Battery pack pedal endurance test device and test method

Abstract

The application relates to the technical field of new energy battery pack testing, and proposes a battery pack treading endurance testing device and a testing method.The device comprises a box body which is a hollow structure; a loading assembly arranged on the top surface of the box body; the output end of the loading assembly penetrates through the box body and is located directly above the battery pack; an airtight adapter pipeline which is arranged on the box body and is connected with a pressure relief valve of the battery pack at one end and connected with an external airtight detection equipment at the other end; a wire harness threading pipe which is arranged on the box body and is connected with a wire harness of the battery pack at one end; a displacement sensor arranged on the upper cover plate of the battery pack; and a control system connected with the loading assembly, the airtight detection equipment, an insulation detection equipment, the displacement sensor and a low-voltage communication line signal of the battery pack respectively. The box body is integrated with loading and multi-parameter detection, the disassembly and circulation of the battery pack are omitted, the test efficiency is improved, physical isolation and real-time monitoring are simultaneously realized, and test safety is ensured.

Description

Technical Field

[0001] This invention relates to the field of new energy battery pack testing technology, specifically to a battery pack step-dwelling durability testing device and testing method. Background Technology

[0002] With the rapid development of die-casting technology in the automotive industry and the ongoing pressure to reduce costs, more and more vehicle manufacturers are adopting CTB (Battery-to-Body) and CTC (Cell-to-Cover) technologies (integrating battery cells directly into the vehicle chassis or body structure). These technologies eliminate the traditional floor structure of automobiles, causing drivers and passengers to directly step on the battery pack's top cover. Therefore, the industry urgently needs a testing system that can realistically simulate the stepping conditions experienced by users during long-term use, to verify the fatigue durability and safety of the battery pack's top cover under repeated stepping, ensuring that the battery pack will not experience internal short circuits, airtightness issues, or other safety hazards due to top cover deformation. Currently, the industry's methods for verifying the tread pressure performance of battery packs are relatively limited. The common practice is to perform static pressure strength verification at a single point on the battery pack. In addition, some vehicle manufacturers have attempted to perform load durability verification on individual battery packs, but no standardized, systematic testing scheme has been developed. The current testing challenges lie in: (1) Due to the serious risk of short circuits and fires in battery packs during durability tests, existing solutions generally lack effective safety protection and emergency response measures. Once an accident occurs, it is very easy to cause equipment damage or even endanger the safety of personnel and factory buildings. (2) In the existing test process, the battery pack needs to be repeatedly disassembled and transferred between multiple devices such as the loading station, the airtightness test station, and the flatness test station. The operation is cumbersome and the cycle is long, which restricts the test efficiency. (3) A single static pressure test can only verify the instantaneous strength of the top cover plate, and cannot simulate the fatigue cumulative damage caused by repeated stepping during use, resulting in insufficient verification. Summary of the Invention

[0003] This application provides a battery pack tread durability testing device and method, which solves the technical problems of significant safety hazards, long testing cycles, and low efficiency caused by the lack of safety protection measures and the need for multiple disassembly and reassembly in the existing technology.

[0004] In a first aspect, embodiments of this application provide a battery pack trampling durability testing device, which includes: The housing is a hollow structure designed to house the battery pack; The loading component is located on the top surface of the enclosure; the output end of the loading component penetrates through the enclosure and is located directly above the battery pack. An airtight transfer pipe is installed on the enclosure, with one end connected to the pressure relief valve interface of the battery pack and the other end connected to an external airtightness testing device. The wiring harness conduit is installed on the housing, and one end is connected to the wiring harness interface of the battery pack to lead out the high-voltage line of the battery pack and connect it to the external insulation testing equipment. Displacement sensor, which is located on the top cover of the battery pack; The control system is connected to the low-voltage communication lines of the loading component, airtightness testing equipment, insulation testing equipment, displacement sensor, and battery pack to apply cyclic loads to the battery pack and acquire test parameters.

[0005] In conjunction with the first aspect, in one embodiment, a water inlet is provided on the top of the box; The enclosure is equipped with smoke and temperature sensors, both of which are connected to the control system signals to alert operators to inject liquid into the enclosure to submerge the battery pack in the event of a fire or abnormal smoke.

