Integrated testing system and method for batteries

Abstract

This invention provides an integrated testing system and method for batteries, belonging to the field of new energy battery testing technology. The system includes a controllable atmosphere chamber, a thermal environment control system, an external control unit, and a discharge testing system. The controllable atmosphere chamber provides an inert gas protective environment to prevent high-temperature oxidation of battery materials. The thermal environment control system employs a liftable heating plate structure to achieve precise control of high temperature and pressure, and supports in-situ battery replacement while maintaining a constant temperature. The discharge testing system connects to the battery via sealed cables, performing high-precision discharge testing and real-time acquisition of electrical performance data. The external control unit centrally manages the atmosphere, temperature, pressure, and discharge parameters. This invention integrates inert atmosphere protection, precise thermal environment simulation, and real-time electrical testing, solving the problems of poor coordination and low testing efficiency in existing technologies, and significantly improving the safety, stability, and data reliability of high-temperature battery testing.

Description

Technical Field

[0001] This invention relates to the field of new energy battery testing technology, and more specifically, to an integrated testing system and method for batteries. Background Technology

[0002] With the increasing demands for high-temperature adaptability of energy components in new energy storage, aerospace, and special equipment fields, single-cell batteries such as thermal batteries and high-temperature solid fuel cells have become core energy carriers in these fields due to their excellent high-temperature discharge stability. Key indicators of these batteries, such as material compatibility, interfacial reaction characteristics, and thermo-pressure-discharge synergistic performance, all require precise testing in high-temperature environments simulating actual operating conditions. Therefore, an integrated system capable of simultaneously achieving inert gas protection, precise thermo-pressure control, and real-time discharge testing is crucial for their research, optimization, and performance evaluation. However, current single-cell battery testing technologies still face bottlenecks. Existing solutions primarily focus on "single-function optimization," lacking a synergistic design encompassing "inert atmosphere – thermo-pressure environment – ​​electrical performance testing," thus failing to meet comprehensive testing requirements.

[0003] In the existing field of new energy battery testing technology, a lithium battery heating test device is disclosed in Chinese patent document CN212586281U. Although it constructs a basic high-temperature environment through ceramic heating plates and monitors the pressure state through pressure sensors, it does not set up a controllable atmosphere chamber. At high temperatures, air can easily enter the test chamber, causing oxidation of the battery's positive electrode material and molten electrolyte. Furthermore, it does not integrate a precise discharge test module and can only detect temperature and pressure data. It cannot simultaneously evaluate the battery's voltage, current, and other electrical performance at high temperatures, and is completely unsuitable for the comprehensive testing needs of high-temperature single-cell batteries.

[0004] A Chinese patent document with publication number CN111354955A discloses a thermal battery single cell testing device. Although high-purity argon gas is introduced into the glove box to create an inert protective atmosphere, solving the problem of material oxidation, the constant temperature system and constant pressure system are set up separately and independently. Moreover, the inert gas is only used for atmosphere replacement in the initial stage of sample assembly and testing, and does not participate in the thermo-pressure-discharge coordinated stability maintenance throughout the entire test process, which cannot guarantee the continuity of battery performance testing at high temperatures.

[0005] Chinese patent document CN118938039A discloses an integrated high-temperature solid fuel cell testing system, which has the basic capability of high-temperature hot-state electrical performance testing. However, its nitrogen-related functions are mainly used for cold-state airtightness testing or cooling protection under fault conditions, and do not extend to the maintenance of inert atmosphere throughout the testing process. In addition, it lacks a flexible thermo-pressure adjustment structure for the testing needs of single cells, and is more suitable for battery samples with fixed specifications. It has certain limitations in meeting the material screening and performance evaluation needs of high-temperature single cells of different thicknesses, and the flexibility of the testing scenario needs to be further improved. Summary of the Invention

[0006] In view of the deficiencies in the prior art, the purpose of this invention is to provide an integrated testing system and method for batteries.

