Improved intelligent testing platform for automobile power battery

Abstract

The application relates to the technical field of automobile power battery testing, in particular to an improved automobile power battery intelligent testing platform, which comprises a testing rack, a BCU master control module, a BSU slave control module, an electronic load, a vehicle-mounted OBC charger, a high-voltage wire harness, an upper integrated machine, a current sensor, a dual-mode fault simulation module, an explosion-proof charging bin and a fixing support; the BCU master control module is connected with the testing rack; the BSU slave control module is connected with the BCU master control module through a CAN communication bus; the electronic load and the vehicle-mounted OBC charger are respectively connected with the BCU master control module through the high-voltage wire harness; the upper integrated machine is arranged on the testing rack and is connected with the BCU master control module through a communication interface; in this way, the technical problems in the prior art that the functions of the testing equipment are relatively dispersed, the testing data cannot be stored and exported, the fault simulation means are relatively single, and flexibility and comprehensiveness cannot be considered are solved.

Description

Technical Field

[0001] This invention relates to the field of automotive power battery testing technology, and in particular to an improved intelligent testing platform for automotive power batteries. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the performance and safety of power batteries, as the core component of electric vehicles, directly determine the vehicle's range, lifespan, and market acceptance. Battery management systems (BMS), as a key technology ensuring the safe operation and performance release of power batteries, are responsible for real-time acquisition of parameters such as cell voltage, current, and temperature; assessment of state of charge (SOC) and state of health (SOH); and execution of equalization management, thermal management, and safety protection strategies. The research and application of power batteries require extensive and repetitive testing. Currently, common battery testing methods include hardware-in-the-loop (HIL) test platforms, battery simulators, electronic loads, and charge / discharge testing equipment.

[0003] However, existing testing equipment has relatively fragmented functions, cannot store and export test data, and has limited fault simulation methods, making it difficult to balance flexibility and comprehensiveness. Summary of the Invention

[0004] The purpose of this invention is to provide an improved intelligent testing platform for automotive power batteries, which solves the technical problems of existing testing equipment having relatively dispersed functions, being unable to store and export test data, and having relatively simple fault simulation methods, making it difficult to balance flexibility and comprehensiveness.

[0005] To achieve the above objectives, the present invention provides an improved intelligent testing platform for automotive power batteries, including a test rack, a BCU master control module, a BSU slave control module, an electronic load, an on-board OBC charger, a high-voltage wiring harness, a host computer, a current sensor, a dual-mode fault simulation module, an explosion-proof charging compartment, and a fixed bracket. The BCU master control module is connected to the test rack, the BSU slave control module is connected to the BCU master control module via a CAN communication bus, the electronic load and the on-board OBC charger are respectively connected to the BCU master control module via the high-voltage wiring harness, the host computer is mounted on the test rack and connected to the BCU master control module via a communication interface, the current sensor is installed inside the fixed bracket and connected to the BCU master control module via a signal line, the dual-mode fault simulation module is connected to the BCU master control module, and the explosion-proof charging compartment is connected to the test rack. The BCU master control module is used to receive the cell voltage and temperature signals collected by the BSU slave control module, control the electronic load to simulate vehicle discharge conditions, control the on-board OBC charger to simulate AC slow charging conditions, and send test data to the host computer. The dual-mode fault simulation module is used to simulate various types of line faults through both mechanical and wireless methods. The explosion-proof charging compartment is used to provide enclosed safety protection during the battery cell charging and discharging test. The fixed bracket is used to reduce the impact of equipment vibration on the current sensor and improve the accuracy of current acquisition.

