A high-performance, high-precision drive box

Abstract

The application discloses a high-performance and high-precision driving box, which comprises a plurality of driving plate modules, and voltage is collected through an external ADC sampling chip of a control plate module; each driving plate module comprises four independent channels, and a plurality of collection interfaces for collecting dynamic data in real time are arranged in each independent channel; the control plate module is used for realizing input and output signal collection, control signal processing and driving plate communication connection; a main control plate module is in communication connection with an upper computer and each driving plate module, realizes channel charging and discharging process control, state data collection and instruction interaction, simultaneously uniformly schedules and manages different test channels, completes channel distribution, operation control and abnormal monitoring, and the application has the advantages of rapid starting, millisecond-level dynamic response and high-speed data collection capability, can collect dynamic data such as voltage and current in real time, and improves data integrity and accuracy in DCIR testing, pulse working condition testing and high-speed dynamic testing processes.

Description

Technical Field

[0001] This invention belongs to the technical field of cyclic testing equipment, specifically relating to a high-performance, high-precision drive box. Background Technology

[0002] With the rapid development of the new energy industry, the requirements for battery performance, safety, and reliability in fields such as new energy vehicles, energy storage systems, and consumer electronics are constantly increasing. During the research and development verification, cycle life testing, DCIR testing, pulse condition simulation, and consistency testing of battery cells, a drive power supply box with high-performance dynamic response, multi-intelligent segmented control, high-precision control, flexible parallel channel connection, and flexible software configuration capabilities is often required to meet the demands for charge and discharge control accuracy, dynamic performance, and system scalability under different test conditions.

[0003] The main technical drawbacks of current driver power supply boxes on the market are as follows:

[0004] ① Insufficient dynamic performance. Traditional drive boxes have a slow response speed and are prone to problems such as current lag and waveform oscillation during pulse testing and operating condition switching, making it difficult to meet the requirements of high-performance testing.

[0005] ② The gear control method is simple, and most of them adopt a fixed gear design, which cannot be intelligently segmented and adjusted according to different test conditions, resulting in poor system flexibility.

[0006] ③ The control accuracy is limited. The voltage and current accuracy of existing equipment is usually only ±0.05%FS or even ±0.1%FS, which is difficult to meet the requirements of high-precision cell testing.

[0007] ④ Insufficient parallel connection capability of channels. Traditional parallel connection methods usually rely on manual replacement of copper busbars or modification of hardware connections, which has problems such as poor parallel connection consistency, uneven current distribution and difficulty in expansion.

[0008] ⑤ The software configuration capability is weak. Most existing equipment adopts fixed control logic, which cannot flexibly realize intelligent configuration for different working conditions, gears and parallel modes, making it difficult to meet the development needs of new energy cell testing systems for high flexibility and intelligent control.

[0009] In summary, there is an urgent need to design a drive box with high precision, high scalability, high stability, and intelligent control. Summary of the Invention

[0010] To address the aforementioned technical problems in existing technologies, this invention provides a high-performance, high-precision drive box with rapid startup, millisecond-level dynamic response, and high-speed data acquisition capabilities. The minimum data acquisition cycle can reach 1ms, and it can acquire dynamic data such as voltage and current in real time, improving the data integrity and accuracy during DCIR testing, pulse condition testing, and high-speed dynamic testing.

[0011] The technical solution adopted in this invention is:

[0012] A high-performance, high-precision drive box, characterized in that it comprises:

[0013] The housing module (1) has a mounting cavity for supporting and protecting other components;

[0014] Multiple drive board modules (2) are arranged side by side in the mounting cavity, and the voltage is collected by the external ADC sampling chip of the control board module (3); each drive board module contains 4 independent channels, each independent channel can carry a maximum current of 50-100A; each independent channel is provided with multiple acquisition interfaces for real-time acquisition of dynamic data;

[0015] The control board module (3) is located inside the mounting cavity and installed above the drive board module (2), and is used to realize input and output signal acquisition, control signal processing and drive board communication connection;

[0016] The backplane module (4) is installed in the mounting cavity and includes a backplane (42) and multiple terminal sockets (41) integrated on the backplane (42). The multiple terminal sockets (41) are plugged into the CPCI connector (27) on the control board module (3) to realize the power supply, signal transmission and communication functions of the drive board module (2).