[0007] An integrated testing system for batteries provided by the present invention includes: a controllable atmosphere chamber, a thermal environment control system, an external control unit, and a discharge testing system; The controllable atmosphere chamber is a closed chamber structure used to provide an inert atmosphere environment. The controllable atmosphere chamber is provided with an inert gas inlet, an exhaust outlet, and a sealed lead-out for electrical signals to pass through. The thermal environment control system is located inside the controllable atmosphere cavity and includes a heating component and a transmission control unit for driving the heating component to close and open, for applying target temperature and pressure to the individual cells placed thereon. The external control unit is located outside the controllable atmosphere chamber and is electrically connected to the thermal environment control system through the sealed lead-out component. It is used to set and control the temperature and pressure parameters of the thermal environment control system. The discharge test system is electrically connected to the individual battery via a test cable, and is used to discharge the individual battery and collect its electrical performance data. The test cable enters the controllable atmosphere cavity through the sealed lead-out part to maintain the airtightness of the cavity.

[0008] Preferably, the controllable atmosphere chamber is further equipped with an oxygen content detection module and an atmosphere flow control unit. The chamber is equipped with a safety interlock device, which can automatically cut off the power supply of the thermal environment control system when the air pressure or oxygen content in the chamber is abnormal.

[0009] Preferably, the heating component of the thermal environment control system includes an upper heating plate and a lower heating plate that can move relative to each other, and the transmission control unit is a servo electric cylinder used to drive the upper heating plate to lift and lower to apply pressure to the individual battery cells placed on the lower heating plate.

[0010] Preferably, the upper heating plate and the lower heating plate are installed via a detachable structure; when the upper heating plate and the lower heating plate are closed, an operating gap is formed between them for replacing individual batteries.

[0011] Preferably, the discharge test system includes an electronic load, a current and voltage acquisition module, and control software; The electronic load supports constant current, constant power, and constant resistance discharge modes. The current and voltage acquisition module has multiple ranges of current and voltage acquisition channels; The control software is used to set discharge parameters and display and record voltage and current waveform data in real time.

[0012] Preferably, the input voltage range of the electronic load is 0–120V, the input current range is 0–30A, and the accuracy of the constant current discharge mode is better than ±0.05%+0.05%FS.

[0013] Preferably, the sampling accuracy of the current and voltage acquisition module is 16 bits, the sampling frequency is adjustable in the range of 1Hz to 10KHz, and it supports multi-channel synchronous acquisition and remote voltage compensation functions.

[0014] Preferably, the single cell has a disc-shaped or columnar structure, with current collecting surfaces on the upper and lower surfaces and clampable terminal areas on the edges.

[0015] Preferably, one end of the test cable is connected to the discharge test system via an aviation connector, and the other end is provided with an alligator clip for clamping the terminal area of ​​the individual battery cell.

[0016] An integrated testing method for batteries according to the present invention includes the following steps: An inert gas is introduced into the controllable atmosphere chamber and pressure is maintained. The target temperature and pressure parameters of the thermal environment control system are set by the external control unit, and heating is started. After the temperature stabilizes, with the thermal environment control system in a heat preservation state, place the individual battery on the heating component and connect it to the test cable of the discharge test system. The thermal environment control system applies pressure to the individual battery cells, and simultaneously starts the discharge test system to perform discharge tests on the individual battery cells, while simultaneously collecting electrical performance data. After a single test is completed, the individual cell is replaced and the test is repeated while maintaining a constant temperature and inert atmosphere.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention constructs an integrated system of "full-process inert atmosphere + precise thermal field + real-time electrical testing". Through sealed lead-out components, it realizes the interconnection of signals of multiple modules, and synchronously records temperature, pressure, voltage and current data, avoiding errors caused by insufficient module coordination and ensuring the repeatability of test data.

[0018] 2. The thermal environment control system of this invention is designed to support standardized and rapid replacement of heating couplers and in-situ replacement of high-temperature single cells, eliminating the need for traditional cooling and inert gas secondary replacement processes and shortening the cycle.