[0006] The dual-mode fault simulation module includes a mechanical fault connector and a wireless APP fault controller. The mechanical fault connector includes a module socket, an adjustable resistor terminal, and a short-circuit jumper terminal. The adjustable resistor terminal is inserted into the corresponding socket of the module socket to simulate a loose connection fault by connecting the adjustable resistor. The short-circuit jumper terminal is used to simulate a short circuit fault by bridging the circuit. The module socket is provided with multiple sets of wire harness plug-in interfaces to simulate a circuit open fault by plugging and unplugging the wire harness. The module socket is also provided with a wire harness cross-plug port to simulate a circuit misconnection fault by cross-plugging different wire harnesses. The wireless APP fault controller includes a wireless communication module and a mobile APP terminal. The mobile APP terminal communicates with the wireless communication module through a wireless network and is used to send intermittent fault setting instructions to the BCU main control module. The BCU main control module then controls the corresponding line to perform on / off switching at a set time interval to simulate intermittent faults.

[0007] The wireless APP fault controller also has a built-in fault type coding library, which stores coding information for various fault types. The mobile APP terminal sends a fault setting command to the BCU main control module by selecting the fault type code. The BCU main control module retrieves the corresponding fault parameters from the fault type coding library according to the received fault type code and performs fault simulation. The fault type coding library covers five basic fault types and their combinations: open circuit fault, short circuit fault, loose connection fault, wire harness cross fault, and intermittent continuity fault. The mobile APP terminal also supports custom intermittent fault parameter settings, including on / off interval time, fault duration and repetition number.

[0008] The host computer has a built-in local storage hard disk and a data export unit. The local storage hard disk is used to automatically record test data during each charge-discharge test and fault test. The test data includes individual cell voltage data, current data, temperature data, and fault codes. The data export unit is used to connect to an external storage device via a USB interface to export test data recorded on the local storage hard drive as an Excel format test report.

[0009] The explosion-proof charging compartment includes an explosion-proof cabinet, a double-door double-lock mechanism, a temperature sensor, a smoke detector, an automatic dry powder fire extinguisher, a multi-channel leakage protection socket, and a cooling fan. The explosion-proof cabinet is fixedly installed on the side of the test rack. The double-door double-lock mechanism is located on the front of the explosion-proof cabinet. The temperature sensor is fixedly installed on the top wall inside the explosion-proof cabinet. The smoke detector is fixedly installed on the top wall inside the explosion-proof cabinet. The automatic dry powder fire extinguisher is fixedly installed on the side wall inside the explosion-proof cabinet. The multi-channel leakage protection socket is fixedly installed on the rear wall inside the explosion-proof cabinet. The cooling fan is fixedly installed at the ventilation grille on the side wall of the explosion-proof cabinet.

[0010] The improved intelligent testing platform for automotive power batteries also includes a remote terminal, which is communicatively connected to the host computer and is used to receive and store test data uploaded by the host computer.

[0011] The improved intelligent testing platform for automotive power batteries also includes a buzzer and an LED indicator. When the BCU main control module detects that the cell voltage exceeds a preset threshold, the cell temperature exceeds a preset threshold, the current exceeds a preset threshold, or a smoke alarm signal appears in the explosion-proof charging compartment, it controls the buzzer and the LED indicator to emit audible and visual alarm signals.

[0012] This invention discloses an improved intelligent testing platform for automotive power batteries. The BCU master control module centrally manages the BSU slave control module, the electronic load, the on-board OBC charger, and the current sensor. Combined with a host computer, it enables real-time storage and export of test data, effectively overcoming the shortcomings of existing testing equipment's fragmented functions and lack of data management, significantly improving the integration and informatization level of the testing process. Simultaneously, the dual-mode fault simulation module combines mechanical and wireless methods, flexibly simulating various types of circuit faults such as open circuits, short circuits, poor contact, and signal interference, ensuring both physical and wireless accuracy. The system offers reliable access while also providing convenient remote wireless control, completely overcoming the limitations and incompleteness of traditional single-fault simulation methods. The explosion-proof charging compartment provides enclosed safety protection during the charging and discharging of the battery cells, effectively isolating the risk of thermal runaway and ensuring the safety of test personnel and equipment. The fixed bracket significantly improves the accuracy of current acquisition by reducing the impact of equipment vibration on the current sensor, ensuring the authenticity and consistency of test data. This approach solves the technical problems of existing technologies where test equipment functions are relatively scattered, unable to store and export test data, and the fault simulation methods are relatively simple, making it difficult to balance flexibility and comprehensiveness. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0014] Figure 1 This is a schematic diagram of the structure of the improved intelligent testing platform for automotive power batteries of the present invention.