[0017] The main control board module (5) is installed in the installation cavity and is connected to the host computer and each drive board module to realize the charging and discharging process control, status data acquisition and command interaction of each channel. At the same time, it performs unified scheduling and management of different test channels, and completes channel allocation, operation control and abnormal monitoring.

[0018] The busbar copper strip module (6) is connected to the ACDC power supply box and the precision copper strip respectively. The signal transmission port of the ACDC power supply box is connected to the CAN interface of the main control board module (5).

[0019] Furthermore, the control board module (3) includes a core processor chip (31) and an external ADC acquisition chip (32). The core processor chip (31) and the external ADC acquisition chip (32) are connected via an SPI interface. The core processor chip (31) drives the power switching device by adjusting the frequency and duty cycle of the pulse signal to achieve precise adjustment of the output voltage, current and power. At the same time, combined with sampling feedback and protection logic, a closed-loop control of the power supply system is formed.

[0020] Furthermore, the front of the drive board module (2) is provided with a flat terminal (21), a positive copper strip (22), a negative copper strip (23), a shunt (24), a copper wire (25), and a CPCI connector (27). The side panel is provided with a 50A drive board positive interface (28), a spring terminal (29), a 400A drive board module negative adapter copper strip (30), and a drive board module negative bus copper strip (31). The CPCI connector is plugged into the terminal socket (41).

[0021] The driver board module (2) collects current through a shunt (24) and collects voltage through an external ADC sampling chip.

[0022] Furthermore, the main control board module (5) includes a sixth-generation aircraft adapter board (51) and a sixth-generation aircraft main control board (52). The sixth-generation aircraft adapter board (51) is plugged into the corresponding terminal socket on the backplane module. The sixth-generation aircraft main control board (52) communicates with the drive board module (2) and the control board module (3) using EtherCAT to uniformly schedule and manage different test channels, and complete channel allocation, operation control and abnormal monitoring.

[0023] Furthermore, the dynamic data includes battery voltage, current, line voltage, auxiliary voltage, channel temperature, and battery temperature.

[0024] Furthermore, the housing module (1) contains a total of 6 drive board modules (2), forming a total of 24 independent channels.

[0025] Furthermore, the individual channels can be connected in parallel to form a larger current output channel according to testing requirements.

[0026] Furthermore, each of the terminal sockets (41) has an insertion portion for inserting the connection terminals of the control board.

[0027] Furthermore, a cooling fan is provided at the rear of the housing module (1) to cool down the drive board module (2) and the control board module (3) in order to reduce the heat generation of power devices and control components during high current operation.

[0028] The innovative aspects of this invention:

[0029] 1. Each driver board module of this invention contains four independent channels, each capable of carrying a maximum current of 50-100A. Without changing other hardware in the driver box, the number of channels can be increased or decreased proportionally, i.e., the number of driver board modules can be directly increased or decreased to meet the channel configuration requirements of different customers. It also features intelligent parallel connection of multiple channels, supporting parallel connection of any channel within a single power supply box, and extended parallel connection between different power supply boxes. Users only need to connect the current lines in parallel at the battery end and complete parameter configuration through the host computer software to achieve high current output and multi-channel collaborative control, without the need for manual replacement of copper busbars or modification of hardware connections. The system can automatically complete current distribution and synchronous control between parallel channels, improving parallel consistency and system scalability, meeting the testing requirements of high-rate, high-power battery cells.

[0030] 2. The backplane of this invention integrates multiple terminal sockets. The drive board plugs into the backplane through the connection terminals on the control board to realize power input, signal transmission and communication functions. The backplane also serves as a unified power supply and interface expansion for each drive board, which can improve system integration, assembly efficiency and channel management capabilities, and ensure the stability and reliability of the whole machine operation.

[0031] 3. The control module of this invention supports 8-channel high-precision PWM output and has multi-channel analog signal sampling capability, enabling real-time monitoring of key parameters such as voltage, current, inductor current, driver board temperature, battery temperature, and bus voltage. The system voltage and current sampling resolution reaches 18 bits, the data recording period meets the 1ms level requirement, and the data sampling frequency is greater than 50kHz. Simultaneously, the analog signal sampling function must meet the reliability and stability requirements under low-temperature conditions.