[0019] 3. The discharge testing system of this invention supports constant current / constant power / constant resistance modes, with current acquisition accuracy of ±0.1A±0.3%FS (0–5A range), voltage accuracy of ±0.01V, and sampling frequency adjustable from 1Hz to 10KHz, adapting to different discharge rates from 0–20A. It also features remote compensation, multi-channel synchronous acquisition, and data export functions, satisfying both the fine-grained testing for material screening and the batch battery performance verification.

[0020] 4. This invention integrates four safety mechanisms: power-off when oxygen content exceeds the standard, interlock for abnormal pressure, protective light curtain (stops heating / lifting when blocked), and leakage protection. At the same time, it eliminates the need to frequently switch the device operation interface, reducing human error and making it suitable for laboratory research and industrial measurement scenarios.

[0021] 5. The present invention integrates the controllable atmosphere chamber into the chamber, and the thermal environment and electrical testing module are designed in an integrated manner, eliminating the need for additional auxiliary equipment; and the environmental requirements are low (no need for a strict low humidity laboratory), and it can operate under normal ventilation conditions, which greatly reduces the testing threshold and long-term maintenance costs. Attached Figure Description

[0022] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a structural diagram of an integrated battery testing system according to the present invention. Figure 2 This is a schematic diagram of the thermal environment control system device of the present invention; Figure 3 This is a parameter setting diagram for the discharge test system of the present invention; Figure 4 The graph shows the test results of battery discharge voltage and current in Embodiment 1 of the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Controlled atmosphere chamber; 2. Thermal environment control system; 3. Individual battery; 4. External control unit; 5. Discharge test system; 6. Metal casing; 7. Integrated control and display unit; 8. Transmission control unit; 9. Heating assembly; 10. Safety control system. Detailed Implementation

[0024] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0025] Example 1 This invention provides an integrated testing system for batteries, aiming to build a controllable testing platform that integrates inert atmosphere protection, precise thermo-pressure control, and real-time electrical testing, suitable for performance evaluation of high-temperature battery materials and individual cells.

[0026] like Figure 1 As shown, the integrated testing system mainly includes a controlled atmosphere chamber 1, a thermal environment control system 2, an external control unit 4, and a discharge testing system 5. The single cell 3 under test is placed on top of the thermal environment control system 2. The entire system works collaboratively through sealed electrical connections, constructing an integrated testing system of "inert atmosphere - high temperature thermal field - electrical testing".

[0027] The controllable atmosphere chamber 1 forms the environmental foundation of the entire system and employs a sealed chamber structure. High-purity inert gases (such as argon or nitrogen) can be introduced into the chamber to replace air, maintaining a low-oxygen, low-moisture testing environment and preventing the battery materials from oxidizing or decomposing at high temperatures. The chamber is equipped with an inert gas inlet, an exhaust outlet, and a pressure balancing valve to achieve atmosphere flow replacement and stabilize the chamber pressure. An oxygen content detection module and an atmosphere flow control unit are integrated inside the chamber for real-time monitoring and adjustment of the atmosphere. For safety, the chamber is equipped with a safety interlock device that automatically cuts off the heating circuit and power supply of the thermal environment control system 2 when abnormal internal pressure or excessive oxygen content is detected. All electrical signals and power cables interacting with the outside are routed through specially designed sealed leads through the chamber wall, ensuring reliable electrical connections while maintaining airtightness. The chamber also features a high-temperature resistant observation window for easy observation of the internal conditions during experiments.

[0028] The thermal environment control system 2, installed inside the controllable atmosphere chamber 1, is the core component providing a high-temperature and high-pressure environment. For example... Figure 2 As shown, it mainly consists of a heating component 9, a transmission control unit 8, an integrated control and display unit 7, and a safety control system 10, and is usually encapsulated and protected by a metal casing 6.

