A multi-dimensional index-based direct cooling plate performance testing system and method

Abstract

The application discloses a kind of based on multidimensional index's direct cooling plate performance test system and method, belong to energy storage thermal management test field, to solve the defects that existing equipment only supports uniform steady-state test, no dynamic and limit working condition, poor data reliability.System contains controllable temperature test chamber, with back heater's refrigerant drive control unit, contact type simulation heat source, adhering pressure device and electrical control system;Adhering pressure device can control interface contact thermal resistance, contact type simulation heat source simulates battery uniform and non-uniform heat generation.Method integrates steady-state matrix, dynamic response, local thermal runaway and other working conditions, synchronously collects refrigerant temperature, pressure and flow, full domain temperature of plate surface, automatically calculates uniform temperature, flow resistance, dynamic response, thermal safety boundary multidimensional index, and outputs test report containing performance spectrum.The application is controllable, working condition covers comprehensively, without battery can complete full-dimension quantitative evaluation, data is reproducible, shortens refrigerant direct cooling plate research and development iteration cycle.

Description

Technical Field

[0001] This invention belongs to the field of energy storage thermal management testing technology, specifically relating to a direct-cooling plate performance testing system and method based on multi-dimensional indicators. Background Technology

[0002] As new energy vehicles and electrochemical energy storage systems rapidly iterate towards higher energy density, larger cell capacity, and high-power fast charging, the heat flux density of battery packs continues to rise. Temperature uniformity and heat accumulation issues have become bottlenecks restricting the lifespan, operational safety, and charge / discharge performance of energy storage battery packs. Traditional ethylene glycol liquid cooling relies on single-phase phase flow heat transfer, and its heat exchange efficiency and plate surface temperature uniformity are approaching their physical limits, making it difficult to meet the temperature control requirements of next-generation high-power energy storage equipment. Refrigerant direct cooling technology, with its advantages of large latent heat of refrigerant phase change, high heat exchange intensity, and good plate surface temperature uniformity, is gradually becoming the mainstream upgrade solution for thermal management of energy storage battery packs.

[0003] As the core heat exchange component of the entire phase change cooling system, the refrigerant direct cooling plate directly determines the overall temperature control performance and thermal safety boundary of the battery pack, including the uniformity of liquid distribution in its internal flow channels, phase change heat transfer efficiency, dynamic temperature control response capability, and extreme operating condition thermal suppression level. Before integrating the battery pack into the vehicle and energy storage cabinet systems, completing precise, standardized, and reproducible component-level performance evaluation of the independent refrigerant direct cooling plate is a necessary preliminary step for optimizing the flow channel structure, selecting plate materials, matching system refrigerant parameters, and shortening the product development cycle. This has key engineering value in reducing the cost of overall system integration and ensuring the performance consistency of mass-produced products.

[0004] Existing technologies have disclosed dedicated testing solutions for direct-cooling plates of energy storage refrigerants, such as the invention patent document with publication number CN120253303A, which discloses a testing system and method for direct-cooling plates of energy storage refrigerants. This solution relies on an integrated heating film to simulate the heating of a battery pack, and judges the cooling performance by the average temperature of the contact surface and the maximum temperature difference on the plate surface. Combined with a pipeline temperature and pressure acquisition and optical detection module, it can automatically complete the basic heat dissipation and condensation detection of the refrigerant direct-cooling plate. Compared with manual testing, it simplifies the basic temperature measurement process. However, for the full-dimensional and extreme-condition quantitative testing of high-power energy storage refrigerant direct-cooling plates, the following problems exist: 1) This existing solution uses an integrated heating film. 1) The membrane can only conduct uniform steady-state heat dissipation tests, making it difficult to reproduce non-uniform and transient heat generation conditions of the battery pack; 2) It only has a single steady-state test process and lacks dynamic and extreme condition test capabilities, making it impossible to quantify the dynamic performance and thermal safety parameters of direct cooling; 3) It relies solely on average temperature and maximum temperature difference for qualitative evaluation, with few quantitative indicators and no energy balance verification, making it difficult to guarantee data reliability; 4) It lacks an independent constant temperature space, and the refrigerant circuit is not equipped with a regenerator, resulting in poor environmental and refrigerant condition stability and weak comparability of test data; 5) The equipment only outputs simple judgment conclusions, data processing relies on manual labor, has a low degree of automation, and is not conducive to multi-product comparison and batch testing. Summary of the Invention

[0005] This invention aims to address the problems existing in current testing technologies by providing a performance testing system and method for direct-cooled plates based on multi-dimensional indicators. Specifically designed for the two-phase phase change heat transfer characteristics of refrigerant direct-cooled plates, it constructs a test platform with independent and controllable boundaries for environment, refrigerant circulation, and heat load. It pioneers a three-in-one test condition set integrating steady-state matrix, dynamic response, and ultimate safety, and is equipped with zoned controllable heat sources, thermocouple matrix layout, synchronous acquisition of all parameters, and a complete thermodynamic index calculation model. Energy balance verification ensures data validity, and temperature cloud maps and standardized test reports are automatically generated. This enables independent, accurate, and reproducible multi-dimensional quantitative evaluation of refrigerant direct-cooled plates at the component level, filling the gap in existing technologies that cannot cover dynamic operating conditions and ultimate thermal safety boundaries.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A performance testing system for direct-cooled plates based on multi-dimensional indicators is characterized by comprising a temperature-controlled test chamber, a refrigerant drive and control unit, a controllable thermal simulation unit, and an electrical control system. The temperature-controlled test chamber is equipped with temperature control units to provide a temperature-controlled testing environment for the refrigerant direct-cooled plates. The refrigerant drive and control unit is connected to the refrigerant inlet and outlet of the refrigerant direct-cooled plates via refrigerant pipelines, providing adjustable refrigerant circulation conditions for the performance testing of the refrigerant direct-cooled plates. The controllable thermal simulation unit includes a contact-type simulated heat source and a pressure-applying device; the contact-type simulated heat source includes several zoned heating modules with visible module numbers. Each zoned heating module is matrix-laid on the heat exchange plate surface of the refrigerant direct-cooled plate using thermally conductive gel, and forms a contact interface with constant contact thermal resistance with the refrigerant direct-cooled plate based on the pressure-applying device. The electrical control system is connected to the temperature control unit, the refrigerant-driven control unit, and the controllable thermal simulation unit, respectively. It is used to control the temperature control unit, the refrigerant-driven control unit, and the controllable thermal simulation unit to cooperate in completing multi-dimensional operating condition tests. The multi-dimensional operating condition tests refer to: under set ambient temperature and refrigerant conditions, controlling the controllable thermal simulation unit to complete multi-dimensional operating condition simulations, including steady-state thermal simulation, transient thermal simulation, and local extreme thermal simulation; completing steady-state performance tests on the refrigerant direct cooling plate under steady-state thermal simulation, completing dynamic performance tests on the refrigerant direct cooling plate under transient thermal simulation, and completing safety boundary limit tests under local extreme thermal simulation; integrating the multi-dimensional performance indicators obtained after the multi-dimensional operating condition tests of the refrigerant direct cooling plate, generating and displaying the performance test report of the refrigerant direct cooling plate.

[0007] Preferably, the electrical control system includes a human-machine interface, a main control unit, a multi-channel programmable power supply, and a data acquisition unit. The human-machine interface is connected to the main control unit and is used to configure ambient temperature parameters, refrigerant condition parameters, and thermal simulation parameters; execute thermal simulation and test control operations; and display the performance test report of the refrigerant direct-cooling plate. The main control unit is connected to the temperature control unit and the refrigerant-driven control unit, and is also connected to the controllable thermal simulation unit through the multi-channel programmable power supply. The main control unit has a built-in multi-dimensional operating condition test program including steady-state performance testing, dynamic performance testing, and safety boundary limit testing. This program controls the temperature control unit, refrigerant-driven control unit, multi-channel programmable power supply, and controllable thermal simulation unit to operate in coordination, completing multi-dimensional operating condition simulations under set ambient temperature parameters, refrigerant condition parameters, and thermal simulation parameters. The main control unit is connected to the temperature control unit, refrigerant-driven control unit, multi-channel programmable power supply, and controllable thermal simulation unit through the data acquisition unit. Based on the multi-dimensional index basic parameters collected by the data acquisition unit during the multi-dimensional operating condition simulation, the main control unit calculates multi-dimensional performance indicators using these basic parameters and generates a performance test report for the refrigerant direct-cooling plate.

[0008] Preferably, the main control unit binds a unique device address and drive channel ID to each zone heating module, generates several digital power signals bound to unique device addresses and drive channel IDs using a multi-channel independent addressing matching mechanism, and packages all digital power signals into a success rate output command to send to the multi-channel programmable power supply.

[0009] Preferably, the multi-channel programmable power supply is provided with several independent output channels, and each zone heating module is connected to the output channel one by one. This is used to parse the digital power signals of each channel in the power output command, match the output of the heating drive power of each zone heating module according to the drive channel ID, and realize independent closed-loop control of the heating drive power of each channel based on the electrical signals fed back from each output channel.

[0010] Preferably, the data acquisition unit includes a thermocouple matrix and a refrigerant parameter acquisition unit. The thermocouple matrix is ​​arranged around the refrigerant direct cooling plate according to the structural design of the refrigerant direct cooling plate, and is used to collect temperature data at preset measuring points on the surface of the refrigerant direct cooling plate. The refrigerant parameter acquisition unit includes a mass flow meter connected to the refrigerant pipeline, an outlet pressure sensor, an outlet temperature sensor, an inlet pressure sensor, and an inlet temperature sensor, which are used to collect the refrigerant mass flow rate and the refrigerant inlet temperature, refrigerant inlet pressure, refrigerant outlet temperature, and refrigerant outlet pressure of the refrigerant direct cooling plate, respectively.

[0011] Preferably, the temperature control unit includes a temperature control module and an ambient temperature sensor; the temperature control module adopts a variable frequency refrigeration and electric heating temperature control configuration and is connected to the electrical control system to execute the ambient temperature control command of the electrical control system; the ambient temperature sensor is connected to the temperature control module and the electrical control system respectively, and is used to collect and feedback the ambient temperature in the controllable temperature test chamber in real time, cooperate with the temperature control module to complete the ambient temperature regulation, and cooperate with the electrical control system to realize the ambient temperature monitoring.

[0012] Preferably, the refrigerant-driven control unit includes a compressor, a condenser, a regenerator, and an electronic expansion valve; the refrigerant pipeline is connected to the refrigerant-driven control unit according to the flow direction of the refrigerant, with the following structure: the refrigerant outlet of the refrigerant direct cooling plate is connected to the high-temperature inlet of the regenerator; the high-temperature outlet of the regenerator is connected to the compressor and condenser in sequence, and then connected to the low-temperature inlet of the regenerator; the low-temperature outlet of the regenerator is connected to the refrigerant inlet of the refrigerant direct cooling plate through the electronic expansion valve.

[0013] Preferably, the bonding pressure application device includes a pressure equalizing plate, a rigid base, a pressure sensor, and several adjustable pressure application units. The rigid base has a placement area for the refrigerant direct cooling plate, and all adjustable pressure application units are evenly distributed along the edge of this placement area. Each adjustable pressure application unit includes a bolt, an adjusting nut, and a spring. The bottom of the bolt is fixedly connected to the rigid base, and the top of the bolt passes through the pressure equalizing plate and the spring in sequence, forming a detachable threaded transmission pair with the adjusting nut. By rotating the adjusting nut to compress the spring, point pressure is applied to the pressure equalizing plate. The pressure equalizing plate is positioned above the refrigerant direct cooling plate and the contact-type simulated heat source, used to convert the point pressure of all adjustable pressure application units into a surface pressure that evenly covers the entire area of ​​the contact-type simulated heat source. The pressure sensor is mounted on the rigid base and connected to the electrical control system, used to collect and feedback the normal pressure applied by the bonding pressure application device to the contact-type simulated heat source and the refrigerant direct cooling plate.

[0014] A performance testing method for direct-cooling plates based on multi-dimensional indicators specifically involves implementing the following steps using the aforementioned performance testing system for direct-cooling plates based on multi-dimensional indicators: S1. Apply thermal conductive gel evenly to the heat exchange plate surface of the refrigerant direct cooling plate, and arrange the heating modules of each zone in a matrix according to the visible module number on the refrigerant direct cooling plate. S2, Place the bonding and pressure device on the test platform in the temperature-controlled test chamber, and use the bonding and pressure device to evenly and tightly bond the heating modules of each zone to the refrigerant direct cooling plate to form a contact interface with constant contact thermal resistance. S3 connects the refrigerant-driven control unit with the refrigerant inlet and outlet of the refrigerant direct cooling plate through refrigerant pipelines, forming a closed refrigerant circulation loop; S4 connects the temperature control unit, refrigerant drive control unit, and controllable thermal simulation unit to the electrical control system respectively, and completes the system initialization upon power-up; S5 establishes a multi-dimensional working condition test set through the electrical control system, which includes steady-state performance testing, dynamic performance testing, and safety boundary limit testing. S6 selects and calls a single-dimensional operating condition test through the electrical control system. After configuring the operating condition simulation parameters according to the requirements, it starts the current dimension operating condition test and simultaneously performs the collection of basic index parameters. Among them, the operating condition simulation parameters include ambient temperature parameters, refrigerant condition parameters, and thermal simulation parameters. S7 performs preprocessing on the collected basic parameters of the indicators, including filtering and time alignment, and calculates the performance indicators under the current working condition test based on the preprocessed basic parameters of the indicators. S8, determine whether all dimensions of the multi-dimensional working condition test set have been completed; if yes, integrate the basic parameters of the multi-dimensional indicators and the multi-dimensional performance indicators obtained after the multi-dimensional working condition test, and proceed to S9; if no, return to S6 to switch to the next dimension of working condition test. S9 uses multi-dimensional indicator parameters and multi-dimensional performance indicators to draw performance graphs and generate a performance test report that includes the performance graphs.

[0015] Preferably, in step S6, when the single-dimensional operating condition test invoked is a steady-state performance test, the configuration of the operating condition simulation parameters includes setting the ambient temperature of the temperature-controlled test chamber through the electrical control system. Evaporation temperature of refrigerant-driven control unit and the heat load power of the controllable thermal simulation unit and form the same ambient temperature Below, based on different evaporation temperatures With different heat load power A two-dimensional steady-state operating condition test matrix is ​​constructed; after starting the current dimension operating condition test, all steady-state operating condition tests in the two-dimensional steady-state operating condition test matrix are traversed and completed sequentially.

[0016] Preferably, in step S6, when the single-dimensional operating condition test invoked is a dynamic performance test, the configuration of the operating condition simulation parameters includes input via the electrical control system: the ambient temperature of the temperature-controlled test chamber. Evaporation temperature of refrigerant-driven control unit And the heat generation curve of the heat load step excitation or the actual charge and discharge of the battery pack; after starting the current dimension operating condition test, the evaporation temperature of the fixed refrigerant driven control unit. The opening degree of the electronic expansion valve is used to simulate sudden changes in heat load and the actual dynamic heat generation of the battery pack.

[0017] Preferably, in step S6, when the single-dimensional operating condition test invoked is a safety boundary limit test, the configuration of the operating condition simulation parameters includes setting the ambient temperature of the temperature-controlled test chamber through the electrical control system. Evaporation temperature of refrigerant-driven control unit and the heat load power of the controllable thermal simulation unit After starting the current dimension operating condition test, based on the steady-state performance test, apply a heating drive power exceeding the allowable range to the local partition heating module of the controllable thermal simulation unit to simulate local thermal runaway, or adjust the opening of the electronic expansion valve to introduce refrigerant side disturbance, and test the ultimate heat dissipation capacity and anti-interference of the refrigerant direct cooling plate accordingly.

[0018] Preferably, in step S6, the basic parameters of the multi-dimensional index include: 1) the following parameters in the steady-state performance test: ambient temperature. Evaporation temperature Heat load power , refrigerant inlet temperature Refrigerant inlet pressure Refrigerant outlet temperature Pressure on refrigerant exports Refrigerant mass flow rate Steady-state temperature at each preset measuring point on the surface of the refrigerant direct cooling plate , 1) The total number of preset measurement points; 2) The following parameters in the dynamic performance test: heat load step time, temperature time series data of each preset measurement point on the surface of the refrigerant direct cooling plate, refrigerant outlet superheat time series data, and refrigerant inlet and outlet pressure time series data; 3) The following parameters in the safety boundary limit test: temperature time series data of thermal runaway hotspot, temperature diffusion time series data of thermal runaway hotspot, refrigerant outlet superheat time series data, and temperature time series data of each preset measurement point on the surface of the refrigerant direct cooling plate.

[0019] Preferably, in S7, when the current dimension operating condition test is a steady-state performance test, the performance indicators include the surface temperature index of the refrigerant direct cooling plate and the internal refrigerant flow heat transfer index of the refrigerant direct cooling plate.

[0020] The surface temperature parameters of a refrigerant direct-cooling plate include the average surface temperature. Maximum temperature difference in effective heat exchange zone Temperature distribution standard deviation and average heat exchange temperature difference ;in: ; ； ; ; In the formula, Indicates the preset measurement point number. Indicates the first The steady-state temperature at each preset measurement point.