[0032] Compared with the prior art, the beneficial effects of the present invention are reflected in:

[0033] 1. The drive box of this invention features rapid start-up, millisecond-level dynamic response, and high-speed data acquisition capabilities. The minimum data acquisition cycle can reach 1ms, enabling real-time acquisition of dynamic data such as voltage and current, improving data integrity and accuracy during DCIR testing, pulse condition testing, and high-speed dynamic testing. Simultaneously, the system supports multiple control modes including constant current, constant voltage, and constant power, and employs a high-speed closed-loop control algorithm to enhance output stability and dynamic tracking performance, reducing problems such as current hysteresis, waveform oscillation, and output overshoot found in traditional drive boxes.

[0034] 2. This invention supports multiple control modes such as constant current, constant voltage, and constant power, and adopts a high-speed closed-loop control algorithm to improve output stability and dynamic tracking performance, and reduce problems such as current hysteresis, waveform oscillation and output overshoot that exist in traditional drive boxes.

[0035] 3. The drive box of this invention adopts multi-intelligent segmented gear control technology, which can automatically switch the output gear according to different test conditions. While ensuring high current output capability, it improves the control accuracy and stability under low current conditions, thereby meeting the high-precision testing requirements of new energy battery cells under different rate conditions. Compared with traditional fixed gear drive boxes, this invention can automatically optimize the output capability according to the battery cell test status, improving system operating efficiency and overall stability.

[0036] 4. The invented drive box can achieve voltage and current control accuracy of ±0.02%FS, voltage resolution of 0.1mV, and current resolution of 0.1mA. It can effectively reduce the cumulative error during long-term cyclic testing and improve the data accuracy and repeatability of cell consistency testing, capacity testing, and DCIR testing.

[0037] 5. This invention features multi-channel intelligent parallel connection, supporting parallel connection of any channel within a single power supply box, as well as extended parallel connection between different power supply boxes. Users only need to connect the current lines in parallel at the battery end and complete the parameter configuration through the host computer software to achieve high current output and multi-channel coordinated control, without the need for manual replacement of copper busbars or modification of hardware connections. The system can automatically complete the current distribution and synchronous control between parallel channels, improving parallel consistency and system scalability, and meeting the testing requirements of high-rate, high-power battery cells.

[0038] 6. This invention supports flexible software configuration, allowing users to freely configure test conditions, output levels, parallel modes, and operating parameters via host computer software, enabling flexible combinations of different test procedures. The system supports multiple test modes such as CCC, CCD, CVC, CVD, CPC, CPD, and pulse conditions, and can quickly switch between modes according to different cell testing needs, improving the equipment's automation level and adaptability to complex operating conditions.

[0039] 7. This invention adopts a modular structure design. Each drive module, control module and communication module adopts a standardized design method, which facilitates later maintenance, replacement and system expansion, and improves the long-term operating stability of the equipment and the flexibility of engineering applications. Attached Figure Description

[0040] Figure 1 This is a diagram showing the connection of the copper strips on the busbar of the drive box in this invention.

[0041] Figure 2 This is a schematic diagram of the drive board structure of the present invention. Figure 1 .

[0042] Figure 3 This is a schematic diagram of the drive board structure of the present invention. Figure 2 .

[0043] Figure 4This is a schematic diagram of the structure of the driver board of the present invention.

[0044] Figure 5 This is a schematic diagram of the overall topology of the driver board of the present invention.

[0045] Figure 6 This is a schematic diagram of the power section topology of the driver board of the present invention.

[0046] Figure 7 This is the overall control flowchart of the present invention.

[0047] Figure 8a This is a schematic diagram of the internal structure of the drive box of the present invention. Figure 1 .

[0048] Figure 8b This is a schematic diagram of the internal structure of the drive box of the present invention. Figure 2 .

[0049] Figure 9 This is a schematic diagram of the main control board structure of the present invention.

[0050] Figure 10 This is a schematic diagram of the backplate assembly structure of the present invention.