[0029] The heating assembly 9 includes an upper heating plate and a lower heating plate. Both can be easily installed via a standardized threaded or other detachable structure, and heating plates made of different materials such as brass, pure gold, pure silver, pure copper, or stainless steel can be selected to meet the thermal characteristic testing requirements of different materials. A thermocouple is embedded inside the heating plate for high-precision temperature detection, with a heating temperature range of 0–1000℃. Because the performance of high-temperature battery materials is extremely sensitive to temperature, even small temperature fluctuations can lead to deviations in test data. Therefore, the temperature control accuracy of this device can reach ±5℃, and the temperature detection accuracy of the thermocouple is ±0.5℃.

[0030] The core of the transmission control unit 8 is a servo electric cylinder, used to drive the upper heating plate for precise lifting and lowering movements. This unit allows for setting and controlling the pressure applied to the individual battery 3, as well as the lifting stroke and speed of the upper heating plate. In a preferred embodiment, the pressure setting range of the servo electric cylinder is 0-700 kg, the pressure detection range is the same as the pressure setting range, and the stroke control accuracy is as high as ±0.1 mm. The lifting stroke of the upper heating plate is between 0.5-10 cm, and the lifting speed is between 0-5 cm / s. When the upper and lower heating plates are closed, they are not completely sealed, but rather have a front operating gap (e.g., approximately 18 mm) and a small thermocouple outlet. This design, while maintaining good heat preservation performance, allows for in-situ battery replacement in "heat preservation mode" by using a special tool through the gap without interrupting the high-temperature inert atmosphere environment, significantly improving testing efficiency.

[0031] The integrated control and display unit 7 (such as a touch screen) is used for parameter setting, status display, and centralized control. The safety control system 10 includes modules such as an emergency stop button, protective light curtains, and leakage protection to ensure operational safety.

[0032] The discharge test system 5 is an independent integrated chassis responsible for electrical performance evaluation. Its core hardware includes an electronic load, a power supply, a high-precision current and voltage acquisition module, and matching test cables.

[0033] The electronic load has a wide input range (e.g., input voltage 0–120V, input current 0–30A) and supports multiple discharge modes such as constant current (CC), constant power (CP), and constant resistance (CR) to meet the needs of different test conditions. Its constant current discharge accuracy can reach ±0.05%+0.05%FS.

[0034] The current and voltage acquisition module features multi-range selection. Current acquisition offers different ranges such as 0–5A and 0–20A; voltage acquisition includes high-precision channels (e.g., 0–5V) and general-purpose channels (e.g., 0–10V). This module boasts high sampling accuracy (e.g., 16-bit), with an adjustable sampling frequency from 1Hz to 10kHz. It supports multi-channel synchronous acquisition and remote voltage compensation to correct measurement errors caused by cable voltage drop.

[0035] One end of the test cable connects to the discharge test system chassis 5 via an aviation connector or similar method, while the other end is equipped with alligator clips for directly clamping the positive and negative terminals of the single cell 3 under test. The cable enters the chamber through a sealed lead-out on the controlled atmosphere chamber 1 to ensure airtightness. The accompanying control software runs on a computer, providing a graphical interface for setting complex discharge steps, displaying voltage and current waveforms in real time, recording test data, and exporting data to common formats such as CSV or Excel for analysis.

[0036] The single cell 3 used in this system is preferably a disc-shaped or disc-cylindrical structure with a diameter ranging from, for example, 10–50 mm. The cell has two flat current-collecting surfaces, top and bottom, ensuring good contact with the heating plate to achieve a uniform thermal field. The cell edge has dedicated terminal areas for clamping, facilitating alligator clip connection without damaging the cell's active material.

[0037] Based on the aforementioned integrated testing system, a general testing method includes the following steps: Step S1: System Preparation and Security Check Turn on the main power supply to the external control unit 4 and the discharge test system 5 to perform a system self-test. Check the connections, seals, and safety device status of each component.

[0038] Step S2: Establish an inert atmosphere environment A set inert gas is introduced into the controllable atmosphere chamber 1. Through intake, exhaust and pressure control, the oxygen content in the chamber is reduced to an extremely low level (e.g., ≤10ppm) and maintained stably.

[0039] Step S3: Set up and start the thermal environment The external control unit 4 sets the target temperature, pressure, lifting stroke and speed of the thermal environment control system 2, and starts the heating program to raise the heating plate to the target value.