[0015] Figure 2 This is a schematic diagram of the improved intelligent testing platform for automotive power batteries of the present invention.

[0016] In the diagram: 1-Test rack, 2-BCU main control module, 3-BSU slave control module, 4-Electronic load, 5-On-board OBC charger, 6-High voltage wiring harness, 7-Host computer, 8-Current sensor, 9-Dual-mode fault simulation module, 10-Explosion-proof charging compartment, 11-Fixed bracket, 12-Mechanical fault connector, 13-Wireless APP fault controller, 14-Module socket, 15-Adjustable resistor terminal, 16-Short-circuit jumper terminal, 17-Wireless communication module 18-Mobile APP terminal, 19-Local storage hard drive, 20-Data export unit, 21-Explosion-proof cabinet, 22-Double door double lock mechanism, 23-Temperature sensor, 24-Smoke detector, 25-Automatic dry powder fire extinguisher, 26-Multi-channel leakage protection socket, 27-Cooling fan, 28-Remote terminal, 29-Buzzer, 30-LED indicator light, 31-Fault type code library, 32-Login module, 33-Authentication module, 34-Access control module; Detailed Implementation

[0017] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0018] Please refer to Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the structure of the improved intelligent testing platform for automotive power batteries of the present invention. Figure 2 This is a schematic diagram of the improved intelligent testing platform for automotive power batteries of the present invention. The embodiment of the present invention provides an improved intelligent testing platform for automotive power batteries, including a test rack 1, a BCU master control module 2, a BSU slave control module 3, an electronic load 4, an on-board OBC charger 5, a high-voltage wiring harness 6, a host computer 7, a current sensor 8, a dual-mode fault simulation module 9, an explosion-proof charging compartment 10, and a fixing bracket 11. The dual-mode fault simulation module 9 includes a mechanical fault connector 12 and a wireless APP fault controller 13. The mechanical fault connector 12 includes a module socket 14, an adjustable resistor terminal 15, and a short-circuit jumper terminal 16. The wireless APP fault controller 13 includes a wireless communication module 1. The system includes a 7-bit mobile APP terminal 18, and the host computer 7 has a built-in local storage hard disk 19 and a data export unit 20; the explosion-proof charging compartment 10 includes an explosion-proof cabinet 21, a double-door double-lock mechanism 22, a temperature sensor 23, a smoke detector 24, an automatic dry powder fire extinguisher 25, a multi-channel leakage protection socket 26, and a cooling fan 27; the improved intelligent testing platform for automotive power batteries also includes a remote terminal 28, a buzzer 29, and an LED indicator 30; the aforementioned solution solves the technical problems in the prior art where the testing equipment functions are relatively scattered, cannot store and export test data, and the fault simulation methods are relatively simple, making it difficult to balance flexibility and comprehensiveness.

[0019] In this specific embodiment, the BCU master control module 2 is used to receive the cell voltage and temperature signals collected by the BSU slave control module 3, control the electronic load 4 to simulate vehicle discharge conditions, control the on-board OBC charger 5 to simulate AC slow charging conditions, and send test data to the host computer 7. The dual-mode fault simulation module 9 is used to simulate various types of line faults through both mechanical and wireless methods. The explosion-proof charging compartment 10 is used to provide enclosed safety protection during the battery cell charging and discharging test; The fixed bracket 11 is used to reduce the impact of equipment vibration on the current sensor 8 and improve the accuracy of current acquisition.

