Energy storage liquid cooling plate bearing hoisting type variable test test tool and test method

Abstract

The application discloses a test tool, in particular to a kind of energy storage liquid cooling plate load lifting type variable test test tool, comprising: load bearing loading module, for applying static or dynamic load to liquid cooling plate;Hoisting simulation module is used to simulate hoisting and swing working condition;Deformation monitoring module is used to monitor the deformation of liquid cooling plate in the process of force in real time;Through the displacement-force double closed loop control of load bearing loading module, the programmed swing of hoisting simulation module and the superposition of dynamic excitation load, the tool can accurately, synchronously reproduce the static load bearing, dynamic lifting, random vibration composite mechanical environment of liquid cooling plate in actual application, solve the problem that traditional test method working condition is single, and coupling is poor, and test result and actual working condition are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of testing equipment technology, and in particular to a testing fixture and method for load-bearing deformation testing of energy storage liquid-cooled plates. Background Technology

[0002] In electrochemical energy storage systems, liquid cooling plates not only serve as thermal management components for the battery pack but also often function as load-bearing structures or hoisting connection points. However, traditional testing fixtures often only target the heat dissipation performance or single mechanical properties (such as pressure testing) of liquid cooling plates, lacking comprehensive testing capabilities for the coupled "load-bearing-hoisting-deformation" multi-condition scenarios. In existing technologies, load-bearing tests of liquid cooling plates typically employ weight stacking, while hoisting tests rely on external cranes for simulation. These two methods cannot be performed synchronously and are difficult to accurately simulate the boundary conditions in actual installation (such as support stiffness and hoisting angle deviation), leading to discrepancies between test results and actual operating conditions. Furthermore, liquid cooling plates are prone to localized deformation during load-bearing and hoisting processes, affecting the sealing of cooling channels. Existing fixtures lack real-time monitoring and feedback mechanisms for micro-deformations, making it impossible to quantify the degree of heat dissipation performance degradation caused by deformation. Therefore, developing a testing fixture that can simultaneously simulate load-bearing, hoisting, and deformation conditions and integrate multi-parameter monitoring functions is crucial for improving the design reliability and verification efficiency of liquid cooling plates. Summary of the Invention

[0003] In order to solve the problems existing in the prior art, the present invention provides a test fixture and test method for load-bearing hoisting deformation test of energy storage liquid-cooled plate, so as to solve the current technical problems.

[0004] The technical solution adopted by this invention to solve its technical problem is: This invention provides a test fixture for load-bearing and deformation testing of energy storage liquid-cooled plates, comprising: Load-bearing module, used to apply static or dynamic loads to liquid cooling plates; The hoisting simulation module is used to simulate hoisting, lifting, and swinging conditions. The deformation monitoring module is used to monitor the deformation of the liquid cooling plate in real time during the stress process; The data acquisition and control system is used to collect sensor data and control the coordinated operation of various modules.

[0005] Preferably, the load-bearing module includes a hydraulic loader, a pressure sensor, and a ball joint. The pressure sensor is integrated into the loading end and is used to provide real-time load data feedback.

[0006] Preferably, the hoisting simulation module includes at least one electric hoist and an adjustable-angle boom, which is infinitely adjustable within the range of 0-30° by a hydraulic cylinder.

[0007] Preferably, the deformation monitoring module includes multiple laser displacement sensors and strain gauges. The laser displacement sensors are arranged at the corners and center of the liquid cooling plate, and the strain gauges are attached to the key stress areas of the liquid cooling plate.

[0008] A test method for load-bearing and hoisting deformation testing of an energy storage liquid-cooled plate, using the test fixture described in any one of claims 1-4, includes the following steps: S1: Perform adaptive load-bearing loading and dynamically adjust the target load based on deformation feedback; S2: Perform dynamic hoisting and multi-condition coupled testing to simulate hoisting lifting, swinging and vibration loads; S3: Real-time safety monitoring and early warning based on multi-sensor data; S4: Online assessment of the correlation between deformation and sealing performance; S5: Unload and evaluate the deformation recovery rate of the liquid cooling plate.

[0009] Preferably, in step S3, Kalman filtering is used to fuse multi-sensor data, and a three-level early warning mechanism is set up to provide prompts, reduce speed, or shut down in an emergency based on deformation and strain thresholds.