[0040] Step S4: Discharge System Calibration and Configuration: Before the test, the current and voltage acquisition channels of the discharge test system 5 can be calibrated. Configure the discharge mode (e.g., constant current discharge), current and voltage ranges, cutoff conditions, protection parameters, etc., for this test in the software.

[0041] Step S5: Battery clamping and testing Once the thermal environment reaches the set temperature and enters "heat preservation mode," use a high-temperature resistant tool to place the individual battery 3 into the center of the lower heating plate through the gap between the operating port and the heating plate. Clamp the positive and negative terminals of the battery using the alligator clips of the discharge test system 5. Start the test program via software; the servo cylinder drives the upper heating plate to descend to the set pressure. Simultaneously, the discharge test system discharges the battery according to preset parameters and synchronously and accurately collects data such as voltage and current.

[0042] Step S6: In-situ replacement and repeat testing After a single discharge test, the upper heating plate is raised. While maintaining a high-temperature inert atmosphere inside the chamber, the tested battery is removed and a new battery to be tested is inserted. Repeating step S5 allows for continuous and efficient multi-set testing without the need for reheating or atmosphere replacement.

[0043] Step S7: Test Completion and Data Processing After all tests are completed, stop the discharge and heating processes and allow the system to cool down naturally. Save all test data, process the data using the software's data analysis functions, and generate a test report.

[0044] Example 2 This embodiment uses the integrated testing system to perform performance testing on NiS2 high-temperature single-cell batteries.

[0045] 1. Battery manufacturing Using NiS2 as the positive electrode active material, combined with lithium boron alloy negative electrode and MgO Molten salt separators are pressed into disc-shaped high-temperature single-cell batteries with a diameter of Φ25mm and a thickness of 2.1mm. After preparation, they are left to stand for 1.5 hours in a dry environment at 25℃ and humidity ≤2% to ensure that there is no moisture or impurities remaining on the surface, and then ready for use.

[0046] 2. System Operation Steps S1. Equipment Start-up and Safety Check Turn on the main power switch of the external control unit 4, start the integrated control touch screen, and wait for the system to self-test; confirm that the leak-proof sealing ring of the controllable atmosphere chamber 1 is undamaged, the high-temperature observation window is intact, the emergency stop button of the thermal environment control system 2 is reset, the protective light grid is unobstructed, and the cable of the discharge test system 5 is undamaged. After the self-test is completed, the touch screen displays the "standby" state.

[0047] Simultaneously start the integrated chassis of the discharge test system: connect the 220VAC power cord, turn on the main power switch on the rear panel, and confirm that the +15V / –15V indicator lights are on; turn on the main power control switch on the front panel, start the single-cell discharge test system software, and check that the PXI module, electronic load, and auxiliary power supply are connected normally and there is no "module not connected" alarm.

[0048] S2, Controllable Atmosphere Chamber Parameter Setting The protective gas for the controllable atmosphere chamber 1 is set to high-purity argon (99.999% purity), with an inlet flow rate of 55 ml / min, an exhaust flow rate of 50 ml / min, and a holding pressure of 0.11 MPa. The atmosphere replacement program is started, and the system automatically enters the "atmosphere holding" state when the oxygen content in the chamber is ≤10 ppm.

[0049] S3, Thermal Environment Control System Parameter Settings Based on the heat conduction requirements and active temperature range of NiS2, brass upper and lower heating plates were selected, and the target heating temperature was set to 460℃. The upper heating plate lifting stroke was set to 2.6cm, the lifting speed to 0.2cm / s, and the servo electric cylinder pressure was set to 35kg. The heating program was started, and the upper and lower heating plates heated up at a rate of 12℃ / min.

[0050] S4. Discharge Test System Calibration and Parameter Configuration (1) Calibration operation: ① Current calibration: Short-circuit the alligator clips on the "5A battery discharge" cable (see...) Figure 3 Enter the software's "System Calibration - Current Acquisition Calibration" interface, select the 0~5A range, set the current output to 0.2A and the step to 0.02A, start automatic calibration, acquire the voltage value and the physical value to fit a linear curve, and save the calibration parameters.