[0021] The internal refrigerant flow heat transfer parameters of the refrigerant direct cooling plate (2) include refrigerant pressure loss. Pressure drop per unit flow rate Refrigerant export overheating Standard deviation of superheat stability The actual heat dissipation of the refrigerant and refrigerant refrigeration energy efficiency coefficient ;in: ; ; ; ; ; ; In the formula, This indicates the saturation temperature corresponding to the refrigerant outlet pressure; This indicates the number of superheat sampling points. Indicates the sampling sequence number. Indicates the first Secondary superheat sampling value, This represents the arithmetic mean of superheat. Indicates the specific enthalpy of the refrigerant inlet. Indicates the specific enthalpy of refrigerant exports; This indicates the power consumption of the compressor (3) in the refrigerant-driven control unit.

[0022] Preferably, in step S7, when the current dimensional operating condition test is a steady-state performance test, the energy relative error needs to be considered before calculating the performance indicators. Perform energy balance verification; where: relative energy error ;when If the value is within the allowed range, the verification passes; otherwise, the basic parameters of the test index are deemed invalid. This represents the actual heat dissipation of the refrigerant.

[0023] Preferably, in step S7, when the current dimension operating condition test is a dynamic performance test, the performance indicators include response latency time. Stable time Temperature overshoot amplitude and dynamic superheat fluctuation amplitude Response latency This refers to the time interval from the start of the heat load step to the moment when the temperature at the preset measuring point on the surface of the refrigerant direct cooling plate begins to change continuously; stabilization time. This refers to the period from the start of a heat load step change to the temperature at the preset measuring point reaching a new steady-state value. The total time of tolerance band and sustained stability; temperature overshoot amplitude This refers to the peak temperature at the preset measuring point. With the new steady-state temperature The difference; the amplitude of dynamic superheat fluctuation. This refers to the maximum superheat value during a dynamic process. With minimum superheat The difference.

[0024] Preferably, in step S7, when the current dimensional operating condition test is a safety boundary limit test, the performance index includes: the temperature rise rate of the thermal runaway hotspot. Critical suppression power thermal spread rate Overheat recovery time and the maximum amplitude of temperature fluctuation The rate of temperature rise at the thermal runaway hotspot , This represents the temperature change at the hotspot of thermal runaway. Indicates the time increment corresponding to the temperature change; critical suppression power This refers to: the maximum local heating power that a refrigerant direct-cooling plate can use to control the temperature of thermal runaway hotspots within a safe threshold; and the thermal spread rate. This refers to: the geometrical diffusion distance of the temperature rise region in the thermal runaway hotspot per unit time; and the superheat recovery time. This refers to: the time it takes for the refrigerant outlet superheat to return to its stable range after a refrigerant-side disturbance is introduced; the maximum amplitude of temperature fluctuation. It refers to the difference between the maximum temperature difference on the surface of the refrigerant direct cooling plate and the maximum steady-state temperature difference during the refrigerant-side disturbance process.

[0025] The beneficial effects of this invention are: 1) This solution uses a multi-channel zoned heating module with a bonding pressure device to simulate the non-uniform heat generation and local high heat flow conditions of the battery pack, stably control the interface contact thermal resistance, and complete the test without the need for real battery cells, reducing the risk of consumables and thermal runaway.

[0026] 2) The electrical control system incorporates three types of test conditions: basic steady-state matrix, dynamic response, and safety boundary limit behavior, overcoming the limitation of existing equipment that can only perform uniform steady-state tests. The basic steady-state test can obtain the heat transfer data of the cold plate under normal operating conditions; the dynamic response test can collect time-series data to calculate dynamic indicators such as response time and temperature overshoot; the safety limit test can evaluate the heat transfer and disturbance rejection performance of the refrigerant direct-cooling plate itself without introducing other system variables.

[0027] 3) The data acquisition unit includes a thermocouple matrix. Combined with the cold plate flow channel structure and infrared thermal imaging results, it plans the preset measurement point locations, enabling more complete capture of the plate surface temperature distribution and facilitating the identification of areas with uneven liquid distribution and weak heat transfer. Temperature and pressure sensors and mass flow meters are respectively installed at the inlet and outlet of the refrigerant pipeline, and a power sensor is provided on the heat source side. All acquisition channels are sampled synchronously with a unified timestamp, reducing data errors caused by timing deviations and improving the accuracy of raw data acquisition under steady-state, dynamic, and extreme operating conditions.

[0028] 4) The system is equipped with an independent temperature-controlled test chamber to reduce the interference of external ambient temperature fluctuations on test results and to unify the environmental benchmarks for each group of tests. The refrigerant-driven control unit is equipped with a regenerator to optimize the circulation pipeline. The refrigerant completes circulation along a fixed path, which can stably maintain the evaporation temperature and outlet superheat, reduce the impact of heat load changes on the refrigerant's operating state, and form a stable and uniform cooling boundary, making it easy to distinguish the flow and heat transfer characteristics of the refrigerant direct cooling plate itself.

[0029] 5) The central controller incorporates a comprehensive performance index calculation model, addressing the limitations of traditional testing that relies solely on average plate temperature and maximum temperature difference for evaluation. Under steady-state conditions, it calculates plate temperature-related indices, refrigerant flow resistance and heat transfer indices, and system energy efficiency. Under dynamic conditions, it calculates response delay, settling time, and temperature overshoot. Under extreme conditions, it statistically analyzes hotspot temperature rise rate, heat spread rate, and temperature fluctuation amplitude, enabling multi-dimensional quantitative evaluation. Simultaneously, an energy balance verification process is implemented. This process calculates heat transfer using the refrigerant enthalpy difference, compares it with the heat source input power to determine the error, and judges the validity of the data based on the error range. It also investigates data deviations caused by sensors, interface heat leakage, etc., ensuring consistent test data.

[0030] 6) The electrical control system can automate the entire testing process through pre-configuration, reducing continuous manual operation. The central controller incorporates steady-state judgment logic and operating condition scheduling programs, enabling switching between various test conditions, determining thermal steady-state conditions, filtering and timing-aligning raw data, and calculating all performance indicators. After all operating condition tests are completed, it can generate cold plate temperature cloud maps, timing curves, and operating condition correlation curves based on preset measurement point coordinates and temperature data. It integrates operating condition simulation parameters, quantitative indicators, and visual charts to generate standardized reports, facilitating horizontal comparisons of different refrigerant direct-cooling plate solutions. The equipment is equipped with over-temperature, over-pressure, and over-current protection logic, automatically shutting down in case of abnormalities to ensure test safety.

[0031] 7) This technical solution can be used to perform performance testing of refrigerant direct cooling plate components separately before the assembly of battery packs and energy storage cabinets. During the R&D stage, the advantages and disadvantages of structural designs such as flow channels and distributors can be verified in advance, defects can be corrected in advance, the amount of rectification work after the assembly of the whole machine can be reduced, the product development cycle can be shortened, and it has practical engineering value. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of a direct-cooling plate performance testing system based on multi-dimensional indicators; Figure 2 A basic implementation flowchart of a performance testing method for direct-cooled plates based on multi-dimensional indicators; Figure 3 This is a schematic diagram of the static temperature distribution cloud map on the surface of a refrigerant direct cooling plate; Figure 4 This is a schematic diagram illustrating the operating principle of a pressure-applying device.

[0033] In the diagram: 1. Temperature-controlled test chamber; 2. Refrigerant direct cooling plate; 3. Compressor; 4. Condenser; 5. Regenerator; 6. Electronic expansion valve; 7. Mass flow meter; 8. Outlet pressure sensor; 9. Outlet temperature sensor; 10. Inlet pressure sensor; 11. Inlet temperature sensor; 12. Zoned heating module; 13. Battery cell; 14. Test platform; 15. Thermocouple; 16. Pressure sensor; 17. Rigid base; 18. Pressure equalizing plate; 19. Adjustable pressure application unit; 19.1. Bolts; 19.2. Adjusting nuts; 20. Thermal conductive gel; 21. Insulation cotton. Detailed Implementation

[0034] To make the purpose, technical solution and advantages of the invention clearer, the technical solution of the invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the invention, but not all embodiments.

[0035] Therefore, the following detailed description of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0036] Example 1 This embodiment discloses a performance testing system for a direct-cooled plate based on multi-dimensional indicators. As a preferred embodiment of the present invention, a complete performance testing platform 14 for the refrigerant direct-cooled plate 2 is constructed, where the environmental boundary, refrigerant circulation boundary, and heat load boundary are completely independent and controllable. The overall testing system includes a temperature-controlled testing chamber 1, a refrigerant drive and control unit, a controllable thermal simulation unit, and an electrical control system. It can independently complete three types of multi-dimensional performance quantitative tests of the refrigerant direct-cooled plate 2—steady-state heat transfer, dynamic thermal response, and local thermal runaway safety limit—in a laboratory environment without the intervention of a real battery pack. It accurately isolates external system interference and purely characterizes the core performance of the refrigerant direct-cooled plate 2 itself, including phase change heat transfer, flow channel liquid distribution, temperature uniformity, anti-disturbance, and thermal suppression. The structure of the entire testing system is as follows: Figure 1 As shown.

[0037] The temperature-controlled test chamber 1 is equipped with a temperature control unit to provide a temperature-controlled testing environment for the refrigerant direct cooling plate 2. Based on the closed-loop feedback control principle, the temperature control unit maintains the ambient temperature at a set value, effectively eliminating the interference of ambient temperature fluctuations on the heat dissipation capacity, refrigerant properties, heat exchange efficiency, and final test results of the refrigerant direct cooling plate 2. The purpose of setting up the temperature-controlled test chamber 1 is to fix the key variable of ambient temperature, ensuring that all tests are conducted under a unified, stable, and reproducible environmental benchmark. It has the significant advantage of simulating various real-world battery pack usage scenarios, including normal temperature, high temperature, and low temperature. Each test can guarantee that the test results are unaffected by changes in the external environment, improving the accuracy and consistency of the test data.

[0038] The refrigerant-driven control unit is connected to the refrigerant inlet and outlet of the refrigerant direct cooling plate 2 via refrigerant piping, forming an independent and closed refrigerant circulation loop. This loop can set and maintain the refrigerant evaporation temperature, providing a controllable phase change working fluid for the refrigerant direct cooling plate 2. This provides reliable refrigerant circulation boundary conditions for the performance testing of the refrigerant direct cooling plate 2, accurately replicating its actual operating state in the refrigerant direct cooling system. By independently adjusting the evaporation temperature through the refrigerant-driven control unit, unaffected by interference from other branches, the phase change heat transfer performance of the refrigerant direct cooling plate 2 can be purely and accurately characterized, avoiding interference from external system factors. Furthermore, outlet pressure sensor 8, outlet temperature sensor 9, inlet pressure sensor 10, and inlet temperature sensor 11 can be placed adjacent to the refrigerant inlet and outlet to obtain real-time basic parameters such as refrigerant inlet and outlet temperatures and pressures.

[0039] The controllable thermal simulation unit includes a contact-type simulated heat source and a pressure-applying device. The contact-type simulated heat source, serving as the heat carrier for simulating battery pack heat generation, adopts a discrete design approach with electrical insulation, independent addressability, and independent temperature control for each zone. Specifically, it includes several independent zone heating modules 12 arranged in a matrix, each zone heating module 12 bearing a visible module number. The specific number of zone heating modules 12 is flexibly determined based on system-level and component-level testing scenarios, combined with the required thermal simulation accuracy (e.g., 104 zone heating modules 12 are used to simulate the heating of a single battery pack in a component-level testing scenario). Based on this, the zone heating modules 12 are arranged in a matrix on the heat exchange plate surface of the refrigerant direct cooling plate 2 according to their visible module numbers. Simultaneously, the zone heating modules 12 are attached to the heat exchange plate of the refrigerant direct cooling plate 2 via thermally conductive gel 20. By filling the tiny gaps between the zone heating modules 12 and the refrigerant direct cooling plate 2 with thermally conductive gel 20, the contact thermal resistance at the interface between the zone heating modules 12 and the refrigerant direct cooling plate 2 is reduced. The bonding pressure device, as a contact thermal resistance control module, employs a mechanical structure with uniform pressure across the entire area. This device performs standardized and controllable pressing of the zone heating modules 12 and the refrigerant direct cooling plate 2, creating a quantifiable, repeatable, and uniformly distributed normal bonding pressure at the interface. Simultaneously, the thermally conductive gel 20 filling the interface completely eliminates the microscopic air gaps between the zone heating modules 12 and the refrigerant direct cooling plate 2, transforming the originally random and uncontrollable contact thermal resistance into a stable and controllable known fixed boundary condition. This results in a contact interface with constant contact thermal resistance between the zone heating modules 12 and the refrigerant direct cooling plate 2. This standardized pressing ensures consistent interface heat transfer conditions in each test, providing direct comparative value for results from different test batches and meeting the needs of laboratory performance calibration and R&D iteration comparison.

[0040] The electrical control system is connected to the temperature control unit, the refrigerant-driven control unit, and the controllable thermal simulation unit, respectively. It is used to control the temperature control unit, the refrigerant-driven control unit, and the controllable thermal simulation unit to cooperate in completing multi-dimensional operating condition tests. The multi-dimensional operating condition tests refer to: under the set ambient temperature and refrigerant conditions, controlling the controllable thermal simulation unit to complete multi-dimensional operating condition simulations, including steady-state thermal simulation, transient thermal simulation, and local extreme thermal simulation; completing steady-state performance tests on the refrigerant direct cooling plate 2 under steady-state thermal simulation, completing dynamic performance tests on the refrigerant direct cooling plate 2 under transient thermal simulation, and completing safety boundary limit tests under local extreme thermal simulation; integrating the multi-dimensional performance indicators obtained after the multi-dimensional operating condition tests of the refrigerant direct cooling plate 2, generating and displaying the performance test report of the refrigerant direct cooling plate 2. Its operation controls the coordinated work of various functional units according to a preset sequence, collecting basic parameters such as temperature, pressure, flow rate, power, and time in real time, and performing quantitative calculations of performance indicators based on thermodynamic formulas. The aim is to achieve automated, standardized, and unattended operation of the entire testing process, ensuring the synchronization, accuracy, and repeatability of multi-source data, and minimizing errors caused by human operation. The electrical control system boasts advantages such as highly standardized processes, traceable data, and horizontal comparability. It can be directly used for the design iteration verification and batch product selection evaluation of the refrigerant direct-cooling plate 2. It is also equipped with a comprehensive real-time safety monitoring and emergency shutdown protection mechanism, effectively ensuring the safe, stable, and reliable operation of the entire testing process.

[0041] Example 2 This embodiment discloses a performance testing system for a direct-cooled plate based on multi-dimensional indicators. As a preferred implementation of the present invention, based on Embodiment 1, a complete performance testing platform 14 for the refrigerant direct-cooled plate 2 is constructed, where the environmental boundary, refrigerant circulation boundary, and heat load boundary are completely independent and controllable. The overall testing system includes a temperature-controlled testing chamber 1, a refrigerant drive and control unit, a controllable thermal simulation unit, and an electrical control system. It can independently complete three types of multi-dimensional performance quantitative tests of the refrigerant direct-cooled plate 2—steady-state heat transfer, dynamic thermal response, and local thermal runaway safety limit—in a laboratory environment without the intervention of a real battery pack. It accurately isolates external system interference and purely characterizes the core performance of the refrigerant direct-cooled plate 2 itself, including phase change heat transfer, flow channel liquid distribution, temperature uniformity, disturbance resistance, and thermal suppression. The structure of the entire testing system is as follows: Figure 1 As shown.

[0042] The temperature-controlled test chamber 1 is equipped with a temperature control unit to provide a temperature-controlled testing environment for the refrigerant direct cooling plate 2. Based on the closed-loop feedback control principle, the temperature control unit maintains the ambient temperature at a set value, effectively eliminating the interference of ambient temperature fluctuations on the heat dissipation capacity, refrigerant properties, heat exchange efficiency, and final test results of the refrigerant direct cooling plate 2. The purpose of setting up the temperature-controlled test chamber 1 is to fix the key variable of ambient temperature, ensuring that all tests are conducted under a unified, stable, and reproducible environmental benchmark. It has the significant advantage of simulating various real-world battery pack usage scenarios, including normal temperature, high temperature, and low temperature. Each test can guarantee that the test results are unaffected by changes in the external environment, improving the accuracy and consistency of the test data.

[0043] The refrigerant-driven control unit is connected to the refrigerant inlet and outlet of the refrigerant direct cooling plate 2 via refrigerant piping, forming an independent and closed refrigerant circulation loop. This loop can set and maintain the refrigerant evaporation temperature, providing a controllable phase change working fluid for the refrigerant direct cooling plate 2. This provides reliable refrigerant circulation boundary conditions for the performance testing of the refrigerant direct cooling plate 2, accurately replicating its actual operating state in the refrigerant direct cooling system. By independently adjusting the evaporation temperature through the refrigerant-driven control unit, unaffected by interference from other branches, the phase change heat transfer performance of the refrigerant direct cooling plate 2 can be purely and accurately characterized, avoiding interference from external system factors. Furthermore, outlet pressure sensor 8, outlet temperature sensor 9, inlet pressure sensor 10, and inlet temperature sensor 11 can be placed adjacent to the refrigerant inlet and outlet to obtain real-time basic parameters such as refrigerant inlet and outlet temperatures and pressures.