[0020] The BCU main control module 2 is connected to the test rack 1. The BSU slave control module 3 is connected to the BCU main control module 2 via a CAN communication bus. The electronic load 4 and the on-board OBC charger 5 are respectively connected to the BCU main control module 2 via the high-voltage wiring harness 6. The host computer 7 is mounted on the test rack 1 and connected to the BCU main control module 2 via a communication interface. The current sensor 8 is installed inside the fixed bracket 11 and connected to the BCU main control module 2 via a signal line. The dual-mode fault simulation module 9 is connected to the BCU main control module 2. The explosion-proof charging compartment 10 is connected to the test rack 1. The BCU master control module 2 centrally manages the BSU slave control module 3, the electronic load 4, the on-board OBC charger 5, and the current sensor 8. Combined with the host computer 7, it enables real-time storage and export of test data, effectively overcoming the shortcomings of existing test equipment's fragmented functions and lack of data management, significantly improving the integration and informatization level of the test process. Simultaneously, the dual-mode fault simulation module 9 combines mechanical and wireless methods, flexibly simulating various types of line faults such as open circuits, short circuits, poor contact, and signal interference, ensuring both the reliability of physical access and balancing... The convenience of remote wireless control is greatly enhanced, and the limitations and incompleteness of traditional single fault simulation methods are completely improved. The explosion-proof charging chamber 10 provides closed safety protection during the charging and discharging of the battery cells, effectively isolating the risk of thermal runaway and ensuring the safety of test personnel and equipment. The fixed bracket 11 significantly improves the accuracy of current acquisition by reducing the impact of equipment vibration on the current sensor 8, ensuring the authenticity and consistency of test data. In this way, the technical problems of the existing test equipment having relatively dispersed functions, being unable to store and export test data, and having relatively simple fault simulation methods that are difficult to balance flexibility and comprehensiveness are solved.

[0021] Secondly, the adjustable resistor terminal 15 is plugged into the corresponding socket of the module socket 14 to simulate a loose connection fault by connecting the adjustable resistor. The short-circuit jumper terminal 16 is used to simulate a short circuit fault by jumping the line. The module socket 14 is provided with multiple sets of wire harness plug-in interfaces to simulate a circuit open fault by plugging and unplugging the wire harness. The module socket 14 is also provided with a wire harness cross-plug port to simulate a misconnection fault by cross-plugging different wire harnesses. The mobile APP terminal 18 communicates with the wireless communication module 17 through a wireless network and is used to send an intermittent fault setting command to the BCU main control module 2. The BCU main control module 2 controls the corresponding line to perform on / off switching at a set time interval to simulate an intermittent fault.

[0022] The wireless APP fault controller 13 also has a built-in fault type coding library 31, which stores coding information for various fault types. The mobile APP terminal 18 sends a fault setting command to the BCU main control module 2 by selecting the fault type code. The BCU main control module 2 retrieves the corresponding fault parameters from the fault type coding library 31 according to the received fault type code and performs fault simulation. The fault type coding library 31 covers five basic fault types and their combinations: open circuit fault, short circuit fault, loose connection fault, wire harness cross fault, and intermittent continuity fault. The mobile APP terminal 18 also supports custom intermittent fault parameter settings, including on / off interval time, fault duration and repetition number.

[0023] Meanwhile, the local storage hard disk 19 is used to automatically record test data during each charge-discharge test and fault test. The test data includes individual cell voltage data, current data, temperature data, and fault codes. The data export unit 20 is used to connect to an external storage device via a USB interface to export the test data recorded in the local storage hard disk 19 as an Excel format test report.

[0024] Furthermore, the explosion-proof cabinet 21 is fixedly installed on the side of the test frame 1, the double-door double-lock mechanism 22 is located on the front of the explosion-proof cabinet 21, the temperature sensor 23 is fixedly installed on the inner top wall of the explosion-proof cabinet 21, the smoke detector 24 is fixedly installed on the inner top wall of the explosion-proof cabinet 21, the automatic dry powder fire extinguisher 25 is fixedly installed on the inner side wall of the explosion-proof cabinet 21, the multi-channel leakage protection socket 26 is fixedly installed on the inner rear wall of the explosion-proof cabinet 21, and the cooling fan 27 is fixedly installed at the ventilation grille on the side wall of the explosion-proof cabinet 21.