[0051] ② Voltage calibration: Connect the programmable power supply to the voltage acquisition CH1 channel, set the voltage step to 0.5V and the maximum value to 20V, start automatic calibration, and complete the 0~5V high-precision channel calibration.

[0052] (2) Parameter configuration ① Go to “Parameter Configuration – Test Configuration” in the software, fill in the battery model, batch, number and other test information, and set the default sampling frequency to 100Hz.

[0053] ② Enter the “Test Plan” tab, select the first group of loads, set the start-up method to start immediately, the working mode to constant current discharge, select 0~5A for the current test channel, select CH1 for the voltage test channel, set the cut-off method to “less than voltage” (cut-off voltage 0V), set the protection current to 0.5A, set the protection power to 240W, and turn off remote compensation.

[0054] S5, Single-cell battery clamping and discharge testing Once the thermocouple detects that the heating plate temperature has stabilized at 460℃, the system enters "heat preservation mode". Wearing high-temperature resistant gloves, through the operating port of the controlled atmosphere chamber 1, use a special high-temperature resistant clamp to place the NiS2 single cell through the 18mm front gap of the thermal environment control system and place the NiS2 in the center of the lower heating plate; clamp the alligator clips of the discharge test system 5 on the positive and negative terminal areas of the battery, and connect the other end of the test cable to the battery discharge interface of the integrated chassis via an aviation connector.

[0055] Click the "Prepare" button in the software to complete the parameter distribution, and click the "Start" button to start the discharge test: the servo electric cylinder drives the upper heating plate to descend at the set speed until the pressure reaches the standard and maintains it; the electronic load outputs constant current, and the accompanying power supply provides 3.3V auxiliary power supply to meet the power balance formula P0 (240W) > P1 (100W) + P2 (battery power); the current and voltage acquisition module collects data in real time (current accuracy ±0.1A ±0.3%FS, voltage accuracy ±0.01V ±0.3%FS), and the waveform display area is refreshed synchronously with voltage-time and current-time curves (voltage gradually decreases from 1.8V to 0V).

[0056] S6, Battery replacement in situ and repeated testing After the first set of battery discharge tests is completed, maintain the "heat preservation mode" and "atmosphere pressure preservation" status, and raise the upper heating plate to the upper limit of its stroke. Remove the tested battery through the 18mm front gap, quickly insert the second set of spare NiS2 batteries, and repeat steps S4 (only reuse the configured parameters, no recalibration is required) – S5, without reheating or atmosphere replacement.

[0057] S7, System Shutdown and Data Processing After all test groups are completed, click the "Stop" button in the software to terminate the discharge and save all data; stop the heating program, allow the thermal environment control system 2 to cool down naturally, and when the temperature detected by the thermocouple drops below 100℃, turn off the gas path of the controllable atmosphere chamber and the power supply of the servo cylinder, and finally turn off the main power supply of the external control box.

[0058] Data Readback and Analysis: In the software, navigate to "Data Processing – Data Readback and Analysis," open the saved file, set the sampling ratio to 10:1, and view the voltage and current waveforms before the cutoff voltage. Extract characteristic data such as discharge voltage changes, discharge duration, and specific capacity, and generate a test report. The discharge capacity deviation of three consecutive battery groups was ≤2%, verifying data repeatability.

[0059] 3. Test Results like Figure 4 As shown, the NiS2 single-cell battery, under a 460℃, 35kg hot-pressure, and argon-protected environment, discharged at a constant current of 0.242A, with the voltage steadily decreasing from 1.8V to 0V in 475.6 seconds. Three sets of batteries were tested consecutively, and the discharge capacity deviation was ≤2%, demonstrating good synergistic stability between the system's thermal field, atmosphere, and electrical testing. No material oxidation or electrolyte decomposition was observed throughout the process, verifying the protective effect of the controllable atmosphere chamber. The current / voltage acquisition accuracy and power balance control of the discharge test system met the design requirements, with no overcurrent or overvoltage alarms.