[0010] Preferably, in step S5, the deformation recovery rate is calculated, and if the recovery rate is less than 95%, it indicates the presence of plastic deformation.

[0011] The beneficial effects of this invention are: High-fidelity multi-physics coupled working condition simulation has been achieved: through the displacement-force dual closed-loop control of the load-bearing module, the programmed swing of the hoisting simulation module, and the superposition of dynamic excitation loads, this fixture can accurately and synchronously reproduce the static load-bearing, dynamic hoisting, and random vibration composite mechanical environment that the liquid cooling plate is subjected to in actual applications. This solves the problems of single working condition and poor coupling in traditional testing methods, and the test results are significantly improved in agreement with the actual working conditions.

[0012] The testing process is made more intelligent and safer: real-time status monitoring based on multi-sensor (laser displacement, strain gauge) data fusion, combined with a three-level early warning logic (record, deceleration, emergency stop), enables adaptive control and proactive risk intervention in the testing process. This effectively avoids accidental damage to the specimen due to overload or abnormal deformation, ensuring testing safety, while reducing reliance on operator experience.

[0013] This invention achieves a quantitative correlation assessment between deformation and sealing performance: By integrating an external leak detector and running an online deformation-leakage correlation model (such as quadratic polynomial fitting), it can quantitatively analyze in real time the attenuation law of the cooling channel sealing performance of the liquid cooling plate during stress deformation. This provides direct data support for assessing the impact of deformation on the reliability of the heat dissipation system, surpassing the traditional testing mode that only makes mechanical qualification judgments.

[0014] Significantly improved testing efficiency and the objectivity of results: The entire testing process (installation, loading, hoisting, monitoring, unloading, and analysis) is automated by the control software, which automatically generates test reports containing complete process data and judgment conclusions. This eliminates human error, shortens the testing cycle for a single product by more than 40%, and supports accurate reproduction of test conditions and standard comparison of batch products.

[0015] High hardware utilization and strong scalability: Without significantly increasing hardware complexity, this invention fully explores and integrates the functional potential of existing sensors and actuators through software algorithm upgrades. The control method and evaluation model can be adjusted according to different test standards (such as changing the load spectrum and oscillation frequency), enabling the tooling to flexibly adapt to the needs of various test specifications. Attached Figure Description

[0016] The above-described aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which: Figure 1 This is a schematic diagram of the test fixture and test method for load-bearing hoisting deformation test of energy storage liquid-cooled plate according to an embodiment of the present invention. Explanation of reference numerals in the attached figures

[0017] exist Figure 1 In the middle, there is hoisting simulation module 1 and load-bearing loading module 2. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 are within the scope of protection of the present invention.

[0019] This invention provides a test fixture for load-bearing and hoisting deformation testing of energy storage liquid-cooled plates, used to simulate and detect the mechanical properties of liquid-cooled plates under load-bearing and hoisting conditions. The structure of the fixture and the connection relationships of its components are as follows: The testing fixture is primarily composed of a stepped steel support frame with overall dimensions of 2500mm (length) × 1200mm (width) × 2000mm (height). The frame has adjustable leveling feet at the bottom and a horizontal load-bearing platform welded to its center. This platform has an array of threaded holes machined into its surface for bolting the liquid-cooled plate under test. Two parallel box-shaped crossbeams are fixedly mounted on the top of the frame. The lower flanges of the crossbeams have positioning holes and adjustable positioning pins for alignment with the lifting lugs on the liquid-cooled plate.

[0020] The load-bearing module 2 includes a hydraulic loader with a maximum load of 50kN. The cylinder of the hydraulic loader is vertically fixed to the frame base below the load-bearing platform via a flange, and its piston rod extends upward through the central hole of the platform. The top of the piston rod is threaded with a pressure sensor with a range of 0-50kN and a ball joint. The upper end of the ball joint contacts the lower surface of the liquid cooling plate through a pressure plate with a ball socket.

[0021] The hoisting simulation module 1 includes two electric hoists with a rated load of 15kN. Each electric hoist is suspended from the track of the top box-shaped crossbeam via a traveling trolley. A boom is hinged to the underside of the traveling trolley, and the inner end of the boom is hinged to the piston rod of a double-acting hydraulic cylinder. The cylinder body is hinged to a fixed lug under the crossbeam, thus forming a drive mechanism that allows the boom to swing steplessly within the range of 0° to 30°. A tension sensor is connected to the underside of the hook of the electric hoist and is connected to the lifting lug of the liquid-cooled plate via a shackle, lifting device, and lifting lug.