[0044] The controllable thermal simulation unit includes a contact-type simulated heat source and a pressure-applying device. The contact-type simulated heat source, serving as the heat carrier for simulating battery pack heat generation, adopts a discrete design approach with electrical insulation, independent addressability, and independent temperature control for each zone. Specifically, it includes several independent zone heating modules 12 arranged in a matrix, each zone heating module 12 bearing a visible module number. The specific number of zone heating modules 12 is flexibly determined based on system-level and component-level testing scenarios, combined with the required thermal simulation accuracy (e.g., 104 zone heating modules 12 are used to simulate the heating of a single battery pack in a component-level testing scenario). Based on this, the zone heating modules 12 are arranged in a matrix on the heat exchange plate surface of the refrigerant direct cooling plate 2 according to their visible module numbers. Simultaneously, the zone heating modules 12 are attached to the heat exchange plate of the refrigerant direct cooling plate 2 via thermally conductive gel 20. By filling the tiny gaps between the zone heating modules 12 and the refrigerant direct cooling plate 2 with thermally conductive gel 20, the contact thermal resistance at the interface between the zone heating modules 12 and the refrigerant direct cooling plate 2 is reduced. The bonding pressure device, as a contact thermal resistance control module, employs a mechanical structure with uniform pressure across the entire area. This device performs standardized and controllable pressing of the zone heating modules 12 and the refrigerant direct cooling plate 2, creating a quantifiable, repeatable, and uniformly distributed normal bonding pressure at the interface. Simultaneously, the thermally conductive gel 20 filling the interface completely eliminates the microscopic air gaps between the zone heating modules 12 and the refrigerant direct cooling plate 2, transforming the originally random and uncontrollable contact thermal resistance into a stable and controllable known fixed boundary condition. This results in a contact interface with constant contact thermal resistance between the zone heating modules 12 and the refrigerant direct cooling plate 2. This standardized pressing ensures consistent interface heat transfer conditions in each test, providing direct comparative value for results from different test batches and meeting the needs of laboratory performance calibration and R&D iteration comparison.

[0045] The electrical control system is connected to the temperature control unit, the refrigerant-driven control unit, and the controllable thermal simulation unit, respectively. It is used to control the temperature control unit, the refrigerant-driven control unit, and the controllable thermal simulation unit to cooperate in completing multi-dimensional operating condition tests. The multi-dimensional operating condition tests refer to: under the set ambient temperature and refrigerant conditions, controlling the controllable thermal simulation unit to complete multi-dimensional operating condition simulations, including steady-state thermal simulation, transient thermal simulation, and local extreme thermal simulation; completing steady-state performance tests on the refrigerant direct cooling plate 2 under steady-state thermal simulation, completing dynamic performance tests on the refrigerant direct cooling plate 2 under transient thermal simulation, and completing safety boundary limit tests under local extreme thermal simulation; integrating the multi-dimensional performance indicators obtained after the multi-dimensional operating condition tests of the refrigerant direct cooling plate 2, generating and displaying the performance test report of the refrigerant direct cooling plate 2. Its operation controls the coordinated work of various functional units according to a preset sequence, collecting basic parameters such as temperature, pressure, flow rate, power, and time in real time, and performing quantitative calculations of performance indicators based on thermodynamic formulas. The aim is to achieve automated, standardized, and unattended operation of the entire testing process, ensuring the synchronization, accuracy, and repeatability of multi-source data, and minimizing errors caused by human operation. The electrical control system boasts advantages such as highly standardized processes, traceable data, and horizontal comparability. It can be directly used for the design iteration verification and batch product selection evaluation of the refrigerant direct-cooling plate 2. It is also equipped with a comprehensive real-time safety monitoring and emergency shutdown protection mechanism, effectively ensuring the safe, stable, and reliable operation of the entire testing process.

[0046] Example 3 This embodiment discloses a performance testing system for direct-cooling plates based on multi-dimensional indicators. As a preferred implementation of the present invention, based on Embodiment 2, the main control unit binds a unique device address and drive channel ID to each zone heating module 12. Combined with a multi-channel independent addressing matching mechanism, it generates several digital power signals bound to unique device addresses and drive channel IDs. All digital power signals are packaged into a success rate output command and sent to a multi-channel programmable power supply. The multi-channel programmable power supply has several independent output channels, which are connected one-to-one to each zone heating module 12. These channels are used to parse the digital power signals in the power output command, match the drive channel IDs, and output the heating drive power corresponding to each zone heating module 12. Independent closed-loop control of the heating drive power of each module is achieved based on the electrical signals fed back from each output channel.

[0047] The multi-dimensional operating condition test program is an embedded algorithm logic package solidified within the main control unit. It includes steady-state calculation subroutines, transient timing coupling subroutines, and operating condition database scheduling subroutines. It is the core computational layer for the entire system to achieve partitioned differentiated thermal field replication: The steady-state calculation subroutine reads the steady-state total power, spatial power distribution matrix, etc., allocates constant power according to weights, and outputs a constant digital power signal to maintain the constant heating power of each partition heating module 12 over a long period of time, which can be used to simulate the constant rate steady-state charging and discharging of the battery; The transient timing coupling subroutine uses a fixed time slice as the refresh period to synchronously load the dynamic power timing curve and spatial power distribution matrix, and performs frame-by-frame coupling calculation to update the dynamic power of each partition, automatically stripping the heat absorption component of the battery pack's thermal capacity, and can reproduce dynamic thermal shocks such as fast charging, rate switching, and intermittent discharge; The operating condition database scheduling subroutine connects to the retrieval command issued by the human-machine interface, completes the index matching of battery pack model and heating condition type, and realizes the reading, creation, storage, and reuse of historical operating condition parameters.

[0048] The unique device address is a read-only fixed code pre-programmed into the built-in temperature sensing chip and heating drive interface of each zone heating module 12 at the factory. It is globally unique and uniquely identifies each zone heating module 12 one-to-one, without being bound to fixed matrix row and column information. The read-only fixed code is an independent hardware serial number, mapped one-to-one with the visible module number printed on the surface of the zone heating module 12. It does not embed matrix row or column fields and is unaffected by adjustments to the matrix row and column numbers during testing. The visible module number printed on the surface of the zone heating module 12 serves only as a manual physical identifier. After the system powers on, it automatically scans and identifies the unique device addresses of all single-channel zone heating modules 12, and then, based on the actual matrix arrangement configured in this simulation, temporarily establishes a dynamic mapping table of "unique hardware device address - current matrix grid position". The unique device address serves as the underlying identifier for the central control unit to identify each independent heating unit, distinguishing between the various zone heating modules 12 and preventing zone confusion and power mismatch during multi-channel power distribution. Even with the addition or removal of modules or adjustments to the matrix row and column arrangement, the unique device address itself remains unchanged; only the correspondence between the unique device address and the grid position is dynamically updated. After power-on, the zone heating module 12 automatically reports its unique device address to the central control unit. The central control unit automatically scans all drive channel IDs of the multi-channel programmable power supply, establishes a temporary "unique device address - drive channel ID" binding relationship, and completes automatic hardware topology identification without manual pairing.

[0049] The drive channel ID is the logical sequence number of each independent output channel within the multi-channel programmable power supply. It is fixedly assigned by the power supply hardware and sequentially numbered starting from 001. Each drive channel ID corresponds to an electrically isolated independent output channel. The output cable of a single drive channel ID connects only to a single zone heating module 12, and is bound one-to-one with the unique device address of the zone heating module 12, forming a unique mapping link of "unique device address - drive channel ID - zone heating module 12". The power output command issued by the central controller within the main control unit carries the drive channel ID corresponding to each group of digital power signals. The multi-channel programmable power supply only outputs the corresponding voltage and current to the channel matching the drive channel ID; other channels are unaffected. The data acquisition unit synchronously collects the corresponding channel electrical parameters and zone temperature data according to the drive channel ID. The human-machine interface displays the full-domain temperature matrix and power list sorted by ID, facilitating zone fault location and hotspot tracing.

[0050] The multi-path independent addressing matching mechanism is the addressing and scheduling logic of the central control unit to achieve precise power distribution to different zones. It connects the mapping relationship between "unique device address, drive channel ID, and spatial power distribution matrix". The complete process logic is as follows: After the system is powered on, all partition heating modules 12 report their own unique device address. The central controller automatically scans all drive channel IDs of the multi-channel programmable power supply, establishes a global binding mapping table of "unique device address - drive channel ID", and locks the dedicated output channel corresponding to each partition heating module 12.

[0051] Load the spatial power distribution matrix (uniform / non-uniform thermal field weight matrix). The row and column numbers of each grid element in the spatial power distribution matrix correspond one-to-one with the matrix arrangement position and unique device address of the partitioned heating module 12, thus completing the binding of the thermal field spatial weights to the hardware partition position.

[0052] When the heating condition is a steady-state thermal field simulation, the total steady-state heating power is read, and the target constant power for each zone is calculated using the spatial power distribution matrix. The target constant power value is then bound to the unique device address of the heating module 12 for the corresponding zone, and converted to the corresponding drive channel ID through a mapping table, generating a constant digital power signal with the drive channel ID identifier. When the heating condition is a transient thermal field simulation, the instantaneous total power in the dynamic power timing curve is read at fixed time slices. The dynamic power of each zone is calculated frame by frame using the synchronously coupled spatial power distribution matrix. After binding to the unique device address, it is converted to the corresponding drive channel ID, generating a dynamic digital power signal with the drive channel ID identifier.

[0053] All digital power signals with drive channel IDs are integrated and packaged into power output commands, which are then sent to the multi-channel programmable power supply. The multi-channel programmable power supply distributes power to the corresponding output channels according to the drive channel IDs, while simultaneously transmitting the actual electrical parameters of each output channel back in real time.

[0054] This multi-channel independent addressing matching mechanism can achieve completely independent decoupling control of thousands of zone heating modules 12. Any single zone power adjustment will not interfere with the thermal field output of other zones, completely solving the defects of traditional integrated heat source synchronous heating across the entire area and inability to replicate local hot spots of the battery. At the same time, it ensures that the thermal field zone addressing logic is completely consistent in multiple tests, and the test data has horizontal comparability.

[0055] Example 4 This embodiment discloses a performance testing system for a direct-cooling plate based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on Embodiment 2 (i.e., any one of Embodiments 1-3), its zone heating module 12 adopts a flexible heating substrate, such as a PI film heating sheet or a silicone rubber heating sheet, and each zone heating module 12 has a pre-embedded built-in temperature sensor. Based on this, before starting the formal performance test of the refrigerant direct-cooling plate 2, a pre-verification battery pack heating simulation can be performed, i.e.: Step 1: After evenly applying thermal conductive gel 20 to the heat exchange plate surface of the refrigerant direct cooling plate 2, place the contact simulated heat source on the heat exchange plate surface of the refrigerant direct cooling plate 2. Specifically, according to the visible module number on the surface of the zone heating module 12, attach all the zone heating modules 12 to the heat exchange plate surface of the refrigerant direct cooling plate 2 in a matrix arrangement according to the configuration of the simulation.

[0056] Step 2: Apply a preset normal bonding pressure to the contact-type simulated heat source and the refrigerant direct cooling plate 2 using the bonding and pressure application device to form a contact interface with constant (controllable and repeatable) contact thermal resistance. The contact thermal resistance between the zoned heating module 12 and the refrigerant direct cooling plate 2 will change significantly with the bonding and pressure application force. Manual bonding lacks a uniform pressure standard, which will cause the heat exchange and temperature distribution data of the same refrigerant direct cooling plate 2 to be discrete in multiple tests. By applying pressure evenly through the bonding and pressure application device, the degree of contact interface compression can be fixed, and a stable heat transfer channel can be formed with the thermal conductive gel 20. Each test can reproduce a consistent contact interface heat transfer boundary, allowing for a basis for horizontal comparison of test results of different samples and batches.

[0057] Step 3: Based on the thermal simulation requirements for the full-area heat dissipation performance test of the direct-cooling plate, the operator configures the thermal simulation parameters in the main control unit. These parameters include steady-state simulated power data, transient simulated power data, and thermal field distribution data. The steady-state simulated power data can be used to simulate the continuous constant charging and discharging heat generation scenario of the battery pack. The transient simulated power data can be used to reproduce the dynamic heat generation process under fast charging and variable rate operation. The thermal field distribution data can distinguish the heat generation differences in areas such as the center, tabs, and edges of the battery pack. The main control unit has a built-in thermal simulation operating condition database, which can directly retrieve previously saved thermal simulation parameters. There is no need to repeatedly enter all the data; configuration can be completed by fine-tuning the values ​​as needed, reducing repetitive operations.

[0058] Steady-state simulation power data includes the total steady-state heat generation power of the battery pack and the steady-state simulation duration. The total steady-state heat generation power corresponds to the average heat generation level of the battery pack during long-term constant-rate charging and discharging, while the steady-state simulation duration sets the continuous running time of a single steady-state test. This set of parameters is mainly used to conduct calibration tests on the long-term uniform temperature performance and stable heat exchange capacity of the refrigerant direct cooling plate 2, simulating the normal operating conditions of continuous constant-power heat generation of the battery pack.

[0059] The core carrier of transient simulation power data is the dynamic power time-series curve of the battery pack's transient heating. This curve records the equivalent net heat output of the battery pack at different times, used to recreate dynamic scenarios with continuously changing heat generation power, such as fast charging, variable rate operation, and intermittent charging and discharging, to adapt to the transient thermal response and short-term hot-spot impact related performance tests of the refrigerant direct cooling plate 2. The dynamic power time-series curve can be obtained through the following methods: experimental simulation (such as electrochemical-thermal coupling simulation calculation based on existing physics simulation software) or actual measurement and calibration of the battery pack's charging and discharging temperature rise to obtain the instantaneous total heat generation power curve of the battery pack under set operating conditions. Synchronous acquisition of battery pack data over time Real-time temperature changes Combined with the quality of the battery pack Average constant-pressure specific heat capacity of the battery pack The power absorption curve of the battery pack due to its own temperature rise was obtained by differential calculation. The calculation formula is: In the formula This indicates the rate of temperature rise of the battery pack. This represents the heat stored due to the temperature rise of the battery pack itself. This heat is not transferred to the refrigerant direct cooling plate 2; it is only stored inside the battery cells 13 and the casing. If the heating power is directly included, it will cause the simulated heat load to be too large and the thermal response to be lagging. Therefore, a thermal balance difference calculation is performed. According to the law of conservation of heat, the total heat generated by the battery pack is divided into two parts: one part is absorbed by the battery pack body for temperature rise, and the other part is transferred to the refrigerant direct cooling plate 2. Therefore, the difference calculation is used to remove the heat capacity buffer term to obtain the equivalent heat source power curve. The calculation formula is: The equivalent heat source power curve This represents the net heat dissipation that the refrigerant direct cooling plate 2 needs to remove instantly at any given moment, completely eliminating the thermal hysteresis effect caused by the battery's heat capacity. The equivalent heat source power curve is shown below. As a dynamic power timing curve, it is imported into the main control unit to participate in transient coupling calculations, thereby filtering out the self-buffering effect of battery heat capacity and directly reflecting the heat that needs to be dissipated in time by the refrigerant direct cooling plate 2. This dynamic power timing curve is a discrete array with a one-to-one correspondence between time and power. It can be directly coupled and split with the spatial power distribution matrix according to fixed time slices, and the output power of the corresponding output channels of each zone heating module 12 is updated in time-division. This accurately reproduces dynamic thermal shock conditions such as fast charging, rate switching, and intermittent charging and discharging, improving the data authenticity and benchmarking value of transient heat dissipation tests.

[0060] The thermal field distribution data adopts a spatial power distribution matrix corresponding to the matrix arrangement structure of each zone heating module 12. Each element in the spatial power distribution matrix corresponds to the power allocation weight of a single zone heating module 12. There are two construction forms: when simulating a uniform thermal field, the spatial power distribution matrix is ​​a matrix of all ones, and all elements are assigned a value of 1, and the output power of each zone is completely equal; when simulating a non-uniform thermal field, the grid projection average discretization method, the regional block integral discretization method, or the pixel gray quantitative discretization method can be used to discretize the battery pack thermal simulation temperature distribution cloud map output by CFD simulation, and complete the assignment of zone weights. The preferred method is the grid projection average discretization method, which divides the temperature cloud map into grids according to the size of the zoned heating module 12, and normalizes the average temperature of a single grid to generate weights. The regional block integration discretization method divides the battery pack thermal simulation temperature distribution cloud map into regions according to the structure of the cell 13, tabs, and edges, and calculates the equivalent heat generation level of each zone through area integration, weakening single-point temperature errors and highlighting the weights of local hot spots. The pixel grayscale quantitative discretization method converts the battery pack thermal simulation temperature distribution cloud map into a grayscale image, and calculates the weights by statistically analyzing the pixel mean values ​​in blocks. All three discretization methods rely on conventional thermal simulation post-processing tools or general image processing software such as Fluent, STAR-CCM+, and Icepak. The output weight values ​​can be directly imported into the main control unit to form a spatial power distribution matrix, without the need for additional custom virtual algorithms. The discretization process is reproducible, and the weight values ​​are traceable, ensuring consistent thermal field boundaries across multiple tests.