[0060] Example 3 This embodiment uses the integrated testing system to perform performance testing on CoS2 high-temperature single-cell batteries.

[0061] 1. Battery manufacturing Using CoS2 as the positive electrode active material, combined with lithium boron alloy negative electrode and MgO Molten salt separators are pressed into disc-shaped high-temperature single-cell batteries with a diameter of Φ20mm and a thickness of 2.1mm. After preparation, they are left to stand for 1.5 hours in a dry environment at 25℃ and humidity ≤2% to ensure that the surface is clean and free of moisture residue, and then ready for use.

[0062] 2. System Operation Steps S1. Equipment Start-up and Safety Check Same as step S1 in Example 2.

[0063] S2, Controllable Atmosphere Chamber Parameter Setting The protective gas for the controllable atmosphere chamber 1 is set to high-purity argon (purity 99.999%), with an inlet flow rate of 50 ml / min, an exhaust flow rate of 45 ml / min, and a holding pressure of 0.10 MPa. The atmosphere replacement program is started, and when the oxygen content in the chamber is ≤10 ppm, the system automatically enters the "atmosphere holding" state.

[0064] S3, Thermal Environment Control System Parameter Settings Select brass upper and lower heating plates, set the target heating temperature to 570℃; set the upper heating plate lifting stroke to 2.6cm and lifting speed to 0.3cm / s, set the servo electric cylinder pressure to 40kg, start the heating program, and the upper and lower heating plates heat up at a rate of 15℃ / min.

[0065] S4. Discharge Test System Calibration and Configuration The calibration and configuration steps are the same as step S4 in Example 2.

[0066] S5, Single-cell battery clamping and discharge testing After the thermocouple detects that the heating plate temperature has stabilized at 570℃, the system enters the "heat preservation mode". Wearing high-temperature resistant gloves, through the operating port of the controllable atmosphere chamber 1, use a special high-temperature resistant clamp to place the CoS2 single cell through the 18mm front gap of the thermal environment control system and place the CoS2 in the center of the lower heating plate. Clamp the alligator clip of the discharge test system 5 on the positive and negative terminal areas of the battery, and connect the other end of the test cable to the battery discharge interface of the integrated chassis through the aviation plug.

[0067] Click the "Prepare" button in the software to complete the parameter distribution, and click the "Start" button to start the discharge test: the servo electric cylinder drives the upper heating plate to descend at the set speed until the pressure reaches the standard and maintains it; the electronic load outputs constant current, and the accompanying power supply provides 3.3V auxiliary power supply to meet the power balance formula P0 (240W) > P1 (100W) + P2 (battery power); the current and voltage acquisition module collects data in real time (current accuracy ±0.1A ±0.3%FS, voltage accuracy ±0.01V ±0.3%FS), and the waveform display area is refreshed synchronously with voltage-time and current-time curves (voltage gradually decreases from 1.904V to 0V).

[0068] S6, Battery replacement in situ and repeated testing Same as step S6 in Example 2, maintain the atmosphere and temperature conditions, and continuously test multiple groups of batteries.

[0069] S7, System Shutdown and Data Processing Same as step S7 in Example 2.

[0070] 3. Test Results The CoS2 single-cell battery was discharged at a constant current of 0.262A under a thermostatic pressure of 570℃ and 40kg, with the voltage steadily decreasing from 1.904V to 0V in 502.3 seconds. The discharge capacity deviation of three consecutive test sets was ≤2%, indicating good system stability and data repeatability. No material oxidation or electrolyte decomposition occurred throughout the process, demonstrating effective controllable atmosphere chamber protection. The discharge test system operated stably without triggering overcurrent or overvoltage protection.

[0071] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features of the present invention can be arbitrarily combined with each other.