[0022] The deformation monitoring module includes five high-precision laser displacement sensors and several foil strain gauges. The five laser displacement sensors are each fixed with an independent rigid bracket, their optical axes perpendicularly aligned with the measurement target fixed at the four corners and geometric center of the liquid-cooled plate. The foil strain gauges are attached to key stress areas on the surface of the liquid-cooled plate.

[0023] The data acquisition and control system includes an NI cDAQ-9188 chassis and supporting analog input, analog output, and digital I / O modules. The signal output terminals of the pressure sensor, tension sensor, laser displacement sensor, and strain gauge are all connected to the analog input module. The analog output module is connected to the proportional valve controlling the hydraulic loader and the boom adjusting hydraulic cylinder. The digital I / O module is connected to the electric hoist controller and angle encoder. The cDAQ-9188 chassis is connected to a host industrial computer via Ethernet. This industrial computer runs control software to coordinate loading and hoisting actions and synchronously acquire all sensor data.

[0024] Before testing, initiate the system self-test program, reset all sensors to zero, preload the hydraulic system to 1kN, and return the boom to zero. The control software will automatically execute the test procedure as follows: S1. Adaptive Load-Bearing Stage The objective is to simulate the static load of the battery pack. The base target load is set to P_base = 20kN, and the loading rate is v_load = 1kN / s. Simultaneously, deformation feedback is introduced for adaptive pressure regulation to prevent local overload. A pressure-displacement dual closed-loop PID control is employed. The outer displacement loop input is the deformation δ_meas of the liquid-cooled plate center point measured by a laser sensor, with a maximum allowable deformation δ_max = 0.5mm. The deformation deviation e_δ(k) = δ_meas(k) - δ_max. The target value for the inner pressure loop is dynamically calculated using the following formula (k is the control cycle number): P_target(k) = P_base - [Kp * e_δ(k) + Ki * Σ(e_δ(j) * T) + Kd * (e_δ(k) - e_δ(k-1)) / T] The proportional coefficient Kp = 5.0 kN / mm, the integral coefficient Ki = 0.2 kN / (mm·s), and the differential coefficient Kd = 0.5 kN·s / mm.

[0025] The hydraulic loader is controlled to load at a rate of v_load, while P_target(k) is calculated in real time. When e_δ(k) > 0, the system automatically reduces the target pressure to ensure that δ_meas(k) always approaches but does not exceed δ_max. After loading to P_base, the load is maintained for 10 minutes, and the load-deformation data throughout the process are recorded.

[0026] S2. Dynamic Lifting and Multi-Condition Coupling Stage This stage simulates the hoisting process and potential swaying. An S-curve velocity planning method is used, with a total lifting height H = 100 mm. It is divided into three segments: Acceleration segment: time t_a = 5 s, acceleration a = 0.02 m / s². Constant velocity segment: velocity v_const = 1 m / min (0.0167 m / s). Deceleration segment: time t_d = 5 s, deceleration a = -0.02 m / s².

[0027] Boom angle coordinated control: To simulate lifting sway, a periodic micro-motion is superimposed on the boom at a set angle θ_set (e.g., 20°). θ(k) = θ_set + A * sin(2π * k * T / τ) The fluctuation amplitude A = 1.5°, and the fluctuation period τ = 8s. During the uniform lifting phase, the hydraulic loader applies an additional 5Hz sinusoidal pulsating load to simulate transportation vibration. P_pulse(t) = 2 * sin(2π * 5 * t) kN The load is superimposed on the static load and applied continuously for 60 seconds.