[0061] Step four: The thermal simulation control process is initiated through the main control unit. Based on the multi-dimensional operating condition test program, the configured thermal simulation parameters are analyzed. A multi-channel independent addressing matching mechanism is used to allocate and output the heating drive power corresponding to each zone heating module 12, thereby controlling the independent heating of each zone heating module 12. This involves distinguishing between steady-state and transient control logic. When the heating condition is a steady-state thermal field simulation, the main control unit retrieves the steady-state simulation power data and the spatial power distribution matrix to perform calculations: first, it reads the total steady-state heating power of the battery pack; then, it sums the values ​​of all elements in the spatial power distribution matrix; and finally, it divides the total steady-state heating power by the sum of the elements to obtain the unit power. The unit power is then multiplied by each element in the spatial power distribution matrix to generate a constant digital power signal corresponding to each zone heating module 12. After integrating all the digital power signals, a power output command is sent to the multi-channel programmable power supply. The multi-channel programmable power supply independently analyzes the constant power value for each output channel, enabling each output channel to continuously output stable heating power, thus achieving a uniform or non-uniform (zone-differentiated) steady-state thermal field under long-term constant charging and discharging scenarios of the battery pack.

[0062] When the heating condition is a transient thermal field simulation, the main control unit synchronously calls the spatial power distribution matrix and the dynamic power time-series curve. Using a coupled computation mechanism with fixed-time-slice rolling refresh, it extracts the instantaneous equivalent thermal power value from the dynamic power time-series curve at uniform time intervals. Following the element allocation calculation logic of the spatial power distribution matrix in steady-state thermal field simulation, it divides the instantaneous total power according to the spatial power distribution matrix elements, updating the dynamic digital power signal corresponding to each partition frame by frame. After each frame of numerical calculation is completed, a new power output command is immediately issued to the multi-channel programmable power supply. The output channels of the multi-channel programmable power supply respond to power changes in real time, dynamically adjusting the output voltage and current. Simultaneously, closed-loop control is used to suppress power deviations caused by line losses and resistance drift of the partition heating module 12, thereby reproducing continuously changing thermal shock conditions such as fast charging, variable rate operation, and intermittent charging and discharging.

[0063] Step 5: Under the control of the main control unit, each zone heating module 12 simulates the uniform or non-uniform heating conditions of the battery pack under steady-state or transient conditions on the heat exchange plate surface of the refrigerant direct cooling plate 2 (including steady-state heating conditions such as uniform heating across the entire area and concentrated high heat in local areas, as well as transient dynamic heating conditions with continuously changing power), matching the thermal simulation requirements of the direct cooling plate's overall heat dissipation performance test. Furthermore, the built-in temperature sensors of each zone heating module 12 continuously collect the surface temperature of the zones, the pressure sensor 16 on the rigid base 17 monitors the feedback interface clamping force (normal contact pressure), and the multi-channel programmable power supply synchronously feeds back the output electrical parameters of each channel. All measured data are synchronously uploaded to the main control unit for storage. Operators can intuitively view the overall temperature gradient, hot spot locations, and regional temperature differences of the contact-simulated heat source through the human-machine interface to determine whether the heating characteristics match those of the actual battery pack.

[0064] The entire method is designed around two core objectives: unified heat transfer boundary and accurate replication of battery pack heat generation. All control logic and assembly operations are based on measurable and calibrable physical parameters. Ordinary laboratory operators can complete standardized tests by following the steps, effectively reducing human error and improving the repeatability and reliability of the heat dissipation performance test data of the refrigerant direct cooling plate 2.

[0065] Example 5 This embodiment discloses a performance testing system for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 2 to 4, its data acquisition unit includes a thermocouple matrix and a refrigerant parameter acquisition unit, etc. All channels of the data acquisition unit adopt a synchronous sampling mode and have their own timestamps to ensure that the time of multi-source data such as temperature, pressure, flow rate, and power is completely aligned.

[0066] The thermocouple matrix can employ several patch-type thermocouples 15, deployed according to an intelligent placement strategy that integrates the structural design of the refrigerant direct cooling plate 2 with measured thermal characteristics. Priority is given to covering key areas such as the inlet of the refrigerant direct cooling plate 2 distributor, the core heat exchange area of ​​the parallel flow channel, the heat conduction area between flow channels, the outlet area of ​​the manifold, and the geometric symmetry axis. The placement is optimized in conjunction with high-temperature areas and high-temperature gradient areas identified by infrared thermal imaging, achieving coverage of the most critical temperature characteristic areas with the fewest preset measurement points under the constraint of a limited number of sensors. Thermocouples 15 are fixed using high-temperature resistant tape, and thermally conductive gel 20 is applied to the measuring end face to reduce contact thermal resistance, ensuring high-fidelity acquisition of the surface temperature field of the refrigerant direct cooling plate 2.

[0067] The refrigerant parameter acquisition unit includes a mass flow meter 7, an outlet pressure sensor 8, an outlet temperature sensor 9, an inlet pressure sensor 10, and an inlet temperature sensor 11. All sensors are installed close to the refrigerant inlet and outlet refrigerant pipelines of the refrigerant direct cooling plate 2 to minimize measurement errors caused by heat exchange and pressure drop in the refrigerant pipelines. It can accurately acquire key phase change state parameters such as refrigerant mass flow rate, refrigerant inlet temperature, refrigerant inlet pressure, refrigerant outlet temperature, and refrigerant outlet pressure in real time.

[0068] This data acquisition unit operates based on the principles of synchronous acquisition of multi-source information, accurate capture of full-field features, and real-time mapping of thermodynamic states. It converts the surface temperature distribution of the refrigerant direct cooling plate 2, the two-phase flow state of the refrigerant, the input power of the heat load, and environmental boundary conditions into quantifiable electrical signals, which are then synchronously uploaded to the main control unit for filtering, calibration, and calculation. Its core purpose is to provide high-precision, highly synchronous, and highly reliable raw data for three major categories of tests: steady-state performance, dynamic response, and safety boundary, ensuring that the calculation results of core performance indicators such as maximum temperature difference, superheat, pressure loss, heat dissipation, response time, and critical suppression power are true and reliable.

[0069] Furthermore, the intelligent placement strategy that integrates the refrigerant direct cooling plate 2 structural design with measured thermal characteristics is as follows: First, before the actual installation and testing of the refrigerant direct cooling plate 2, based on the design drawings, flow channel layout, layered structure and phase change heat transfer mechanism of the refrigerant direct cooling plate 2, the structural key areas that determine the temperature field shape and heat transfer performance are predefined, including the distributor and refrigerant inlet area where refrigerant distribution begins, the core heat transfer area of ​​the parallel flow channel with the highest heat transfer intensity, the heat conduction area of ​​the inter-flow channel fins that undertake the function of temperature equalization, the manifold and refrigerant outlet area that reflects the final state of phase change, and the geometric symmetry axis area of ​​the refrigerant direct cooling plate 2 used for symmetry verification. These key areas are then converted into a three-dimensional spatial coordinate range on the surface of the refrigerant direct cooling plate 2, forming a mandatory set of key point candidates. This ensures that the thermocouple 15 can cover all structurally sensitive areas and performance core areas, avoiding the omission of key temperature field information from the design mechanism level.

[0070] The distributor and refrigerant inlet area: This area is the initial distribution and phase change start-up control zone after the refrigerant enters the refrigerant direct cooling plate 2. The flow channel geometry is complex and the fluid hydraulic characteristics are sensitive. It is easy for the refrigerant flow distribution in each parallel flow channel to be uneven due to the design deviation of the distributor structure and the manufacturing error. This can lead to problems such as local flow channel drying, sudden drop in heat exchange efficiency, and local overheating. It needs to be regarded as a first-level forced critical area to monitor the difference between the initial temperature of the refrigerant and the temperature at the flow channel inlet, and to invert the uniformity of the flow distribution.

[0071] Parallel flow channel core heat exchange region: This region is the main reaction zone for phase change heat exchange of the refrigerant direct cooling plate 2. It occupies the largest heat exchange area of ​​the refrigerant direct cooling plate 2. The heat transfer and phase change process is the most intense. The temperature distribution directly reflects the core heat exchange capacity of the refrigerant direct cooling plate 2. It also includes locations of thermal abrupt changes such as flow channel branches and cross-sectional changes. It needs to be regarded as a secondary core key region to characterize the overall temperature field morphology of the refrigerant direct cooling plate 2 and evaluate the heat exchange intensity.

[0072] Heat conduction area between flow channels: This area is a solid heat conduction structure between the internal flow channels of the refrigerant direct cooling plate 2. It undertakes the functions of heat transfer and temperature equalization compensation between flow channels. Its heat conduction efficiency and structural integrity directly determine the overall temperature uniformity of the refrigerant direct cooling plate 2. It is a key area for judging the interlayer bonding and brazing quality of the refrigerant direct cooling plate 2. It needs to be regarded as a third-level key area for monitoring the temperature gradient between flow channels and evaluating the temperature uniformity performance.

[0073] Manifold and refrigerant outlet area: This area is where the refrigerant collects and flows out after completing phase change and heat transfer. It can directly reflect the degree of phase change completion and outlet superheat of the refrigerant. It is the core location for calculating the overall heat transfer of the refrigerant direct cooling plate 2 and evaluating the integrity of heat transfer. It should be regarded as a level 4 critical area for comparing the inlet and outlet temperature difference and calculating heat transfer performance indicators.

[0074] Cold plate geometric symmetry axis region: This region is the reference line for the symmetry of the refrigerant direct cooling plate 2 structure, the symmetry of heat flow loading, and the symmetry of refrigerant distribution. Under ideal working conditions, the temperature field is symmetrically distributed. In actual testing, the temperature data in this region can be used to judge problems such as processing deviation, uneven heat loading, and unbalanced flow distribution. It needs to be used as a key reference area for temperature field symmetry verification and anomaly tracing.

[0075] Secondly, after the refrigerant direct cooling plate 2 completes system installation, interface construction, initial calibration, and enters typical steady-state operating conditions to achieve thermal stability, a high-precision infrared thermal imager is used to perform a full-area non-contact scan at a vertical position directly above the refrigerant direct cooling plate 2 to obtain a complete surface temperature field thermal image. Through pixel-level coordinate mapping and temperature calibration, the image pixel coordinates are converted into the physical space coordinates of the refrigerant direct cooling plate 2. Temperature values ​​are extracted point by point, and thermal features such as temperature peak points, valley points, gradient abrupt change points, and high and low temperature zones are identified and marked. At the same time, false feature points and invalid data generated by environmental radiation, instrument noise, etc. are eliminated. Finally, a candidate set of measured thermal feature points that can truly reflect the actual heat transfer characteristics and temperature distribution law of the refrigerant direct cooling plate 2 is formed, providing measured data support for subsequent multi-source information fusion.

[0076] Furthermore, the structural key regions and the measured thermal characteristic regions are uniformly mapped to the two-dimensional plane coordinate system on the surface of the refrigerant direct cooling plate 2 to achieve spatial alignment. A two-dimensional comprehensive information weight distribution map of the entire refrigerant direct cooling plate 2 is generated according to the assignment rule of the highest weight of the overlapping region, the second highest weight of the structural key region, the higher weight of the measured thermal characteristic region, and the low weight of the smooth region. An optimized placement mathematical model is constructed with a fixed number of thermocouples 15 as a constraint, the core objective of maximizing the total weight of the 15 thermocouple points as a core objective, and the minimum spacing between points and the effective boundary as constraints. A genetic algorithm is used for population initialization, binary encoding, selection, crossover, mutation, and iterative evolution. A penalty mechanism is used to eliminate clustered and invalid schemes. When the iteration error is less than a set threshold, the optimal placement coordinate set is output, realizing the optimal configuration of a limited number of sensors in high information value regions.

[0077] Finally, the optimal set of point coordinates obtained by the algorithm convergence is subjected to mandatory point location verification and spatial distribution verification to ensure that it completely includes key points such as the distributor inlet, core heat exchange zone, and outlet manifold, and that there is no local clustering, no boundary exceedance, and no area omission. After double verification, the planar coordinates of each thermocouple 15 are converted into the three-dimensional spatial coordinates of the refrigerant direct cooling plate 2. A unique number is assigned to each thermocouple 15 and the coordinates are bound. Finally, the physical layout of the thermocouple matrix is ​​completed according to the optimization scheme, and the total number of thermocouples 15 and the precise spatial position of each preset measuring point are determined, providing high-precision and highly representative measured data for subsequent steady-state testing, parameter calibration, and temperature field inversion.

[0078] Compared with traditional random sampling, distributed acquisition, and asynchronous recording methods, the data acquisition unit defined in this embodiment has significant advantages such as scientific and efficient sampling, high temperature resolution, accurate status acquisition, good multi-channel synchronization, and strong long-term stability. It can accurately reflect the temperature uniformity, flow uniformity, and phase change heat transfer characteristics of the refrigerant direct cooling plate 2, and provide complete data support for performance diagnosis, problem tracing, and design optimization. At the same time, it is highly compatible with intelligent sampling algorithms and thermodynamic index calculation models, which greatly improves testing efficiency, data accuracy, and evaluation credibility, enabling the precise component-level evaluation of the refrigerant direct cooling plate 2 to be truly realized.

[0079] Example 6 This embodiment discloses a performance testing system for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any of embodiments 1 to 5, the temperature control unit includes a temperature control module and an ambient temperature sensor. The temperature control module adopts a composite temperature control configuration of variable frequency refrigeration and electric heating, and is connected to the electrical control system to execute the environmental temperature control commands of the electrical control system. A high and low temperature test chamber, a walk-in environmental chamber, or an industrial constant temperature air conditioner can be flexibly selected according to the size of the test object and the test requirements. The ambient temperature sensor is connected to both the temperature control module and the electrical control system, and is evenly distributed in key positions inside the test chamber. It is used to collect and feedback the ambient temperature in the controllable temperature test chamber 1 in real time, working with the temperature control module to complete the ambient temperature regulation, and working with the electrical control system to achieve ambient temperature monitoring.

[0080] This temperature control unit operates based on the closed-loop feedback control principle. The ambient temperature sensor continuously compares the real-time temperature with the set target temperature. The temperature control module automatically adjusts the cooling and heating power according to the deviation, quickly offsetting environmental fluctuations and strictly stabilizing the test space temperature at the set value. This completely eliminates the interference of ambient temperature changes on the heat dissipation capacity, refrigerant physical parameters, heat exchange efficiency, and test data accuracy of the refrigerant direct cooling plate 2. Its core purpose is to fix the key boundary variable of ambient temperature, ensuring that all test conditions are performed under a unified, stable, and repeatable environmental benchmark, providing a consistent and reliable environmental premise for steady-state performance testing, dynamic response testing, and extreme safety testing.

[0081] Compared with traditional open or simple temperature-controlled environments, the temperature control unit defined in this embodiment has significant advantages such as clear environmental boundaries, high temperature control accuracy, strong adaptability, and good stability. It can achieve an environmental temperature control accuracy of ±0.5℃ in the controllable temperature test chamber 1, meeting the testing requirements of the refrigerant direct cooling plate 2 under different environmental conditions such as normal temperature, high temperature, and low temperature. It fully covers various environmental scenarios of real battery pack operation, and the testing process is not affected by external environmental interference, greatly improving the consistency, reliability, and reproducibility of test results, and providing a solid environmental guarantee for the accurate performance evaluation of the refrigerant direct cooling plate 2.

[0082] Example 7 This embodiment discloses a performance testing system for direct-cooling plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 1 to 6, the refrigerant-driven control unit includes a compressor 3, a condenser 4, a regenerator 5, and an electronic expansion valve 6. The refrigerant pipelines are connected sequentially according to the actual circulation direction of the refrigerant to form a complete closed phase change refrigeration circuit. Specifically, the refrigerant outlet of the refrigerant direct-cooling plate 2 is connected to the high-temperature inlet of the regenerator 5; the high-temperature outlet of the regenerator 5 is sequentially connected to the compressor 3 and the condenser 4, and then connected back to the low-temperature inlet of the regenerator 5; the low-temperature outlet of the regenerator 5 is finally connected to the refrigerant inlet of the refrigerant direct-cooling plate 2 through the electronic expansion valve 6, forming an independent, closed, and precisely controllable refrigerant circulation path.

[0083] In this circuit, the electronic expansion valve 6 adopts a dynamic response throttling component, which, together with the frequency conversion regulation of the compressor 3, can quickly stabilize the refrigerant evaporation pressure and evaporation temperature. The regenerator 5 is used to recover the refrigerant's cooling capacity, improve system energy efficiency, and stabilize the refrigerant outlet superheat. When the refrigerant-driven control unit is running, it can maintain the evaporation temperature control accuracy within ±0.5℃ and stabilize the refrigerant outlet superheat within the ideal range of 1-5K. At the same time, temperature sensors and pressure sensors 16 are arranged close to the refrigerant inlet and refrigerant outlet of the refrigerant direct cooling plate 2 to obtain refrigerant status parameters in real time.