Claims

1. An integrated testing system for batteries, characterized in that, include: Controllable atmosphere chamber (1), thermal environment control system (2), external control unit (4) and discharge test system (5); The controllable atmosphere cavity (1) is a closed cavity structure used to provide an inert atmosphere environment. The controllable atmosphere cavity (1) is provided with an inert gas inlet, an exhaust outlet and a sealed lead-out for electrical signals to pass through. The thermal environment control system (2) is located in the controllable atmosphere cavity (1) and includes a heating component (9) and a transmission control unit (8) for driving the heating component (9) to close and open, for applying target temperature and pressure to the single cell (3) placed thereon; The external control unit (4) is located outside the controllable atmosphere cavity (1) and is electrically connected to the thermal environment control system (2) through the sealed lead-out part. It is used to set and control the temperature and pressure parameters of the thermal environment control system (2). The discharge test system (5) is electrically connected to the single cell (3) via a test cable, and is used to discharge the single cell (3) and collect its electrical performance data. The test cable enters the controllable atmosphere cavity (1) through the sealed lead-out part to maintain the airtightness of the cavity.

2. The integrated testing system for batteries according to claim 1, characterized in that, The controllable atmosphere chamber (1) is also equipped with an oxygen content detection module and an atmosphere flow control unit. The chamber is equipped with a safety interlock device. When the air pressure or oxygen content in the chamber is abnormal, the safety interlock device can automatically cut off the power supply of the thermal environment control system (2).

3. The integrated testing system for batteries according to claim 1, characterized in that, The heating component (9) of the thermal environment control system (2) includes an upper heating plate and a lower heating plate that can move relative to each other. The transmission control unit (8) is a servo electric cylinder used to drive the upper heating plate to lift and lower to apply pressure to the single battery (3) placed on the lower heating plate.

4. The integrated testing system for batteries according to claim 3, characterized in that, The upper heating plate and the lower heating plate are installed by a detachable structure; when the upper heating plate and the lower heating plate are closed, an operating gap is formed between them for replacing individual batteries (3).

5. The integrated testing system for batteries according to claim 1, characterized in that, The discharge test system (5) includes an electronic load, a current and voltage acquisition module, and control software; The electronic load supports constant current, constant power, and constant resistance discharge modes. The current and voltage acquisition module has multiple ranges of current and voltage acquisition channels; The control software is used to set discharge parameters and display and record voltage and current waveform data in real time.

6. The integrated testing system for batteries according to claim 5, characterized in that, The electronic load has an input voltage range of 0–120V and an input current range of 0–30A, and the accuracy of the constant current discharge mode is better than ±0.05%+0.05%FS.

7. The integrated testing system for batteries according to claim 5, characterized in that, The current and voltage acquisition module has a sampling accuracy of 16 bits, an adjustable sampling frequency from 1Hz to 10KHz, and supports multi-channel synchronous acquisition and remote voltage compensation functions.

8. The integrated testing system for batteries according to any one of claims 1 to 7, characterized in that, The single cell (3) has a disc-shaped or columnar structure, with current collection surfaces on the upper and lower surfaces and clampable terminal areas on the edges.

9. The integrated testing system for batteries according to any one of claims 1 to 7, characterized in that, One end of the test cable is connected to the discharge test system (5) via an aviation plug, and the other end is provided with an alligator clip for clamping the terminal area of ​​the single cell (3).

10. An integrated testing method for batteries, based on the integrated testing system for batteries according to any one of claims 1 to 9, characterized in that, Includes the following steps: An inert gas is introduced into the controllable atmosphere chamber (1) and pressure is maintained; The target temperature and pressure parameters of the thermal environment control system (2) are set by the external control unit (4) and heating is started. After the temperature stabilizes, while the thermal environment control system (2) is in a heat preservation state, place the single battery (3) on the heating component (9) and connect it to the test cable of the discharge test system (5); The thermal environment control system (2) applies pressure to the single cell (3), and at the same time, the discharge test system (5) is started to perform discharge test on the single cell (3) and collect electrical performance data simultaneously. After a single test is completed, the individual cell is replaced (3) and the test is repeated while maintaining a heat-insulating and inert atmosphere.

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