next process, completing the test loop.

[0063] Optionally, before the offline testing module executes the full offline project testing, the following may also be included: Wake up the battery management system; Obtain the current output by the battery management system; After the battery management system is woken up based on the current output by the battery management system, the step of executing the offline test module to perform the offline full-item test is executed.

[0064] Before conducting the full-scale offline testing, the battery management system (BMS) needs to be woken up to obtain parameters such as voltage and temperature of individual cells, enabling the completion of certain tests within the full-scale offline testing program. After sending a wake-up signal to the BMS, the system is controlled to wake up, and the output current of the BMS is acquired. The system's wake-up status is determined based on the current or the power calculated from the current. If the system is woken up, the full-scale offline testing is executed.

[0065] In one specific implementation, the control module uses an Advantech IPC-610L with a main frequency ≥3.0GHz and memory ≥16GB; the six-axis robot uses a KUKA KR C4 with a repeatability of ±0.02mm; the image acquisition unit uses a Cognex In-Sight 3D with a positioning accuracy of ±0.05mm; the quick-change module uses a SCHUNK MPG-plus with a switching time ≤2s; the airtightness testing module has a test pressure range of 0-20KPa and a detection accuracy of 0.05%FS; the multimeter unit uses a Keithley DMM 7510; the safety testing instrument uses a Chroma 19073; and the battery tester uses a HIOKI 3563A. The control module communicates with the battery management system via CAN, with the MES system via the OPC UA protocol, and with the PLC on the production line via the Profinet protocol. The offline testing system is also equipped with a temperature and humidity sensor, using the TS-01, with a measurement range of -40~125℃ and a humidity accuracy of ±1%RH. The test subject is a certain type of power battery pack (voltage range 300-400V, number of individual cells 100 in series). The test environment is: normal temperature environment on the production line (20-25℃) and humidity 40%-60%.

[0066] Test steps: After the battery pack arrives at the testing station, the arrival detection module sends an arrival detection signal, and the scanning module scans the battery pack's identifier to obtain the battery pack's basic information. The mobile unit performs visual positioning through the image acquisition unit and completes the automatic docking of the high-voltage test plug and the low-voltage communication test plug within 15 seconds. The full-item test was performed according to the preset procedure, which took 180 seconds. All electrical performance indicators met the process requirements. The quick-change module is switched to the air tightness test module. The inflation time is 60 seconds, the inflation pressure is 3 kPa, the pressure holding time is 30 seconds, the test time is 30 seconds, the leakage is 15 Pa, and the battery pack is deemed to be airtight. The test report is generated and uploaded to the MES system. The mobile unit disconnects the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module. The total test time is 320 seconds.

[0067] The entire single-item testing time is reduced by 53% compared to the traditional manual method (680 seconds). Test data is accurately bound to the product ID, eliminating errors caused by misoperation. Furthermore, by changing four different specifications of power battery packs (transferring 80-120 strings of individual batteries, with plug position differences ≤100mm), automatic docking and accurate testing are achieved by adjusting the position of the quick-connect placement rack and the test software parameter configuration. The test consistency accuracy is ≤±0.3%, and the changeover adjustment time is ≤5 minutes, meeting the multi-model compatibility requirements of the production line.

[0068] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0069] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A battery pack off-line testing system, characterized in that, include: Control module; An airtightness testing module, connected to both the battery pack and the control module, is configured to perform airtightness testing on the battery pack. An automatic plug-in / plug-out module, connected to the control module, is configured to connect the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module, respectively. The offline test module is connected to the high-voltage test plug, the low-voltage communication test plug, and the control module, and is configured to perform a full offline test. The control module is configured to perform full-item offline testing through the offline testing module, and simultaneously perform airtightness testing of the battery pack through the airtightness testing module during the full-item offline testing.

2. The battery pack offline testing system according to claim 1, characterized in that, The automatic plug-in / plug-out module includes: Mobile unit; At least one quick-connect holder is disposed on one side of the test station and is configured to hold the high-voltage test plug and the low-voltage communication test plug; The quick-change module is detachably connected at one end to the robotic arm of the mobile unit, and at the other end is detachably connected to the high-voltage test plug or the low-voltage communication test plug under the control of the control module. An image acquisition unit is fixed to one end of the robotic arm that connects the quick-change module to the mobile unit and is connected to the control module. It is configured to acquire first image information when the battery pack is docked with the high-voltage test plug, acquire second image information when the battery pack is docked with the low-voltage communication test plug, and acquire third image information when the battery pack is docked with the airtightness test module. The control module is configured to control the moving unit to move according to the first image information so that the battery pack docks with the high-voltage test plug, to control the moving unit to move according to the second image information so that the battery pack docks with the low-voltage communication test plug, and to control the moving unit to move according to the third image information so that the battery pack docks with the airtightness test module.