[0084] The refrigerant-driven control unit adjusts the compressor speed 3 and the opening of the electronic expansion valve 6 through closed-loop control logic to achieve precise maintenance of evaporation temperature, flow rate, and superheat. This ensures uniform two-phase flow distribution and stable phase change process inside the refrigerant direct cooling plate 2, truly replicating the cooling boundary conditions of the vehicle / energy storage direct cooling system. Its core purpose is to provide the refrigerant direct cooling plate 2 with an independent, standard, and accurately reproducible refrigerant phase change working environment, avoiding interference from other branch loads and control strategies on the test results.

[0085] Example 8 This embodiment discloses a performance testing system for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, it is based on any one of embodiments 1-7, such as... Figure 4 As shown, its pressure application device includes a pressure equalizing plate 18, a rigid base 17, a pressure sensor 16, and several adjustable pressure application units 19. The specific number of adjustable pressure application units 19 is determined according to the area of ​​the contact-type simulated heat source to be covered, so as to ensure that the pressure can be uniform even for large-size refrigerant direct cooling plates 2. For example, small refrigerant direct cooling plates 2 can be pressurized at 4 points, and large refrigerant direct cooling plates 2 can be pressurized at 6, 8 or 12 points.

[0086] The rigid base 17 serves as the load-bearing base for the entire pressure-applying device. It can be made of high-flatness rigid metal sheet, which is not easily deformed under pressure. It can provide a flat support surface for the refrigerant direct cooling plate 2 above, preventing the bottom of the refrigerant direct cooling plate 2 from being suspended and sinking under pressure during pressurization. This ensures that the pressure only acts on the contact surface between the contact-type simulated heat source and the refrigerant direct cooling plate 2, without causing structural deformation of the refrigerant direct cooling plate 2. This fundamentally avoids local gaps, poor contact, and sudden changes in contact thermal resistance between the refrigerant direct cooling plate 2 and the various zone heating modules 12 due to deformation of the refrigerant direct cooling plate 2. The rigid base 17 is provided with a placement area for the refrigerant direct cooling plate 2. All adjustable pressure-applying units 19 are evenly distributed along the edge of this placement area to ensure uniform application of the clamping force and avoid unilateral clamping and local pressure concentration.

[0087] The adjustable pressure unit 19 is an actuator that fits into the pressure application device to achieve adjustable, controllable, and lockable normal pressure. It adopts a purely mechanical threaded transmission scheme and features simple structure, high precision, high reliability, low cost, and convenient maintenance. It is suitable for long-term, high-frequency testing in the laboratory. The adjustable pressure unit 19 includes a bolt 19.1, an adjusting nut 19.2, and a known stiffness coefficient. The bottom of the bolt 19.1 is fixedly connected to the rigid base 17, and the top of the bolt 19.1 extends vertically upward. Its screw passes vertically through the upper pressure equalizing plate 18 and the spring in sequence. Small gaps are reserved between the screw and the through hole of the pressure equalizing plate 18 and between the screw and the spring to ensure that the spring can be compressed smoothly and that the pressure equalizing plate 18 can float freely up and down without jamming or eccentric load. This ensures that the pressure is transmitted vertically downward and does not generate lateral force. The adjusting nut 19.2 can be a high-tightness nut, and can be equipped with anti-slip teeth, anti-loosening washers, or a double-nut locking structure. A handwheel or socket interface can be added to the outer ring for easy manual / tool ​​adjustment. The adjusting nut 19.2 is positioned above the spring component and matches the external thread of the bolt 19.1, forming a detachable threaded transmission pair with the bolt 19.1. More specifically, the adjusting nut 19.2, the spring component, and the pressure equalizing plate 18 form a top-down axial force transmission path. The pressure applied by the downward movement of the adjusting nut 19.2 is elastically transmitted to the pressure equalizing plate 18 through the spring component, allowing the pressure to be transmitted through the spring compression. Precise calibration. Furthermore, the spring components can be high-precision, linear, and low-hysteresis cylindrical helical compression springs; all adjustable pressure units 19 use spring components of the exact same specifications; the spring stroke meets the pressure adjustment range, and under pressure, it does not coil out or become unstable. According to Hooke's Law, the normal pressure output by a single adjustable pressure unit 19... Since all spring components are of identical specifications, the spring compression of all adjustable pressure units 19 will be... If they are consistent, then the normal pressure output by all adjustable pressure units 19 will be consistent. They are exactly the same. The multi-point input forces on the equalizing plate 18 are completely equal, and the pressure of the contact simulated heat source and the refrigerant direct cooling plate 2 is uniform and consistent throughout the entire area.

[0088] The equalizing plate 18 is positioned above the refrigerant direct cooling plate 2 and the contact-type simulated heat source. It converts the point pressure of all adjustable pressure units 19 into a uniform surface pressure covering the entire area of ​​the contact-type simulated heat source. Each adjustable pressure unit 19 operates independently. A single adjustable pressure unit 19 applies pressure at a point, which can lead to pressure concentration, localized overheating, and uneven adhesion. By detachably covering the equalizing plate 18 above the overall contact-type simulated heat source and simultaneously coordinating multiple adjustable pressure units 19 on the equalizing plate 18, multiple point pressures can be converted into continuous, uniform surface pressure. All adjustable pressure units 19 have bolts 19.1 of consistent length, thread specifications, and adjusting nuts 19.2 with consistent torque control. A symmetrical, step-by-step adjustment method can be used: first pre-tighten diagonally, then evenly tighten around the perimeter. This avoids excessive pressure on one side at a time, which could cause the equalizing plate 18 to tilt or jam, ultimately ensuring that the pressure at all points is uniform, achieving isobaric pressure across the entire area. Based on this, the operator can individually adjust the feed amount of some adjusting nuts 19.2 to correct minor assembly deviations, ensure uniform downward pressure stroke at all points on the bottom surface of the pressure equalizing plate 18, and make the normal bonding pressure between all zone heating modules 12 and refrigerant direct cooling plate 2 tend to be consistent, achieving full-area equal pressure bonding, and ensuring no pressure attenuation / deviation throughout the testing process, eliminating the pressure dispersion problem caused by manual pressing and single-point pressure application.

[0089] Pressure sensor 16 is mounted on the rigid base 17 in the placement area of ​​the refrigerant direct cooling plate 2 and connected to the electrical control system. It is used to collect and feedback the normal pressure applied by the bonding pressure device to the contact simulated heat source and the refrigerant direct cooling plate 2. This normal pressure is equivalent to the normal bonding pressure. This achieves the following: transforming the manually adjusted, fuzzy pressure into a precise, digitally displayable, recordable, and reproducible pressure value; real-time monitoring of the pressure throughout the test process to prevent contact thermal resistance drift caused by loosening, attenuation, or offset; providing real-time pressure feedback to the electrical control system for subsequent contact thermal resistance calculation and automatic power compensation; and ensuring completely consistent interface conditions for each test, improving data repeatability and comparability. Furthermore, ultra-thin film or distributed pressure sensors 16 can be used to avoid affecting interface flatness and heat transfer. Depending on the size of the refrigerant direct cooling plate 2, a single-point central arrangement or a multi-point symmetrical arrangement can be selected to accurately collect the true normal bonding pressure across the entire interface between the contact simulated heat source, the thermally conductive gel 20, and the refrigerant direct cooling plate 2. Based on this, pressure monitoring and safety protection programs can be built into the electrical control system as needed. During the entire process of pressurization, stabilization and testing, alarms and protections will be provided for pressure abnormalities. At the same time, the pressure data will be used as the core feedback quantity to retrieve the pre-stored pressure-thermal resistance calibration curve to calculate the current contact thermal resistance. This will enable automatic compensation and correction of the output power of the zone heating module 12, ultimately making the interface pressure quantifiable, monitorable, traceable and closed-loop controllable. This will significantly improve the repeatability, stability and thermal simulation fidelity of the test, and ensure that the data from multiple tests and different samples are comparable.

[0090] Example 9 This embodiment discloses a performance testing method for direct-cooling plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, a performance testing system for direct-cooling plates based on multi-dimensional indicators of this technical solution is adopted, such as... Figure 2 As shown, it includes the following steps: S1, uniformly and quantitatively coat the heat exchange surface of the refrigerant direct cooling plate 2 with a specified thickness of thermally conductive gel 20 to eliminate micro-gaps on the contact surface and reduce contact thermal resistance; arrange the heating modules 12 of each zone in a matrix according to the visible module number on the refrigerant direct cooling plate 2.

[0091] S2, the bonding pressure device is placed on the test platform 14 in the temperature-controlled test chamber 1. The bonding pressure device is used to uniformly and tightly bond each zone heating module 12 with the refrigerant direct cooling plate 2. The normal bonding pressure is adjusted and recorded to stabilize the interface contact thermal resistance within the preset calibrable range, forming a low thermal resistance coupling interface with consistent and repeatable heat transfer, ensuring that the heat input boundary conditions are exactly the same for each test.

[0092] S3 uses a dedicated refrigerant pipeline to seal and prevent leakage between the output end of the refrigerant drive control unit and the refrigerant inlet of the refrigerant direct cooling plate 2, ensuring that there are no air bubbles or abnormal pressure drop in the pipeline, forming a closed refrigerant circulation loop that is sealed, stable, and independently adjustable. This provides a stable flow path for refrigerant phase change heat transfer and avoids flow fluctuations, abnormal pressure, and test failures caused by loose connections or leaks.

[0093] S4 connects the temperature control unit, refrigerant drive control unit, and controllable thermal simulation unit to the electrical control system to complete hardware wiring checks, insulation checks, and channel verification. Then, the system is started for initialization, and all data acquisition components such as temperature sensors, pressure sensors, mass flow meters 7, and power sensors are zero-point calibrated and range verified to ensure that all signals are accurate, drift-free, and interference-free.

[0094] S5 establishes a multi-dimensional operating condition test set through the electrical control system, which includes steady-state performance testing, dynamic performance testing, and safety boundary limit testing. It sets input ports for operating condition parameters such as ambient temperature, evaporation temperature, heat load power, step amplitude, thermal runaway zone power, and disturbance amplitude, forming a comprehensive and logically clear test task.

[0095] S6 selects and calls a single-dimensional operating condition test through the electrical control system. After configuring the operating condition simulation parameters according to the requirements, it starts the current dimension operating condition test and simultaneously performs the collection of basic index parameters. Among them, the operating condition simulation parameters include ambient temperature parameters, refrigerant condition parameters, and thermal simulation parameters.

[0096] S7 performs preprocessing on the collected raw data, including digital filtering, outlier removal, and time axis alignment, to eliminate noise interference and timing deviations. Then, based on thermodynamic formulas, phase change heat transfer models, and index calculation models, it automatically calculates the temperature uniformity index, flow resistance index, superheat index, dynamic response index, and safety boundary index under the operating condition, ensuring that the results are true and reliable.

[0097] S8: Determine whether all dimensions of the multi-dimensional working condition test set have been completed. If yes, integrate the basic parameters of the multi-dimensional indicators and the multi-dimensional performance indicators obtained after the multi-dimensional working condition test, and proceed to S9. If no, return to S6 to switch to the next dimension of working condition test.

[0098] S9 uses multi-dimensional indicator parameters and multi-dimensional performance indicators to draw performance graphs and generate a performance test report that includes the performance graphs.

[0099] Example 10 This embodiment discloses a performance testing method for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on embodiment 9, in S6, when the single-dimensional operating condition test called is a steady-state performance test, the configuration of the operating condition simulation parameters includes setting the ambient temperature of the controllable temperature test chamber 1 through the electrical control system. Evaporation temperature of refrigerant-driven control unit and the heat load power of the controllable thermal simulation unit and form the same ambient temperature Below, based on different evaporation temperatures With different heat load power A two-dimensional steady-state operating condition test matrix is ​​constructed; after starting the current dimension operating condition test, all steady-state operating condition tests in the two-dimensional steady-state operating condition test matrix are traversed and completed sequentially.

[0100] Among them, the ambient temperature of the temperature-controlled test chamber 1 Depending on the testing requirements, the settings are not limited to 25℃ or 45℃. Typical values ​​include 10℃. Evaporation temperature of refrigerant-driven chiller units. Typical values ​​such as 10℃, 15℃, 20℃, and 25℃ can be selected, and the temperature is stabilized in a closed loop by compressor 3 and electronic expansion valve 6. The heat load power of the controllable thermal simulation unit... Covering battery pack rated power to peak power, such as 500W, 1000W, 1500W, 2000W, etc. Based on this, the system enters each group sequentially. After the operating condition is reached, the refrigerant-driven control unit stabilizes the saturation temperature corresponding to the refrigerant evaporation pressure at the refrigerant inlet of the refrigerant direct cooling plate 2 at the target temperature. The controllable thermal simulation unit outputs constant power. A stable heat flow input is established, and the data acquisition unit simultaneously collects ambient temperature, refrigerant inlet and outlet temperatures and pressures, flow rate, temperatures at multiple preset measurement points on the cold plate surface, and actual power of the heat source. After meeting the steady-state criteria, data from the stable period is recorded for index calculation. Its principle lies in fixing the environmental boundary through high-precision temperature control, eliminating the influence of ambient temperature on heat dissipation, refrigerant properties, and heat transfer coefficient, ensuring repeatable testing and comparable results. Simultaneously, the evaporation temperature is used as the basis for... A phase change cooling benchmark is established, the interference of system control strategy is removed, and the heat exchange and temperature uniformity performance of the refrigerant direct cooling plate 2 is purely characterized. The equivalent simulation of heat load is achieved by using a contact-type simulated heat source, so that heat is unidirectionally transferred to the refrigerant direct cooling plate 2 through a low thermal resistance coupling interface, making the thermal excitation quantifiable and reproducible.

[0101] Dynamic stability observation: During the test, a brief flow fluctuation caused by the adjustment of the refrigerant unit was captured. The refrigerant outlet temperature of the refrigerant direct cooling plate 2 fluctuated slightly, but the maximum temperature difference inside the plate was always controlled within 1.5℃, indicating that the refrigerant direct cooling plate 2 has good liquid distribution uniformity and strong anti-disturbance ability.

[0102] This embodiment fully replicates the component-level, standardized, and multi-dimensional testing process of the present invention. Without using a real battery pack, it accurately obtains core performance indicators such as steady-state heat transfer, temperature uniformity, flow resistance, and operational stability of the refrigerant direct cooling plate 2. The test results can be directly used for design verification, scheme selection, and quality certification. This embodiment fully demonstrates that the present invention can effectively isolate system interference and achieve independent, accurate, and repeatable quantitative evaluation of the performance of the refrigerant direct cooling plate 2, providing reliable component-level testing support for the research and development iteration and engineering implementation of refrigerant direct cooling technology.

[0103] Example 11 This embodiment discloses a performance testing method for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 9-10, in step S6, when the single-dimensional operating condition test called is a dynamic performance test, the configured operating condition simulation parameters include the ambient temperature of the temperature-controlled test chamber 1, input through the electrical control system. Evaporation temperature of refrigerant-driven control unit And the heat generation curve of the heat load step excitation or the actual charge and discharge of the battery pack; after starting the current dimension operating condition test, the evaporation temperature of the fixed refrigerant driven control unit. The opening degree of the electronic expansion valve 6 simulates sudden changes in heat load and the actual dynamic heat generation of the battery. The heat load step excitation can be achieved through... Internally, power will be transferred from low heat load. Rapid step transition to high heat load For example, from 500W to 1500W, the actual charge / discharge heat generation curve is imported into the battery pack's standard charge / discharge power timing script, with the minimum time resolution. The cooling side maintains a constant evaporation temperature and electronic expansion valve 6 opening throughout the entire process, without actively adjusting based on temperature feedback. During testing, the system first operates under low heat load until a steady-state baseline is established. The electrical control system then issues step or timing curve commands and simultaneously marks the zero point of time. The data acquisition unit records timing data at a high sampling frequency, including heat load, preset measuring point temperature of the cold plate, refrigerant superheat, and inlet / outlet pressure, and then extracts the response delay time. Stable time Indicators such as temperature overshoot amplitude and dynamic superheat fluctuation amplitude are measured. The principle is to use a unidirectional thermal disturbance input method, changing only the heat load while keeping the cooling side constant, thus exposing the thermal inertia of the refrigerant direct cooling plate 2 independently. This avoids the system's dynamic adjustment masking the characteristics of the refrigerant direct cooling plate 2. Simultaneously, relying on the timing synchronization principle, the command and data acquisition are aligned to ensure accurate indicator extraction. Furthermore, through the thermal inertia characterization principle, the response speed, steady-state recovery capability, and robustness of the refrigerant direct cooling plate 2 to thermal shock are quantified using response delay and settling time.