[0051] Figure 11 This is a high-precision display diagram of the present invention.

[0052] Figure 12 This is a schematic diagram of the working process of the drive box of the present invention.

[0053] Figure 13 This is a schematic diagram of the control board topology of the present invention. Detailed Implementation

[0054] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0055] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0056] The present invention will now be described in detail with reference to the accompanying drawings and exemplary embodiments.

[0057] refer to Figures 1 to 12 The present invention provides a high-performance, high-precision drive box, comprising:

[0058] Box module 1 has a mounting cavity for supporting and protecting other components;

[0059] Multiple driver board modules 2 are arranged side by side in the mounting cavity, and the voltage is acquired through the external ADC sampling chip of the control board module 3; each driver board module contains 4 independent channels, each independent channel can carry a maximum current of 50-100A; each independent channel is provided with multiple acquisition interfaces for real-time acquisition of dynamic data;

[0060] The control board module 3 is located inside the mounting cavity and is mounted above the drive board module 2. It is used to realize input and output signal acquisition, control signal processing and drive board communication connection.

[0061] The backplane module 4 is disposed in the mounting cavity and includes a backplane 42 and multiple terminal sockets 41 integrated on the backplane 42. The multiple terminal sockets 41 are plugged into the CPCI connector on the control board to realize the power supply, signal transmission and communication functions of the drive board module.

[0062] The main control board module 5 is installed in the installation cavity and communicates with the host computer and each driver board module to realize the charging and discharging process control, status data acquisition and command interaction of each channel. At the same time, it performs unified scheduling and management of different test channels, and completes channel allocation, operation control and abnormal monitoring.

[0063] The busbar copper strip module 6 is connected to the ACDC power supply box and the precision component copper strip, respectively. The signal transmission port of the ACDC power supply box is connected to the CAN interface of the main control board module 5.

[0064] In one embodiment, the control board module 3 includes a core processor chip 31 and an external ADC acquisition chip 32. The core processor chip 31 and the external ADC acquisition chip 32 are connected via an SPI interface. The core processor chip 31 drives the power switching device by adjusting the frequency and duty cycle of the pulse signal to achieve precise adjustment of the output voltage, current and power. At the same time, combined with sampling feedback and protection logic, a closed-loop control of the power supply system is formed.

[0065] In one embodiment, the front of the drive board module 2 is provided with a flat terminal 21, a positive copper strip 22, a negative copper strip 23, a shunt 24, a copper wire 25, and a CPCI connector 27. The side panel is provided with a 100A drive board positive interface 28, a spring terminal 29, a 400A drive board module negative adapter copper strip 30, and a drive board module negative bus copper strip 31. The CPCI connector is plugged into the terminal socket 41.

[0066] The driver board module 2 collects current through the shunt 24 and collects voltage through an external ADC sampling chip.

[0067] In one embodiment, the main control board module 5 includes a sixth-generation fighter adapter board 51 and a sixth-generation fighter main control board 52. The sixth-generation fighter adapter board 51 is plugged into the corresponding terminal socket on the backplane module. The sixth-generation fighter main control board 52 communicates with the drive board module 2 and the control board module 3 via EtherCAT to uniformly schedule and manage different test channels, and to complete channel allocation, operation control and anomaly monitoring.

[0068] In one embodiment, the dynamic data includes battery voltage, current, line voltage, auxiliary voltage, channel temperature, and battery temperature.

[0069] In one embodiment, the housing module 1 contains a total of 6 drive board modules 2, forming a total of 24 independent channels.

[0070] In one embodiment, the individual channels can be connected in parallel as needed to form a larger current output channel.

[0071] In one embodiment, the plurality of terminal sockets 41 have insertion portions for inserting the connection terminals of the control board.

[0072] In one embodiment, a cooling fan is provided at the rear of the housing module 1 to cool down the drive board module 2 and the control board module 3, thereby reducing the heat generation of power devices and control components during high-current operation.