[0025] Furthermore, the remote terminal 28 is communicatively connected to the host computer 7 and is used to receive and store the test data uploaded by the host computer 7; When the BCU main control module 2 detects that the cell voltage exceeds a preset threshold, the cell temperature exceeds a preset threshold, the current exceeds a preset threshold, or a smoke alarm signal appears in the explosion-proof charging compartment 10, it controls the buzzer 29 and the LED indicator 30 to emit audible and visual alarm signals.

[0026] Furthermore, the improved intelligent testing platform for automotive power batteries also includes a login module 32, an identity verification module 33, and an access control module 34. The login module 32 is connected to the remote terminal 28, the identity verification module 33 is connected to the login module 32, and the access control module 34 is connected to the identity verification module 33. The login module 32 receives the user credentials input by the remote terminal 28, encrypts them, and transmits them to the identity verification module 33. This module uses the SHA-256 hash algorithm to compare passwords and verify dynamic tokens to prevent replay attacks. After successful verification, the access control module 34 dynamically assigns operation permissions such as device start / stop, parameter modification, and data export based on the RBAC algorithm according to roles, and feeds back the permission results to the BCU main control module 2. At the same time, it uploads the authentication and authorization log to the host computer 7.

[0027] Working principle: The BCU master control module 2 centrally manages the BSU slave control module 3, the electronic load 4, the on-board OBC charger 5, and the current sensor 8, and works with the host computer 7 to achieve real-time storage and export of test data. This effectively overcomes the shortcomings of existing test equipment, such as fragmented functions and lack of data management, and significantly improves the integration and informatization level of the test process. Meanwhile, the dual-mode fault simulation module 9 combines mechanical and wireless methods to flexibly simulate various types of line faults such as open circuits, short circuits, poor contact, and signal interference, ensuring the reliability of physical access. It also takes into account the convenience of remote wireless control, and completely improves the limitations and incompleteness of traditional single fault simulation methods; the explosion-proof charging chamber 10 provides closed safety protection during the charging and discharging of the battery cells, effectively isolating the risk of thermal runaway and ensuring the safety of test personnel and equipment; the fixed bracket 11 reduces the impact of equipment vibration on the current sensor 8, greatly improves the accuracy of current acquisition, and ensures the authenticity and consistency of test data. In this way, it solves the technical problems of existing test equipment having relatively dispersed functions, being unable to store and export test data, and having relatively simple fault simulation methods, making it difficult to balance flexibility and comprehensiveness.

[0028] The above-disclosed embodiments are merely one or more preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art will understand that all or part of the processes for implementing the above embodiments and equivalent variations made in accordance with the claims of this application are still within the scope of this application.

Claims

1. An improved intelligent testing platform for automotive power batteries, characterized in that, Includes a test rack, BCU master control module, BSU slave control module, electronic load, on-board OBC charger, high-voltage wiring harness, host computer, current sensor, dual-mode fault simulation module, explosion-proof charging compartment and mounting bracket; The BCU master control module is connected to the test rack, the BSU slave control module is connected to the BCU master control module via a CAN communication bus, the electronic load and the on-board OBC charger are respectively connected to the BCU master control module via the high-voltage wiring harness, the host computer is mounted on the test rack and connected to the BCU master control module via a communication interface, the current sensor is installed inside the fixed bracket and connected to the BCU master control module via a signal line, the dual-mode fault simulation module is connected to the BCU master control module, and the explosion-proof charging compartment is connected to the test rack. The BCU master control module is used to receive the cell voltage and temperature signals collected by the BSU slave control module, control the electronic load to simulate vehicle discharge conditions, control the on-board OBC charger to simulate AC slow charging conditions, and send test data to the host computer. The dual-mode fault simulation module is used to simulate various types of line faults through both mechanical and wireless methods. The explosion-proof charging compartment is used to provide enclosed safety protection during the battery cell charging and discharging test. The fixed bracket is used to reduce the impact of equipment vibration on the current sensor and improve the accuracy of current acquisition.