[0104] Example 12 This embodiment discloses a performance testing method for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 9 to 11, in step S6, when the single-dimensional working condition test called is a safety boundary limit test, the configuration of the working condition simulation parameters includes setting the ambient temperature of the temperature-controlled test chamber 1 through the electrical control system. Evaporation temperature of refrigerant-driven control unit and the heat load power of the controllable thermal simulation unit After initiating the current dimensional operating condition test, based on the steady-state performance test, apply a heating power exceeding the allowable range to the localized heating module 12 of the controllable thermal simulation unit to simulate local thermal runaway, or adjust the opening of the electronic expansion valve 6 to introduce refrigerant-side disturbances, correspondingly testing the ultimate heat dissipation capacity and anti-interference capability of the refrigerant direct cooling plate 2. The local thermal runaway simulation can select a single zone less than 5% of the total area, jumping the heat power from a normal level to an ultra-high power density. The refrigerant-side disturbance is achieved by rapidly changing the opening of the electronic expansion valve 6 during the steady-state operation of the refrigerant direct cooling plate 2, actively introducing refrigerant loop state fluctuations. Before the test, baseline operating condition stabilization is completed, and the temperature field and refrigerant state of the refrigerant direct cooling plate 2 are recorded. After applying the ultimate excitation, data such as hotspot temperature, diffusion range, superheat, and pressure loss are simultaneously collected. The hotspot temperature rise rate, critical suppression power, thermal spread rate, superheat recovery time, and temperature fluctuation amplitude are calculated to complete the ultimate heat dissipation, thermal spread suppression, and robustness evaluation of the refrigerant direct cooling plate 2. The principle is to target the hot spot suppression and heat spread blocking capabilities of the refrigerant direct cooling plate 2 by using local high heat flux excitation to target the heat concentration weak points such as the end of the flow channel and the liquid separation dead zone. Based on the robustness evaluation principle, the superheat stability, temperature field recovery speed and resistance to liquid hammer / dry burning risk are tested under two-phase flow fluctuations by refrigerant side disturbance. Through the safety boundary quantification principle, the safe operating upper limit of the refrigerant direct cooling plate 2 is defined by indicators such as critical suppression power and temperature rise rate, providing component-level quantitative basis for system thermal safety design.

[0105] Example 13 This embodiment discloses a performance testing method for a direct-cooling plate based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 9 to 12, in step S6, the basic parameters of the multi-dimensional indicators include: The following parameters are used in steady-state performance testing: ambient temperature Evaporation temperature Heat load power , refrigerant inlet temperature Refrigerant inlet pressure Refrigerant outlet temperature Pressure on refrigerant exports Refrigerant mass flow rate Steady-state temperature at each preset measuring point on the surface of the refrigerant direct cooling plate 2 , This represents the total number of preset measurement points. The ambient temperature of the temperature-controlled testing chamber 1 is also included. The high-precision ambient temperature sensor, located within the temperature-controlled test chamber 1, collects data to fix the environmental boundaries and eliminate the influence of external temperature fluctuations on heat dissipation and refrigerant properties; refrigerant inlet temperature... Refrigerant inlet pressure Refrigerant outlet temperature Pressure on refrigerant exports The temperature data is collected by inlet temperature sensor 11, inlet pressure sensor 10, outlet temperature sensor 9, and outlet pressure sensor 8, which are installed and calibrated adjacent to the inlet and outlet pipes of the refrigerant direct cooling plate 2. This avoids measurement deviations caused by heat exchange and pressure drop in the refrigerant pipeline and is used to calculate superheat, saturation temperature, pressure loss, and specific enthalpy of the refrigerant inlet and outlet, etc.; refrigerant mass flow rate. The heat power collected by the mass flow meter 7 before the electronic expansion valve 6 or after the condenser 4 in the refrigerant circuit represents the actual heat dissipation of the refrigerant. The calculation provides the basis for the flow rate; the steady-state temperature of each preset measuring point on the surface of the refrigerant direct cooling plate 2. The data is collected by a patch thermocouple matrix deployed according to an intelligent deployment strategy. The deployment prioritizes coverage of the distributor, flow channel heat exchange area, outlet flow collection area and infrared scanning high temperature area, so as to cover the most critical temperature characteristics with the fewest sensors. This is used to obtain temperature uniformity indicators such as the average surface temperature, maximum temperature difference and temperature standard deviation of the refrigerant direct cooling plate 2.

[0106] The following parameters are used in the dynamic performance test: the moment of heat load step change, the time-series temperature data of each preset measuring point on the surface of the refrigerant direct cooling plate 2, the time-series superheat data of the refrigerant outlet, and the time-series pressure data of the refrigerant inlet and outlet. The moment of heat load step change is synchronously marked by the electrical control system when it issues a power step command, serving as the zero point of the dynamic curve. The time-series temperature data of each preset measuring point on the surface of the refrigerant direct cooling plate 2 is collected at a high sampling frequency to extract the response delay time, settling time, and temperature overshoot amplitude. The time-series superheat data of the refrigerant outlet is calculated in real time from the saturation temperature corresponding to the outlet temperature and outlet pressure, used to observe the fluctuation amplitude of the two-phase flow and system stability. The time-series pressure data of the refrigerant inlet and outlet are collected synchronously to analyze the pressure loss changes during the dynamic process. Its acquisition principle is as follows: taking the heat load step as the only excitation and keeping the cooling side unchanged, through high-frequency and synchronized time-series acquisition, the temperature and refrigerant state changes of the refrigerant direct cooling plate 2 from disturbance to recovery are fully recorded, accurately characterizing the thermal inertia, response speed and anti-disturbance robustness of the refrigerant direct cooling plate 2, and avoiding the distortion of dynamic indicators due to asynchronous acquisition or insufficient sampling rate.

[0107] The following parameters are used in the safety boundary limit test: temperature time-series data of the thermal runaway hotspot, temperature diffusion time-series data of the thermal runaway hotspot, refrigerant outlet superheat time-series data, and temperature time-series data of each preset measuring point on the surface of the refrigerant direct cooling plate 2. Specifically, the temperature time-series data of the runaway hotspot reflects the heat dissipation rate of the refrigerant direct cooling plate 2 to extreme heat flow; the temperature diffusion time-series data of the thermal runaway hotspot is acquired synchronously from the thermocouple matrix and temperature contour map, used to determine the range and speed of heat spread; the refrigerant outlet superheat time-series data records the entire process from the start of the disturbance to the return of superheat to the stable range, used to evaluate the system's robustness and resistance to fluctuations; and the temperature time-series data of each preset measuring point on the surface of the refrigerant direct cooling plate 2 is used to determine whether the safety threshold has been exceeded and to trigger protection. Its acquisition principle is as follows: the most dangerous position and most sensitive parameters of the refrigerant direct cooling plate 2 under extreme working conditions are collected in a targeted manner, and the local thermal runaway trend, thermal diffusion path and refrigerant phase change fluctuation characteristics are accurately captured. This enables the quantitative evaluation of the safety boundary, thermal spread suppression capability and system robustness of the refrigerant direct cooling plate 2, and provides component-level extreme data support for thermal safety design.

[0108] Example 14 This embodiment discloses a performance testing method for a direct cooling plate based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on embodiment 13, in S7, when the current dimension operating condition test is a steady-state performance test, the performance indicators include the surface temperature index of the refrigerant direct cooling plate 2 and the internal refrigerant flow heat transfer index of the refrigerant direct cooling plate 2.

[0109] The surface temperature parameters of the refrigerant direct cooling plate 2 include the average surface temperature. Maximum temperature difference in effective heat exchange zone Temperature distribution standard deviation and average heat exchange temperature difference .

[0110] Average surface temperature In the formula, Indicates the preset measurement point number. Indicates the first The steady-state temperature at each preset measuring point. This index, calculated by arithmetically averaging the temperatures at all measuring points on the surface of the refrigerant direct cooling plate 2, characterizes the overall heating and cooling level of the refrigerant direct cooling plate 2. It reflects the average thermal level to which the refrigerant direct cooling plate 2 is cooled under the current evaporation temperature and heat load. The average temperature directly determines the overall temperature level of the bottom boundary of the battery pack, serving as the basis for judging whether the refrigerant direct cooling plate 2 can control the heat source temperature within the safe and target temperature range. It also provides a benchmark for calculating the average heat transfer temperature difference and is a fundamental statistical measure for evaluating overall heat dissipation capacity.

[0111] Maximum temperature difference in effective heat exchange zone 。 This indicator is the difference between the highest and lowest temperatures at the same time on the surface of the refrigerant direct cooling plate 2, directly reflecting the temperature uniformity of the refrigerant direct cooling plate 2. The refrigerant direct cooling plate 2 achieves temperature uniformity through internal flow channel liquid distribution and phase change heat transfer. The maximum temperature difference is determined by the flow channel structure, liquid distribution uniformity, fin thermal conductivity, and two-phase flow distribution stability. The smaller the value, the more balanced the heat exchange in each flow channel and the more consistent the heat transfer. This corresponds to a smaller temperature difference between each cell 13 in the battery pack module, which can effectively delay inconsistent aging of the cells 13 and reduce the risk of local overheating. It is the most core and intuitive indicator for evaluating whether the refrigerant direct cooling plate 2 meets the consistency requirements of battery pack thermal management.

[0112] Temperature distribution standard deviation This indicator, based on the principles of statistical variance and standard deviation, quantifies the overall dispersion of the surface temperature field of the refrigerant direct cooling plate 2, and reflects the uniformity of temperature distribution more comprehensively than the maximum temperature difference. The smaller the value, the more concentrated the temperature at each measuring point is around the average value, and the smoother and more uniform the temperature field. The larger the value, the more pronounced the local overheating and undercooling phenomena, and the more prominent the problems of uneven liquid distribution in the flow channel, heat transfer dead zones, and two-phase flow imbalance. (Settable settings) For excellence For good This provides a standardized basis for judging the temperature performance of the refrigerant direct cooling plate.

[0113] Average heat exchange temperature difference This indicator characterizes the overall phase change heat transfer intensity between the surface of the refrigerant direct cooling plate 2 and the refrigerant, and is a core parameter for measuring the inherent heat transfer efficiency of the refrigerant direct cooling plate 2. Under the same heat load and the same evaporation temperature, the smaller the average heat transfer temperature difference, the faster the heat transfer from the surface of the refrigerant direct cooling plate 2 to the refrigerant, the smaller the heat transfer thermal resistance, and the more complete the phase change heat transfer. Conversely, the larger the temperature difference, the more obvious the heat transfer bottleneck, the higher the thermal resistance, and the lower the heat transfer efficiency. This indicator is directly related to system energy efficiency. A larger temperature difference requires a lower evaporation temperature to achieve the same heat dissipation effect, resulting in an increase in the compressor 3 pressure ratio, increased power consumption, and a decrease in COP.

[0114] The internal refrigerant flow heat transfer parameters of the refrigerant direct cooling plate 2 include refrigerant pressure loss. Pressure drop per unit flow rate Refrigerant export overheating Standard deviation of superheat stability The actual heat dissipation of the refrigerant and refrigerant refrigeration energy efficiency coefficient .

[0115] Refrigerant pressure loss This indicator represents the steady-state pressure difference between the refrigerant inlet and outlet, directly reflecting the flow resistance within the internal flow channels of the refrigerant direct-cooling plate 2. When the refrigerant flows within these channels, pressure losses occur due to factors such as abrupt changes in the channel cross-section, bends, liquid separation, flow collection, and two-phase flow friction. Greater pressure losses result in lower suction pressure for compressor 3, higher overall pressure ratio, significantly increased power consumption of compressor 3, and reduced system energy efficiency. This indicator directly determines the impact of the refrigerant direct-cooling plate 2 on system energy consumption; its figure of merit is typically controlled at 20. 30 kPa is a direct reflection of the rationality of the flow channel design and the level of pressure drop control.

[0116] Pressure drop per unit flow This indicator normalizes pressure loss to refrigerant mass flow rate, eliminating the influence of different test flow rates on pressure loss results and achieving comparable flow resistance performance across operating conditions and products. Under different flow rates, simply... It lacks direct comparative significance; however, by introducing pressure drop per unit flow rate, the hydraulic performance of the flow channel itself can be objectively evaluated, and it can be determined whether the flow resistance deteriorates sharply with the increase of flow rate. This provides a more realistic reflection of the merits and demerits of the flow channel structure design, and offers a unified standard for comparing the refrigerant direct cooling plate scheme and optimizing the flow channel.

[0117] Refrigerant Export Overheating In the formula, This indicates the saturation temperature corresponding to the refrigerant outlet pressure. Refer to the refrigerant saturation property table (or call the property function). Superheat is the most crucial state indicator for a refrigerant phase change direct cooling system, directly characterizing the degree of phase change completion and two-phase flow state of the refrigerant within the refrigerant direct cooling plate 2. If the temperature is too low (close to 0K), liquid refrigerant will still be present at the outlet, which can easily enter compressor 3 and cause liquid slugging, severely damaging compressor 3; If the superheat is too high, the refrigerant will completely evaporate in the middle section of the flow channel, resulting in dry burning in the latter half of the flow channel, a sharp drop in heat exchange efficiency, and exacerbation of uneven surface temperature on the refrigerant direct cooling plate 2. The ideal range is 1-5K, at which point the refrigerant completes its phase change at the outlet, achieving the highest heat exchange efficiency and the most stable flow. The degree of superheat directly reflects the uniformity of liquid distribution and the sufficiency of heat exchange in the flow channel, and is a key criterion for determining the rationality of the phase change design of the refrigerant direct cooling plate 2.

[0118] Assuming that during a steady-state operating period (e.g., 5 minutes), at equal time intervals... Collected indivual Sample value Then there is a standard deviation of superheat stability. In the formula, This indicates the number of superheat sampling points. Indicates the sampling sequence number. Indicates the first Secondary superheat sampling value, This represents the arithmetic mean of superheat. This index statistically measures the fluctuation range of superheat under steady-state conditions, and also reflects the uniformity of the two-phase flow distribution inside the refrigerant direct cooling plate 2 and the control accuracy of the refrigerant unit. The smaller the value, the more evenly the refrigerant is distributed among the flow channels, the more stable the boiling process, and the more precise the system control. A larger value indicates a larger flow deviation between channels, significant two-phase flow oscillation, and defects in the liquid separation structure. A threshold can be set: Determining that the flow is unstable requires optimizing the distributor, flow channel structure, or control parameters, which is a key indicator for diagnosing the flow stability of the refrigerant direct cooling plate 2.

[0119] The actual heat dissipation of the refrigerant In the formula, Indicates the specific enthalpy of the refrigerant inlet. Refrigerant export enthalpy, according to and The refrigerant's physical property function (NISTRefprop or a similar database) is used for calculation. Based on energy conservation and the two-phase flow enthalpy difference method, the actual heat absorbed by the refrigerant within the refrigerant direct cooling plate 2 is calculated, providing the most direct quantitative result of the refrigerant direct cooling plate 2's true heat dissipation capacity. The refrigerant absorbs heat through latent heat and sensible heat of phase change within the flow channel, causing its enthalpy to rise. The total heat absorption can be accurately calculated using mass flow rate and enthalpy difference, unaffected by interfacial thermal resistance, environmental heat dissipation, or heat loss. This accurately reflects the ultimate heat dissipation capacity of the refrigerant direct cooling plate 2 under current operating conditions and serves as the core basis for performance evaluation and energy balance verification.

[0120] Refrigerant Refrigeration Energy Efficiency Coefficient In the formula, This indicates the power consumption of compressor 3 in the refrigerant-driven chiller unit. An energy meter (which can be expanded by the data acquisition module of the electrical control system) is connected in series at the power input terminal of compressor 3. The power consumption of compressor 3 is calculated by subtracting the readings from the energy meter. The greater the pressure drop, the greater the power consumption of compressor 3: this is due to the refrigerant pressure loss at the refrigerant direct cooling plate 2. The larger the pressure ratio, the lower the suction pressure of compressor 3. The increased pressure ratio leads to increased power consumption of compressor 3. A larger average heat exchange temperature difference means a lower evaporation temperature is required to transfer the same amount of heat, which also leads to an increase in pressure ratio and compressor power consumption (input power). Reduce; superheat stability This indirectly affects the suction state of compressor 3 and system stability. Excessive superheat fluctuations may cause compressor 3 to lose efficiency or shut down for protection, thus affecting... This can be achieved through comparison. and The deviation between the measured value and the design target value is used to qualitatively determine the refrigerant direct cooling plate 2. Potential impacts: and The smaller, The closer it is to the ideal value, the better. This assessment helps to quickly screen refrigerant direct-cooling plate 2 designs that have the least impact on system energy efficiency at the component level.

[0121] Example 15 This embodiment discloses a performance testing method for a direct-cooled plate based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any of embodiments 13-14, in step S7, when the current dimension operating condition test is a steady-state performance test, the performance indicators need to be calculated based on the energy relative error before calculating the performance indicators. Perform energy balance verification; where: relative energy error ;when If the value is within the allowed range, the verification is considered successful; otherwise, the basic parameters of the test indicators are deemed invalid.

[0122] Energy balance verification is a core quality control step for ensuring the accuracy and consistency of data in this testing system. It is based on the principle of energy conservation in a thermodynamically closed system. During the test, the heat load power... Total heat input to the system; heat power of the actual refrigerant dissipation. This is the total output. Ideally, the two should be close; differences arise from interface heat loss, ambient heat dissipation, sensor errors, pipeline heat exchange, etc. The following judgment rules can be set: This indicates that the verification has passed (is satisfactory). The test system exhibits low heat loss, good sensor accuracy and consistency, reliable interface heat transfer, and self-consistent data, and can be directly used for performance calculations and report output.