[0028] S3. Real-time security monitoring based on multi-sensor data fusion A Kalman filter algorithm was used to fuse data from five laser displacement sensors and strain gauges to obtain a more accurate estimate of the deformation and strain state of the liquid-cooled plate. The process noise covariance matrix Q and the observation noise covariance matrix R were set as follows: Q = diag([0.01², 0.01², 0.01², 0.001², 0.001², 0.001²]) (corresponding to displacement and velocity states) R = diag([0.005², 0.005², 0.005², 0.005², 0.005², 10²]) (corresponding to displacement and strain observations) This invention employs a three-level early warning and adaptive intervention system: Level 1 Early Warning (Notification): When deformation > ±0.3 mm or strain > 500 με at any monitoring point, the system records the information and illuminates a yellow warning light. Level 2 Early Warning (Intervention): When deformation > ±0.4 mm or strain > 800 με, the system automatically reduces the loading / lifting rate to 50% of its original value (i.e., 0.5 kN / s and 0.5 m / min). Level 3 Early Warning (Shutdown): When deformation > ±0.5 mm or strain > 1200 με, the system immediately triggers an emergency shutdown, the hydraulic loader quickly unloads, and the electric hoist lifts the liquid-cooled plate to a safe height.

[0029] S4. Online assessment of sealing performance degradation Throughout the test, the data acquisition system synchronously records the flow rate data of the cooling channel (via a connected flow meter). Online identification of the relationship between deformation and leakage flow rate: Q_leak(k) = α * [δ_avg(k)]^2 + β * [δ_avg(k)] + γ Where δ_avg(k) is the average deformation measured by multiple laser sensors, and Q_leak(k) is the leakage flow rate (mL / min). The model parameters α, β, γ are updated online using the recursive least squares (RLS) method. The forgetting factor λ=0.95, and the initial parameter values ​​[α, β, γ] = [2.5, 0.8, 0.1].

[0030] The model parameters are updated every 10 seconds, and the deformation-leakage relationship curve is plotted in real time.

[0031] S5. Uninstallation, Recovery, and Performance Evaluation Phase The hydraulic load was removed at a rate of 0.5 kN / s, while the electric hoist smoothly lowered the liquid-cooled plate to its initial position at a speed of 0.5 m / min. After the test, the ratio of the residual deformation to the maximum deformation of the liquid-cooled plate was calculated to obtain the deformation recovery rate η: η = (δ_residual / δ_max) * 100% If η > 95%, the deformation is determined to be mainly elastic deformation; otherwise, it indicates the presence of plastic deformation.

[0032] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A test fixture for load-bearing and deformation testing of an energy storage liquid-cooled plate, characterized in that, include: Load-bearing module, used to apply static or dynamic loads to liquid cooling plates; The hoisting simulation module is used to simulate hoisting, lifting, and swinging conditions. The deformation monitoring module is used to monitor the deformation of the liquid cooling plate in real time during the stress process; The data acquisition and control system is used to collect sensor data and control the coordinated operation of various modules.

2. The testing fixture according to claim 1, characterized in that: The load-bearing module includes a hydraulic loader, a pressure sensor, and a ball joint. The pressure sensor is integrated into the loading end and is used to provide real-time load data feedback.

3. The testing fixture according to claim 1, characterized in that: The hoisting simulation module includes at least one electric hoist and an adjustable-angle boom, which is infinitely adjustable within the range of 0-30° by a hydraulic cylinder.

4. The testing fixture according to claim 1, characterized in that: The deformation monitoring module includes multiple laser displacement sensors and strain gauges. The laser displacement sensors are arranged at the corners and center of the liquid cooling plate, and the strain gauges are attached to the key stress areas of the liquid cooling plate.

5. A test method for load-bearing and hoisting deformation testing of an energy storage liquid-cooled plate, employing the test fixture described in any one of claims 1-4, characterized in that, Includes the following steps: S1: Perform adaptive load-bearing loading and dynamically adjust the target load based on deformation feedback; S2: Perform dynamic hoisting and multi-condition coupled testing to simulate hoisting lifting, swinging and vibration loads; S3: Real-time safety monitoring and early warning based on multi-sensor data; S4: Online assessment of the correlation between deformation and sealing performance; S5: Unload and evaluate the deformation recovery rate of the liquid cooling plate.

6. The test method according to claim 5, characterized in that: In step S3, Kalman filtering is used to fuse multi-sensor data, and a three-level early warning mechanism is set up to provide prompts, reduce speed, or shut down in an emergency based on deformation and strain thresholds.

7. The test method according to claim 5, characterized in that: In step S5, the deformation recovery rate is calculated. If the recovery rate is less than 95%, it indicates that plastic deformation exists.

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