2. The improved intelligent testing platform for automotive power batteries as described in claim 1, characterized in that, The dual-mode fault simulation module includes a mechanical fault connector and a wireless APP fault controller. The mechanical fault connector includes a module socket, an adjustable resistor terminal, and a short-circuit jumper terminal. The adjustable resistor terminal is inserted into the corresponding socket of the module socket to simulate a loose connection fault by connecting the adjustable resistor. The short-circuit jumper terminal is used to simulate a short circuit fault by bridging the circuit. The module socket is provided with multiple sets of wire harness plug-in interfaces to simulate a circuit open fault by plugging and unplugging the wire harness. The module socket is also provided with a wire harness cross-plug port to simulate a circuit misconnection fault by cross-plugging different wire harnesses. The wireless APP fault controller includes a wireless communication module and a mobile APP terminal. The mobile APP terminal communicates with the wireless communication module through a wireless network and is used to send intermittent fault setting instructions to the BCU main control module. The BCU main control module then controls the corresponding line to perform on / off switching at a set time interval to simulate intermittent faults.

3. The improved intelligent testing platform for automotive power batteries as described in claim 2, characterized in that, The wireless APP fault controller also has a built-in fault type coding library, which stores coding information for various fault types. The mobile APP terminal sends a fault setting command to the BCU main control module by selecting the fault type code. The BCU main control module retrieves the corresponding fault parameters from the fault type coding library according to the received fault type code and performs fault simulation. The fault type coding library covers five basic fault types and their combinations: open circuit fault, short circuit fault, loose connection fault, wire harness cross fault, and intermittent continuity fault. The mobile APP terminal also supports custom intermittent fault parameter settings, including on / off interval time, fault duration and repetition number.

4. The improved intelligent testing platform for automotive power batteries as described in claim 3, characterized in that, The host computer has a built-in local storage hard drive and a data export unit; The local storage hard disk is used to automatically record test data during each charge-discharge test and fault test. The test data includes individual cell voltage data, current data, temperature data, and fault codes. The data export unit is used to connect to an external storage device via a USB interface to export test data recorded on the local storage hard drive as an Excel format test report.

5. The improved intelligent testing platform for automotive power batteries as described in claim 4, characterized in that, The explosion-proof charging compartment includes an explosion-proof cabinet, a double-door double-lock mechanism, a temperature sensor, a smoke detector, an automatic dry powder fire extinguisher, a multi-channel leakage protection socket, and a cooling fan. The explosion-proof cabinet is fixedly installed on the side of the test rack. The double-door double-lock mechanism is located on the front of the explosion-proof cabinet. The temperature sensor is fixedly installed on the top wall inside the explosion-proof cabinet. The smoke detector is fixedly installed on the top wall inside the explosion-proof cabinet. The automatic dry powder fire extinguisher is fixedly installed on the side wall inside the explosion-proof cabinet. The multi-channel leakage protection socket is fixedly installed on the rear wall inside the explosion-proof cabinet. The cooling fan is fixedly installed at the ventilation grille on the side wall of the explosion-proof cabinet.

6. The improved intelligent testing platform for automotive power batteries as described in claim 5, characterized in that, The improved intelligent testing platform for automotive power batteries also includes a remote terminal, which is communicatively connected to the host computer and is used to receive and store test data uploaded by the host computer.

7. The improved intelligent testing platform for automotive power batteries as described in claim 6, characterized in that, The improved intelligent testing platform for automotive power batteries also includes a buzzer and an LED indicator; when the BCU main control module detects that the cell voltage exceeds a preset threshold, the cell temperature exceeds a preset threshold, the current exceeds a preset threshold, or a smoke alarm signal appears in the explosion-proof charging compartment, it controls the buzzer and the LED indicator to emit audible and visual alarm signals.

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