[0123] This indicates a critical range (warning / review). The system exhibits acceptable but slightly elevated heat loss or measurement deviation, not reaching the point of failure, but deviating from ideal conditions. Possible sources include minor environmental fluctuations, uneven thickness of the thermally conductive gel 20, excessively high contact thermal resistance of thermocouple 15, minor fluctuations in refrigerant condition, and limited heat exchange in the piping. The data is usable, but the source of the deviation should be identified and review is recommended. If this is for R&D comparative testing, it is recommended to recalibrate the sensor, optimize insulation, and standardize the clamping process before retesting to improve data reliability.

[0124] This indicates that the verification failed (unqualified / invalid data). The system has significant errors, resulting in distorted test results that cannot be used for performance evaluation. Possible causes include uncalibrated sensors, severe heat leakage, insufficient clamping pressure, refrigerant piping abnormalities, poor interface contact, and malfunctioning flow / temperature / pressure measurements. This data set must not be used; the problem must be identified, and the system reassembled and tested.

[0125] Taking a refrigerant direct-cooling plate 2 based on R410A as the working fluid as an example, 24 patch thermocouples 15 (C1–C24) are uniformly and symmetrically arranged on its surface to form a high-resolution temperature acquisition matrix. High-precision inlet temperature sensor 11, inlet pressure sensor 10, outlet temperature sensor 9, outlet pressure sensor 8, and mass flow meter 7 are installed close to the refrigerant inlet and outlet to synchronously collect refrigerant state parameters. The following three typical operating conditions are set, and each group is run to thermal steady state (judgment criterion: the rate of temperature change at all preset measuring points). and remain stable Operating condition 1, heat load power evaporation temperature Operating condition 2, heat load power evaporation temperature Operating condition 3, heat load power evaporation temperature The maximum temperature difference in the effective heat exchange zone of the refrigerant direct cooling plate under three typical operating conditions. The temperatures achieved were 0.94℃, 1.17℃, and 1.21℃, respectively, all significantly better than the design threshold of 5℃, directly verifying the excellent temperature uniformity and two-phase flow distribution capability of the refrigerant direct cooling plate 2. The actual heat dissipation was calculated based on the refrigerant enthalpy difference method. With heat load power Comparison, relative error ,satisfy The qualified standards are that the test data is consistent, the heat loss is controllable, and the results are reliable.

[0126] Example 16 This embodiment discloses a performance testing method for a direct-cooling plate based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 13-15, in step S7, when the current dimension operating condition test is a dynamic performance test, the performance indicators include response delay time. Stable time Temperature overshoot amplitude and dynamic superheat fluctuation amplitude .

[0127] Response latency This refers to the time interval from the start of a heat load jump to the moment when the temperature at a preset measuring point on the surface of the refrigerant direct cooling plate 2 shows a continuous change. This indicator characterizes the sensing speed and initial thermal inertia response characteristics of the refrigerant direct cooling plate 2 to sudden changes in heat load. When the heat load suddenly increases, heat must first be conducted through the interface and stored in the heat capacity of the refrigerant direct cooling plate 2 substrate before a noticeable temperature rise occurs. The shorter the response delay time, the smaller the heat capacity of the refrigerant direct cooling plate 2, the lower the interface thermal resistance, the faster the heat transfer, and the more sensitive it is to thermal shock. If the delay is too long, it indicates that the thermal inertia of the refrigerant direct cooling plate 2 is too large, and it is prone to temperature tracking lag under transient conditions such as fast charging and acceleration, leading to localized short-term overheating.

[0128] Stabilization time This refers to the period from the start of a heat load step change to the temperature at the preset measuring point reaching a new steady-state value. The total time it takes for the refrigerant direct cooling plate 2 to maintain a stable temperature within the tolerance range. This indicator reflects the speed and recovery capability of the refrigerant direct cooling plate 2 in re-establishing thermal equilibrium after being subjected to thermal disturbances. After a heat load step, the temperature of the refrigerant direct cooling plate 2 first rises rapidly, and then gradually tends to a new steady state under the heat dissipation effect of refrigerant phase change; the shorter the stabilization time, the higher the heat exchange efficiency of the refrigerant direct cooling plate 2, the more stable the two-phase flow distribution, and the stronger the system's resistance to disturbances and recovery capability. This indicator directly determines the temperature control robustness of the refrigerant direct cooling plate 2 in response to power surges under real-world operating conditions and is the core evaluation criterion for dynamic thermal management capability.

[0129] Temperature overshoot amplitude This refers to the peak temperature at the preset measuring point. With the new steady-state temperature The difference. Temperature overshoot originates from the mismatch between the heat capacity and heat exchange rate of the refrigerant direct cooling plate 2: at the moment of sudden change in heat load, the rate of heat generation is much greater than the rate of heat dissipation, and the rapid accumulation of heat causes the temperature to surge to a peak value first, and then drop back to a steady state under continuous cooling. The smaller the overshoot amplitude, the stronger the instantaneous heat dissipation capacity of the refrigerant direct cooling plate 2 and the better the thermal inertia matching degree, which can effectively suppress transient hot spots; the larger the overshoot amplitude, the greater the risk of short-term over-temperature under dynamic operating conditions, directly threatening the safety boundary of the battery pack.

[0130] Dynamic superheat fluctuation amplitude This refers to the maximum superheat value during the dynamic process. With minimum superheat The difference is used to evaluate the stability of the refrigerant two-phase flow and the robustness of the system under thermal shock. Sudden changes in heat load can cause instantaneous changes in the refrigerant evaporation intensity, leading to fluctuations in dryness, flow velocity, and pressure within the flow channel, which in turn causes significant fluctuations in the outlet superheat. The smaller the fluctuation amplitude, the better the uniformity of liquid distribution in the refrigerant direct cooling plate 2 flow channel, the more stable the phase change heat transfer, and the stronger the adaptability to thermal disturbances; excessive fluctuation indicates that there is an imbalance in the distribution of the flow channel, local dry burning, or intermittent liquid accumulation, which can easily cause system oscillation, temperature control failure, or even compressor 3 malfunction.

[0131] Example 17 This embodiment discloses a performance testing method for direct-cooled plates based on multi-dimensional indicators. As a preferred embodiment of the present invention, based on any one of embodiments 13-16, in S7, when the current dimension operating condition test is a safety boundary limit test, the performance indicators include: the temperature rise rate of the thermal runaway hotspot. Critical suppression power thermal spread rate Overheat recovery time and the maximum amplitude of temperature fluctuation .

[0132] Temperature rise rate of thermal runaway hotspot ; This indicates the temperature change at the hotspot of thermal runaway; This indicates the time increment corresponding to the temperature change. This indicator describes the rate of temperature rise of the hotspot under local high heat flux, directly reflecting the instantaneous heat removal capacity of the refrigerant direct cooling plate 2 for extreme concentrated heat loads. The lower the temperature rise rate, the faster the refrigerant direct cooling plate 2 conducts heat, the more timely the phase change heat absorption, and the more sufficient the heat diffusion under local high heat flux. If the temperature rise rate is too high, it indicates that the local heat cannot be quickly removed, and the temperature will show an accelerated upward trend, which is very easy to trigger thermal runaway. It is the core dynamic indicator for judging whether the refrigerant direct cooling plate 2 has the ability to suppress thermal runaway in the early stage.

[0133] Critical suppression power This refers to the maximum local heat generation power that the refrigerant direct cooling plate 2 can use to control the temperature of the thermal runaway hotspot within a safe threshold. This indicator is used to quantitatively define the local heat dissipation safety boundary of the refrigerant direct cooling plate 2. In local thermal runaway simulations, the local heat load is gradually increased. When the power is below the critical value, the refrigerant direct cooling plate 2 can stabilize the hotspot temperature below the safe threshold (e.g., 45℃ / 60℃). When the power exceeds this value, the hotspot temperature will enter an uncontrollable rise stage, and will continue to rise even after heating is stopped. The higher the critical suppression power, the stronger the local heat exchange capacity of the refrigerant direct cooling plate 2, the more reasonable the flow channel layout, and the greater the suppression margin for thermal runaway. It is the most critical safety threshold indicator at the component level in battery pack thermal safety design.

[0134] thermal spread rate This refers to the geometrical diffusion distance of the area where the temperature rises from the thermal runaway hotspot per unit time. This indicator characterizes the speed at which local overheating is transferred and expanded to the surrounding area, directly evaluating the ability of the refrigerant direct cooling plate 2 to block heat spread. The lower the heat spread rate, the more uniform the thermal conductivity of the refrigerant direct cooling plate 2 substrate, the stronger the thermal conductivity compensation capacity of the fins, and the wider the heat absorption range of the refrigerant phase change, which can effectively limit heat spread and prevent single-point overheating from expanding into a large-area high temperature. If the spread rate is too fast, it indicates that the refrigerant direct cooling plate 2 has poor temperature uniformity, heat is easy to accumulate, and it cannot achieve uniform heat dissipation across the entire area, which will significantly increase the risk of thermal runaway chain propagation.

[0135] Overheat recovery time This refers to the time it takes for the refrigerant outlet superheat to return to its stable range after a refrigerant-side disturbance is introduced. This indicator is used to evaluate the speed at which the two-phase flow state of the refrigerant at the direct-cooling plate 2 stabilizes after a disturbance in the refrigerant circuit, directly reflecting the system's robustness. When the opening of the electronic expansion valve 6 changes rapidly, the refrigerant flow rate, pressure, and evaporation intensity fluctuate instantaneously, and the outlet superheat deviates significantly from the ideal range. A shorter recovery time indicates better liquid distribution stability in the refrigerant direct-cooling plate 2 flow channel, stronger self-regulating phase change heat transfer capability, and better system anti-interference capability. A longer recovery time indicates uneven distribution, flow lag, or control mismatch issues in the flow channel.

[0136] Maximum temperature fluctuation This refers to the difference between the maximum temperature difference on the surface of the refrigerant direct cooling plate 2 and the maximum temperature difference in steady state during refrigerant-side disturbances. This indicator is used to quantify the degree to which refrigerant-side disturbances disrupt the temperature field uniformity of the refrigerant direct cooling plate 2. Under steady state, the temperature distribution of the refrigerant direct cooling plate 2 is uniform. Disturbances can cause sudden changes in local heat transfer, significantly increasing the surface temperature difference. The smaller the fluctuation amplitude, the better the temperature uniformity of the refrigerant direct cooling plate 2 can be maintained under fluctuating operating conditions, indicating high temperature field stability. The larger the amplitude, the stronger the impact of the disturbance on the heat transfer uniformity, making it prone to local overheating and undercooling, threatening the temperature consistency of the battery pack and the safety of system operation.

[0137] Example 18 This embodiment discloses a performance testing method for a direct-cooling plate based on multi-dimensional indicators. As a preferred implementation of the present invention, based on any one of the embodiments 7 to 17, in S9, the performance spectrum is divided into a steady-state performance spectrum, a dynamic response spectrum, and a safety limit boundary spectrum.

[0138] Steady-state performance graphs include the static temperature distribution cloud map of the surface of the refrigerant direct-cooling plate 2 (e.g.) Figure 3 The system displays various parameters, including the two-dimensional steady-state operating condition matrix correlation curve and the refrigerant two-phase flow steady-state characteristic curve. The static temperature distribution cloud map on the surface of the refrigerant direct-cooling plate 2 is the core visualization carrier of the steady-state performance spectrum. The system relies on temperature data from preset measurement points across the entire region collected by the thermocouple matrix to perform interpolation calculations, restoring the complete plate surface temperature gradient field. It visually presents the plate surface temperature distribution characteristics under different evaporation temperatures and different heat loads under steady-state operating conditions. It can clearly locate local high-temperature accumulation areas, low-temperature cold areas, and areas with weak heat transfer caused by internal flow channel liquid distribution imbalance, providing an intuitive evaluation of the basic temperature uniformity capability and the quality of the flow channel liquid distribution design of the refrigerant direct-cooling plate 2. The two-dimensional steady-state operating condition matrix correlation curves establish multiple sets of comparative relationships around three types of boundary variables: environment, refrigerant, and heat load. On the one hand, it plots the change curves of heat load and average temperature of heat exchange plate surface, and heat load and maximum temperature difference of heat exchange plate surface, quantifying the impact of increased heat input on the overall temperature and temperature uniformity of refrigerant direct cooling plate 2. On the other hand, it outputs the corresponding curves of evaporation temperature and refrigerant pressure loss, and evaporation temperature and refrigerant outlet superheat, characterizing the effect of refrigerant phase change boundary on pipeline flow and two-phase heat transfer state. At the same time, based on the full matrix operating condition data, it generates contour maps of average heat transfer temperature difference and refrigeration COP, which can intuitively read the heat transfer efficiency and system energy efficiency level under any combination of operating conditions. The refrigerant two-phase flow steady-state characteristic curve focuses on the core parameters of refrigerant flow and heat transfer, including three sets of key curves: the corresponding curve of refrigerant mass flow rate and pressure loss, used to evaluate the hydraulic resistance characteristics of the internal flow channel of the refrigerant direct cooling plate 2; the curve of heat load and actual heat transfer of refrigerant, which intuitively reflects the ultimate heat dissipation capacity of the refrigerant direct cooling plate 2; and the steady-state superheat fluctuation time series curve, which records the continuous fluctuation state of outlet superheat under stable operating conditions, quantifies the stability of two-phase flow distribution, and fully covers the three key evaluation dimensions of refrigerant flow, phase change heat transfer, and operational stability in steady-state testing.

[0139] The dynamic response graph is used to fully present the transient heat transfer characteristics of the refrigerant direct cooling plate 2 in response to sudden changes in heat load and under actual battery charging and discharging conditions. It includes three types of visualization charts: the first is the heat load step time series curve, which adopts a multi-curve synchronous superposition method to simultaneously output the heat source power change curve, the temperature time series curve of key preset measuring points on the refrigerant direct cooling plate 2, the refrigerant outlet superheat time series curve, and the refrigerant inlet and outlet pressure fluctuation curve, fully recording the synchronous change law of multiple parameters throughout the entire process of a single thermal shock; the second is the dynamic characteristic index comparison bar chart, which targets different power step amplitudes. The system uses group statistics and intuitive comparisons of response delay time, temperature overshoot amplitude, and temperature stabilization time under various operating conditions to quantify the impact of heat load disturbance amplitude on the dynamic temperature control performance of the refrigerant direct cooling plate 2. Thirdly, it provides continuous dynamic curves of heat generation during real battery charging and discharging, which can import the time series data of continuous heat generation during fast charging and variable rate operation of energy storage devices. This fully replicates the continuous change trajectory of the temperature, refrigerant flow rate, and superheat of the entire heat exchange plate surface of the refrigerant direct cooling plate 2 during long-term dynamic operation, and comprehensively evaluates the temperature control robustness and thermal inertia level of the refrigerant direct cooling plate 2 under real complex transient heat input.

[0140] The safety boundary limit map is used to quantify the thermal safety protection and anti-interference performance of the refrigerant direct cooling plate under two extreme conditions: local thermal runaway and refrigerant loop disturbance. It includes three types of visualization charts: The first type is the local thermal runaway hotspot temperature rise time-series curve, recording the entire process of hotspot temperature rise over time when ultra-high local power is applied by the zoned heat source. The curve marks the temperature rise rate and the critical suppression power inflection point, intuitively defining the safe upper limit of local heat load that the refrigerant direct cooling plate 2 can stably control; the second type is the heat spread diffusion cloud map sequence, extracting heat exchange plate surface temperature cloud maps at multiple key time points after thermal runaway for comparison and display, showing the temperature at different times. The first category quantifies the thermal spread rate of lateral heat conduction within the expanded area, assessing the cold plate's ability to prevent cascading overheating. The second category is the refrigerant disturbance recovery characteristic curve, simulating the refrigerant-side disturbance caused by the sudden change in the opening of the electronic expansion valve 6. It fully plots the outlet superheat and the maximum temperature difference change curves on the heat exchange plate from the occurrence of the disturbance to the system's return to stability, and marks two core indicators: superheat recovery time and the maximum temperature fluctuation. This comprehensively reflects the self-stabilizing recovery capability of the refrigerant two-phase flow after disturbance, fully covering two typical extreme safety scenarios for energy storage thermal management: local high-temperature runaway and refrigerant flow disturbance. It quantifies the safe operation boundary and anti-disturbance robustness of the cold plate.

[0141] Furthermore, it also includes horizontal comparison charts. These charts employ both bar charts and line graphs for visualization. Under completely uniform environmental temperature, refrigerant operating conditions, and heat load testing conditions, test data from multiple refrigerant direct-cooling plates with different flow channel structures and plate materials are simultaneously loaded. The charts centrally compare core indicators such as heat exchanger plate surface temperature uniformity, refrigerant flow resistance, dynamic thermal response level, and critical suppression power for local thermal runaway. This provides a clear and intuitive presentation of the performance differences between different design schemes, offering standardized and visualized data support for flow channel structure optimization and selection, plate material selection, and product solution iteration benchmarking during the R&D phase.