3. The battery pack offline testing system according to claim 2, characterized in that, The automatic plug-in / plug-out module also includes a balance hanger module corresponding to each of the quick-plug placement frames, which is installed on the crossbeam of the corresponding quick-plug placement frame. The balance hanger module includes multiple balance hangers, and the cantilever end of the balance hanger is used to pass through and support the wire harness connected to the high-voltage test plug or the wire harness connected to the low-voltage communication test plug.

4. The battery pack offline testing system according to claim 1, characterized in that, The offline testing module includes: a multimeter unit, a capacitor unit, a battery tester, a safety tester, an equipotential tester, and a collision simulation unit; The multimeter unit is connected to the battery pack and the control module respectively, and is configured to collect the total voltage of the battery pack; The capacitor unit is connected between the positive and negative terminals of the battery pack and is also connected to the control module. The control module is used to obtain the voltage across the capacitor unit when the battery pack is pre-charged. The battery tester is connected to both the battery pack and the control module, and is configured to detect the internal resistance of the battery pack. The safety tester is connected to the battery pack and the control module respectively, and is configured to detect the insulation resistance between the positive terminal of the battery pack and the battery pack casing, and the insulation resistance between the negative terminal of the battery pack and the battery pack casing. The equipotential tester is connected to the battery pack and the control module respectively, and is configured to detect the insulation resistance of the grounding terminal of the battery pack; The collision simulation unit is connected to the battery pack and the control module respectively, and is configured to send a collision signal to the battery pack so that the battery pack responds to the collision signal and sends a collision feedback signal back to the control module.

5. The battery pack offline testing system according to claim 1, characterized in that, It also includes a scanning module; The scanning module is configured to scan the battery pack's identifier under the control of the control module to obtain the battery pack's basic information, and transmit the basic information to the control module; the basic information includes the battery pack's identification information.

6. The battery pack offline testing system according to claim 1, characterized in that, The battery pack includes multiple individual cells and a battery management system, and the offline testing module also includes a communication unit. The control module is connected to the battery management system through the communication unit. The control module is configured to acquire the voltage and temperature of each individual battery cell through the battery management system, and is also configured to determine the module voltage difference and the module temperature difference based on the voltage of each individual battery cell. The module voltage difference is the difference between the maximum and minimum voltage values ​​of each individual battery cell, and the module temperature difference is the difference between the maximum and minimum temperature values ​​of each individual battery cell.

7. A method for testing a battery pack after it is removed from the production line, characterized in that, For controlling the battery pack offline testing system according to any one of claims 1-6, and executed by the control module; comprising: The automatic plugging and unplugging module is controlled to connect the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug and the airtightness test module respectively. The offline testing module is controlled to perform all offline tests and acquire all offline test data. At the same time, the airtightness testing module is controlled to perform airtightness testing on the battery pack and acquire airtightness testing data. A test report is generated based on the offline test data and the airtightness test data.

8. The battery pack offline testing method according to claim 7, characterized in that, The battery pack off-line testing system also includes an arrival detection module and a scanning module, wherein the arrival detection module is located at the testing station; Before the automatic insertion / removal module connects the battery pack located at the test station to the high-voltage test plug, the low-voltage communication test plug, and the airtightness test module respectively, the following steps are included: Upon receiving the arrival detection signal, the scanning module is controlled to scan the battery pack's identifier to obtain the battery pack's basic information; wherein, the arrival detection signal is a signal generated by the arrival detection module when it detects that the battery pack is located at the test station; the basic information includes the battery pack's identification information.

9. The battery pack offline testing method according to claim 7, characterized in that, The battery pack includes a battery management system and a communication unit. The control module is connected to the battery management system through the communication unit. The offline testing module includes a multimeter unit, a capacitor unit, a battery tester, a safety tester, an equipotential bonding tester, and a collision simulation unit. The multimeter unit is connected to both the battery pack and the control module. The capacitor unit is connected between the positive and negative terminals of the battery pack and is also connected to the control module. The battery tester is connected to both the battery pack and the control module. The safety tester is connected to both the battery pack and the control module. The equipotential bonding tester is connected to both the battery pack and the control module. The collision simulation unit is connected to both the battery pack and the control module. The controlled offline test module performs full offline testing, including: The battery pack total voltage, polarity, and short circuit tests are performed using a multimeter unit. The individual cell voltage, individual cell temperature, voltage difference, and temperature difference tests are performed using the battery management system. The insulation withstand voltage test, the equipotential test, the internal resistance test, the collision simulation unit, and the pre-charge test are performed using the capacitor unit. Each test is performed sequentially.

10. The battery pack offline testing method according to claim 7, characterized in that, The battery pack includes a battery management system; and before the control offline test module performs the full offline test, it also includes: Wake up the battery management system; Obtain the current output by the battery management system; After the battery management system is woken up based on the current output by the battery management system, the step of executing the offline test module to perform the offline full-item test is executed.

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