[0073] This invention features multi-channel intelligent parallel connection, supporting parallel connection of any channel within a single power supply box, as well as extended parallel connection between different power supply boxes. Users only need to connect the current lines in parallel at the battery end and complete parameter configuration via host computer software to achieve high current output and multi-channel coordinated control, without the need for manual replacement of copper busbars or modification of hardware connections. The system can automatically complete current distribution and synchronization control between parallel channels, improving parallel consistency and system scalability, meeting the testing requirements of high-rate, high-power battery cells.

[0074] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0075] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0076] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0077] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0078] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0079] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A high-performance, high-precision drive box, characterized in that, include: The housing module (1) has a mounting cavity for supporting and protecting other components; Multiple drive board modules (2) are arranged side by side in the mounting cavity, and the voltage is collected by the external ADC sampling chip of the control board module (3); each drive board module contains 4 independent channels, each independent channel can carry a maximum current of 50-100A; each independent channel is provided with multiple acquisition interfaces for real-time acquisition of dynamic data; The control board module (3) is located inside the mounting cavity and installed above the drive board module (2), and is used to realize input and output signal acquisition, control signal processing and drive board communication connection; The backplane module (4) is installed in the mounting cavity and includes a backplane (42) and multiple terminal sockets (41) integrated on the backplane (42). The multiple terminal sockets (41) are plugged into the CPCI connector (27) on the control board module (3) to realize the power supply, signal transmission and communication functions of the drive board module (2). The main control board module (5) is installed in the installation cavity and is connected to the host computer and each drive board module to realize the charging and discharging process control, status data acquisition and command interaction of each channel. At the same time, it performs unified scheduling and management of different test channels, and completes channel allocation, operation control and abnormal monitoring. The busbar copper strip module (6) is connected to the ACDC power supply box and the precision copper strip respectively. The signal transmission port of the ACDC power supply box is connected to the CAN interface of the main control board module (5).

2. The high-performance, high-precision drive box according to claim 1, characterized in that, The control board module (3) includes a core processor chip (32) and an external ADC acquisition chip (33). The core processor chip (32) and the external ADC acquisition chip (33) are connected via an SPI interface. The core processor chip (32) drives the power switching device by adjusting the frequency and duty cycle of the pulse signal to achieve precise adjustment of the output voltage, current and power. At the same time, combined with sampling feedback and protection logic, a closed-loop control of the power supply system is formed.

3. The high-performance, high-precision drive box according to claim 1, characterized in that, The front of the drive board module (2) is provided with a flat terminal (21), a positive copper strip (22), a negative copper strip (23), a shunt (24), a copper wire (25), and a CPCI connector (27). The side panel is provided with a 100A drive board positive interface (28), a spring terminal (29), a 400A drive board module negative adapter copper strip (30), and a drive board module negative bus copper strip (31). The CPCI connector is plugged into the terminal socket (41). The driver board module (2) collects current through a shunt (24) and collects voltage through an external ADC sampling chip.

4. The high-performance, high-precision drive box according to claim 1, characterized in that, The main control board module (5) includes a sixth-generation aircraft adapter board (51) and a sixth-generation aircraft main control board (52). The sixth-generation aircraft adapter board (51) is plugged into the corresponding terminal socket on the backplane module. The sixth-generation aircraft main control board (52) communicates with the drive board module (2) and the control board module (3) using EtherCAT to uniformly schedule and manage different test channels, and complete channel allocation, operation control and abnormal monitoring.

5. The high-performance, high-precision drive box according to claim 1, characterized in that, The dynamic data includes battery voltage, current, line voltage, auxiliary voltage, channel temperature, and battery temperature.

6. A high-performance, high-precision drive box according to claim 2, characterized in that, The housing module (1) contains a total of 6 drive board modules (2), forming a total of 24 independent channels.

7. A high-performance, high-precision drive box according to claim 6, characterized in that, The individual channels can be connected in parallel to form a larger current output channel according to test requirements.

8. A high-performance, high-precision drive box according to claim 2, characterized in that, The plurality of terminal sockets (41) have insertion portions for inserting the connection terminals of the control board.

9. A high-performance, high-precision drive box according to claim 1, characterized in that, The rear of the enclosure module (1) is equipped with a cooling fan to cool down the drive board module (2) and the control board module (3) in order to reduce the heat generation of power devices and control components during high current operation.

Images