Claims

1. A performance testing system for direct-cooled plates based on multi-dimensional indicators, characterized in that: It includes a temperature-controlled test chamber (1), a refrigerant-driven control unit, a controllable thermal simulation unit, and an electrical control system; The temperature controllable test chamber (1) is equipped with a temperature control unit to provide a temperature controllable test environment for the refrigerant direct cooling plate (2); The refrigerant drive control unit is used to provide adjustable refrigerant circulation conditions for the performance testing of the refrigerant direct cooling plate (2); specifically, the refrigerant drive control unit includes a compressor (3), a condenser (4), a regenerator (5) and an electronic expansion valve (6); the refrigerant pipeline is connected to the refrigerant drive control unit according to the flow direction of the refrigerant medium in the following structure: the refrigerant outlet of the refrigerant direct cooling plate (2) is connected to the high temperature inlet of the regenerator (5); the high temperature outlet of the regenerator (5) is connected to the compressor (3) and the condenser (4) in sequence, and then connected to the low temperature inlet of the regenerator (5); the low temperature outlet of the regenerator (5) is connected to the refrigerant inlet of the refrigerant direct cooling plate (2) through the electronic expansion valve (6); The controllable thermal simulation unit includes a contact-type simulated heat source and a bonding pressure device; the contact-type simulated heat source includes several partitioned heating modules (12) with visible module numbers. Each partitioned heating module (12) is laid in a matrix on the heat exchange plate surface of the refrigerant direct cooling plate (2) through thermal conductive gel (20), and forms a contact interface with constant contact thermal resistance with the refrigerant direct cooling plate (2) based on the bonding pressure device; The electrical control system is connected to the temperature control unit, the refrigerant drive control unit, and the controllable thermal simulation unit, respectively, and is used to control the temperature control unit, the refrigerant drive control unit, and the controllable thermal simulation unit to cooperate in completing multi-dimensional operating condition tests. The multi-dimensional operating condition tests refer to: under the set ambient temperature and refrigerant conditions, controlling the controllable thermal simulation unit to complete multi-dimensional operating condition simulations including steady-state thermal simulation, transient thermal simulation, and local extreme thermal simulation; completing steady-state performance tests of the refrigerant direct cooling plate (2) under steady-state thermal simulation, completing dynamic performance tests of the refrigerant direct cooling plate (2) under transient thermal simulation, and completing safety boundary limit tests under local extreme thermal simulation; integrating the multi-dimensional performance indicators obtained after the multi-dimensional operating condition tests of the refrigerant direct cooling plate (2), generating and displaying the performance test report of the refrigerant direct cooling plate (2); wherein: Steady-state thermal simulation is achieved by reading the total steady-state heating power and loading the spatial power distribution matrix, distributing the total steady-state heating power to each zone heating module (12) according to the spatial weight of the thermal field, generating a power output command containing several constant digital power signals, and controlling the multi-channel programmable power supply to complete the constant power output corresponding to each zone heating module (12). Local extreme thermal simulation is based on steady-state thermal simulation. It applies a heating drive power exceeding the allowable range to the local partition heating module (12) of the controllable thermal simulation unit to simulate local thermal runaway, or adjusts the opening of the electronic expansion valve (6) to introduce refrigerant side disturbance. Transient thermal simulation involves synchronously loading the spatial power distribution matrix and dynamic power timing curves, refreshing the calculation with fixed time slices, coupling the dynamic power timing curves with the spatial power distribution matrix, and generating power output commands containing several dynamic digital power signals. These commands control a multi-channel programmable power supply to complete the dynamic power output corresponding to each zone heating module. The method for obtaining the dynamic power timing curves is as follows: The instantaneous total heat generation curve of the battery pack under set operating conditions was obtained through experimental simulation. Simultaneously, the power absorption curve of the battery pack due to its own temperature rise was obtained. ;in, ; Indicates the mass of the battery pack. This indicates the average constant-pressure specific heat capacity of the battery pack; This indicates the rate of temperature rise of the battery pack. Indicates temperature. Indicates time; Based on the instantaneous total heat production power curve and power curve The equivalent heat source power curve was calculated. ,Right now The equivalent heat source power curve This serves as the dynamic power timing curve.

2. The direct-cooling plate performance testing system based on multi-dimensional indicators as described in claim 1, characterized in that: The electrical control system includes a human-machine interface, a main control unit, a multi-channel programmable power supply, and a data acquisition unit. The human-machine interface is connected to the main control unit and is used to configure ambient temperature parameters, refrigerant condition parameters and thermal simulation parameters, perform thermal simulation and test control operations, and display the performance test report of the refrigerant direct cooling plate (2). The main control unit is connected to the temperature control unit and the refrigerant-driven control unit, and is also connected to the controllable thermal simulation unit through a multi-channel programmable power supply. The main control unit has a built-in multi-dimensional operating condition test program that includes steady-state performance testing, dynamic performance testing, and safety boundary limit testing. It is used to control the temperature control unit, the refrigerant-driven control unit, the multi-channel programmable power supply, and the controllable thermal simulation unit to work together to complete multi-dimensional operating condition simulation under set ambient temperature parameters, refrigerant condition parameters, and thermal simulation parameters. The main control unit is connected to the temperature control unit, refrigerant drive control unit, multi-channel programmable power supply and controllable thermal simulation unit through the data acquisition unit. Based on the data acquisition unit, after collecting the basic parameters of multi-dimensional indicators during the multi-dimensional working condition simulation, the multi-dimensional performance indicators are calculated using the basic parameters of multi-dimensional indicators, and a performance test report of the refrigerant direct cooling plate (2) is generated.

3. The direct-cooling plate performance testing system based on multi-dimensional indicators as described in claim 2, characterized in that: The main control unit binds a unique device address and drive channel ID to each zone heating module (12), and generates several digital power signals bound to unique device addresses and drive channel IDs by combining a multi-channel independent addressing matching mechanism. All digital power signals are packaged and output as a success rate command and sent to the multi-channel programmable power supply.

4. The direct-cooling plate performance testing system based on multi-dimensional indicators as described in claim 3, characterized in that: The multi-channel programmable power supply is equipped with several independent output channels, and each zone heating module (12) is connected to the output channel one by one. It is used to parse the digital power signals in the power output command, match the output of the heating drive power of each zone heating module (12) according to the drive channel ID, and realize the independent closed-loop control of each heating drive power based on the electrical signal fed back from each output channel.

5. The direct-cooling plate performance testing system based on multi-dimensional indicators as described in claim 2, characterized in that: The data acquisition unit includes a thermocouple matrix and a refrigerant parameter acquisition unit; The thermocouple matrix is ​​arranged around the refrigerant direct cooling plate (2) according to the structural design of the refrigerant direct cooling plate (2) and is used to collect temperature data of preset measuring points on the surface of the refrigerant direct cooling plate (2). The refrigerant parameter acquisition unit includes a mass flow meter (7), an outlet pressure sensor (8), an outlet temperature sensor (9), an inlet pressure sensor (10), and an inlet temperature sensor (11) connected to the refrigerant pipeline, which are used to acquire the refrigerant mass flow rate and the refrigerant inlet temperature, refrigerant inlet pressure, refrigerant outlet temperature, and refrigerant outlet pressure of the refrigerant direct cooling plate (2), respectively.

6. The performance testing system for a direct-cooling plate based on multi-dimensional indicators as described in claim 1, characterized in that: The temperature control unit includes a temperature control module and an ambient temperature sensor; the temperature control module adopts a variable frequency refrigeration and electric heating temperature control configuration and is connected to the electrical control system to execute the ambient temperature control command of the electrical control system; the ambient temperature sensor is connected to the temperature control module and the electrical control system respectively, and is used to collect and feedback the ambient temperature in the controllable temperature test chamber (1) in real time, cooperate with the temperature control module to complete the ambient temperature regulation, and cooperate with the electrical control system to realize the ambient temperature monitoring.

7. The performance testing system for a direct-cooling plate based on multi-dimensional indicators as described in claim 1, characterized in that: The bonding pressure device includes a pressure equalizing plate (18), a rigid base (17), a pressure sensor (16), and several adjustable pressure units (19). The rigid base (17) is provided with a placement area for the refrigerant direct cooling plate (2), and all adjustable pressure units (19) are evenly arranged along the edge of the placement area; The adjustable pressure unit (19) includes a bolt (19.1), an adjusting nut (19.2), and a spring. The bottom of the bolt (19.1) is fixedly connected to the rigid base (17). The top of the bolt (19.1) passes through the equalizing plate (18) and the spring in sequence, and forms a detachable threaded transmission pair with the adjusting nut (19.2). By rotating the adjusting nut (19.2) to compress the spring, point pressure is applied to the equalizing plate (18). The equalizing plate (18) is placed above the refrigerant direct cooling plate (2) and the contact simulated heat source, and is used to convert the point pressure of all adjustable pressure units (19) into a surface pressure that uniformly covers the entire area of ​​the contact simulated heat source. The pressure sensor (16) is mounted on a rigid base (17) and connected to an electrical control system to collect and feedback the normal pressure applied by the pressure-applying device to the contact-type simulated heat source and the refrigerant direct cooling plate (2).

8. A performance testing method for a direct-cooling plate based on multi-dimensional indicators, characterized in that: The following steps are performed using a multi-dimensional index-based performance testing system for direct-cooled plates as described in any one of claims 1 to 7: S1, apply thermal conductive gel (20) evenly to the heat exchange plate surface of the refrigerant direct cooling plate (2), and arrange the heating modules (12) of each zone in a matrix on the refrigerant direct cooling plate (2) according to the visible module number; S2, place the bonding pressure device on the test platform (14) in the temperature controllable test chamber (1), and use the bonding pressure device to uniformly and tightly bond each zone heating module (12) with the refrigerant direct cooling plate (2) to form a contact interface with constant contact thermal resistance; S3, the refrigerant drive control unit is sealed and connected to the refrigerant inlet and refrigerant outlet of the refrigerant direct cooling plate (2) through the refrigerant pipeline to form a closed refrigerant circulation loop; S4 connects the temperature control unit, refrigerant drive control unit, and controllable thermal simulation unit to the electrical control system respectively, and completes the system initialization upon power-up; S5 establishes a multi-dimensional working condition test set through the electrical control system, which includes steady-state performance testing, dynamic performance testing, and safety boundary limit testing. S6 selects and calls a single-dimensional operating condition test through the electrical control system. After configuring the operating condition simulation parameters according to the requirements, it starts the current dimension operating condition test and simultaneously performs the collection of basic index parameters. Among them, the operating condition simulation parameters include ambient temperature parameters, refrigerant condition parameters, and thermal simulation parameters. S7 performs preprocessing on the collected basic parameters of the indicators, including filtering and time alignment, and calculates the performance indicators under the current working condition test based on the preprocessed basic parameters of the indicators. S8, determine whether all dimensions of the multi-dimensional working condition test set have been completed; if yes, integrate the basic parameters of the multi-dimensional indicators and the multi-dimensional performance indicators obtained after the multi-dimensional working condition test, and proceed to S9; if no, return to S6 to switch to the next dimension of working condition test. S9 uses multi-dimensional indicator parameters and multi-dimensional performance indicators to draw performance graphs and generate a performance test report that includes the performance graphs.

9. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 8, characterized in that: In S6, when the single-dimensional operating condition test called is a steady-state performance test, the operating condition simulation parameters are configured including setting the ambient temperature of the temperature-controlled test chamber (1) through the electrical control system. Evaporation temperature of refrigerant-driven control unit and the heat load power of the controllable thermal simulation unit and form the same ambient temperature Below, based on different evaporation temperatures With different heat load power A two-dimensional steady-state operating condition test matrix is ​​constructed; after starting the current dimension operating condition test, all steady-state operating condition tests in the two-dimensional steady-state operating condition test matrix are traversed and completed sequentially.

10. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 8, characterized in that: In S6, when the single-dimensional operating condition test called is a dynamic performance test, the operating condition simulation parameters are configured to include the ambient temperature of the temperature-controlled test chamber (1) input through the electrical control system. Evaporation temperature of refrigerant-driven control unit And the heat generation curve of the heat load step excitation or the actual charge and discharge of the battery pack; after starting the current dimension operating condition test, the evaporation temperature of the fixed refrigerant driven control unit. The opening degree of the electronic expansion valve (6) is used to simulate sudden changes in heat load and the actual dynamic heat generation of the battery pack.

11. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 8, characterized in that: In S6, when the single-dimensional working condition test called is a safety boundary limit test, the configuration of the working condition simulation parameters includes setting the ambient temperature of the temperature-controlled test chamber (1) through the electrical control system. Evaporation temperature of refrigerant-driven control unit and the heat load power of the controllable thermal simulation unit After starting the current dimension working condition test, on the basis of steady-state performance test, apply a heat driving power exceeding the allowable range to the local partition heating module (12) of the controllable thermal simulation unit to simulate local thermal runaway, or adjust the opening of the electronic expansion valve (6) to introduce refrigerant side disturbance, and test the ultimate heat dissipation capacity and anti-interference of the refrigerant direct cooling plate (2).

12. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 8, characterized in that: In S6, the basic parameters of the multi-dimensional indicators include: The following parameters are used in steady-state performance testing: ambient temperature Evaporation temperature Heat load power , refrigerant inlet temperature Refrigerant inlet pressure Refrigerant outlet temperature Pressure on refrigerant exports Refrigerant mass flow rate Steady-state temperature at each preset measuring point on the surface of the refrigerant direct cooling plate (2) , This represents the total number of preset measurement points; The following parameters in the dynamic performance test: heat load step time, temperature time series data of each preset measuring point on the surface of the refrigerant direct cooling plate (2), refrigerant outlet superheat time series data, and refrigerant inlet and outlet pressure time series data; The following parameters in the safety boundary limit test: temperature time series data of thermal runaway hot spot, temperature diffusion time series data of thermal runaway hot spot, refrigerant outlet superheat time series data, and temperature time series data of each preset measuring point on the surface of refrigerant direct cooling plate (2).

13. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 12, characterized in that, In S7, when the current dimension working condition test is a steady-state performance test, the performance indicators include the surface temperature of the refrigerant direct cooling plate (2) and the internal refrigerant flow heat transfer indicators of the refrigerant direct cooling plate (2). The surface temperature parameters of the refrigerant direct cooling plate (2) include the average surface temperature. Maximum temperature difference in effective heat exchange zone Temperature distribution standard deviation and average heat exchange temperature difference ;in: ； ； ； ； In the formula, Indicates the preset measurement point number. Indicates the first Steady-state temperature at a preset measurement point; The internal refrigerant flow heat transfer parameters of the refrigerant direct cooling plate (2) include refrigerant pressure loss. Pressure drop per unit flow rate Refrigerant export overheating Standard deviation of superheat stability The actual heat dissipation of the refrigerant and refrigerant refrigeration energy efficiency coefficient ;in: ； ； ； ； ； ； In the formula, This indicates the saturation temperature corresponding to the refrigerant outlet pressure; This indicates the number of superheat sampling points. Indicates the sampling sequence number. Indicates the first Secondary superheat sampling value, This represents the arithmetic mean of superheat. Indicates the specific enthalpy of the refrigerant inlet. Indicates the specific enthalpy of refrigerant exports; This indicates the power consumption of the compressor (3) in the refrigerant-driven control unit.

14. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 12, characterized in that, In S7, when the current dimension operating condition test is a steady-state performance test, the energy relative error needs to be considered before calculating the performance indicators. Perform energy balance verification; where: relative energy error ;when If the value is within the allowed range, the verification passes; otherwise, the basic parameters of the test index are deemed invalid. This represents the actual heat dissipation of the refrigerant.

15. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 12, characterized in that, In S7, when the current dimension operating condition test is a dynamic performance test, the performance indicators include response latency time. Stable time Temperature overshoot amplitude and dynamic superheat fluctuation amplitude ;in: Response latency It refers to the time interval from the start of the heat load step to the moment when the temperature at the preset measuring point on the surface of the refrigerant direct cooling plate (2) changes continuously; Stabilization time This refers to the period from the start of a heat load step change to the temperature at the preset measuring point reaching a new steady-state value. The tolerance band and the total time during which it remains stable; Temperature overshoot amplitude This refers to the peak temperature at the preset measuring point. With the new steady-state temperature The difference; Dynamic superheat fluctuation amplitude This refers to the maximum superheat value during the dynamic process. With minimum superheat The difference.

16. The method for testing the performance of a direct-cooling plate based on multi-dimensional indicators as described in claim 12, characterized in that, In S7, when the current dimensional operating condition test is a safety boundary limit test, the performance indicators include: the temperature rise rate of the thermal runaway hotspot. Critical suppression power thermal spread rate Overheat recovery time and the maximum amplitude of temperature fluctuation ;in: Temperature rise rate of thermal runaway hotspot ; This indicates the temperature change at the hotspot of thermal runaway; This represents the time increment corresponding to the temperature change. Critical suppression power This refers to the maximum local heating power that the refrigerant direct cooling plate (2) can control the temperature of the thermal runaway hot spot within a safe threshold. thermal spread rate This refers to the geometrical diffusion distance of the region where the temperature of the thermal runaway hotspot increases per unit time. Overheat recovery time This refers to the time it takes for the refrigerant outlet superheat to return to a stable range after a refrigerant-side disturbance is introduced. Maximum temperature fluctuation It refers to the difference between the maximum temperature difference on the surface of the refrigerant direct cooling plate (2) and the maximum steady-state temperature difference during the refrigerant side disturbance process.

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