[0006] In conjunction with the first aspect, in one embodiment, a pressure relief valve is provided on the top of the housing; The chamber is equipped with a pressure sensor that is connected to the control system signal to remind the operator to open the pressure relief valve when the pressure inside the chamber reaches a preset threshold.

[0007] In conjunction with the first aspect, in one embodiment, the loading component includes an electric cylinder and a loading rod; The loading rod passes through the top surface of the housing, with one end outside the housing connected to the output shaft of the electric cylinder, and the other end inside the housing serving as the output end; the electric cylinder is also connected to the control system signal.

[0008] In conjunction with the first aspect, in one embodiment, the output end of the loading rod may be detachably equipped with a loading simulation head, which includes a flat-bottomed loading head and a pointed loading head.

[0009] In conjunction with the first aspect, in one embodiment, one end of the loading vertical rod located outside the housing is magnetically connected to the output shaft of the electric cylinder via a magnetic adapter, so as to allow the electric cylinder to disengage from the loading vertical rod immediately.

[0010] In conjunction with the first aspect, in one embodiment, a carpet layer is also included, which is laid on the surface of the top cover of the battery pack; The displacement sensor is a through-type travel sensor, whose measuring probe passes through the carpet layer and directly contacts the top cover of the battery pack.

[0011] In conjunction with the first aspect, in one embodiment, the bottom of the housing is provided with a base for securing the battery pack; The enclosure is made of transparent material so that the battery pack status can be observed without opening the enclosure.

[0012] Secondly, embodiments of this application provide a method for testing the durability of a battery pack under foot pressure, comprising: Cyclic loads are applied to the battery pack inside the enclosure using a loading component; During loading, the deformation of the top cover of the battery pack is collected by displacement sensor, the air tightness parameters of the battery pack are detected by air tightness detection equipment connected by air tightness transfer pipeline, the insulation resistance value of the battery pack is detected in real time by low-voltage communication line of the battery pack, and the insulation of the battery pack is checked by high-voltage line led out by wire harness conduit when the predetermined durability number is reached. The battery pack's tread durability is evaluated based on the deformation, airtightness parameters, and insulation resistance values ​​obtained from the control system.

[0013] In conjunction with the second aspect, in one embodiment, the insulation check is triggered when the number of cycles of the loading components counted by the control system reaches a preset threshold. The control system then controls the insulation detection equipment to measure the insulation resistance of the high-voltage circuit of the battery pack. The measured insulation resistance value is compared with the insulation resistance value detected in real time by the low-voltage communication line to determine the trend of insulation performance degradation of the battery pack during long-term durability testing.

[0014] The beneficial effects of the technical solutions provided in this application include: A battery pack tread durability testing device is proposed. This device uses airtightness transfer tubing and wiring harness conduits to bring the key interfaces of the battery pack from the enclosed enclosure to the outside. This allows airtightness and insulation testing equipment to connect to the battery pack without opening the enclosure or removing the battery pack, achieving integrated loading, airtightness testing, and insulation monitoring. This avoids the cumbersome process of repeatedly disassembling and transferring the battery pack between different workstations in existing technologies, shortening the testing cycle and improving efficiency. Furthermore, the control system is simultaneously connected to the loading component, airtightness testing equipment, insulation testing equipment, displacement sensor, and the low-voltage communication line of the battery pack, forming a monitoring and control system. During the application of cyclic loads to the loading components, displacement sensors provide real-time feedback on the deformation of the top cover, airtightness testing equipment provides real-time feedback on the sealing status, and insulation testing equipment monitors insulation resistance in real-time via a low-voltage communication line. The control system then uses this multi-dimensional data to determine the battery pack status. If any abnormality occurs, the control system can immediately issue an alert and take protective measures. The enclosure itself acts as a physical isolation barrier, enclosing the hazardous battery pack testing process within, while all testing equipment is placed outside the enclosure and connected via pipelines. This ensures testing accuracy and isolates personnel from potential hazards, thus solving the safety risks of equipment damage and personnel injury that may result from test failures in existing technologies. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the battery pack trampling durability testing device provided in an embodiment of this application; Figure 2 This is a schematic diagram of the battery pack treading durability test method provided in an embodiment of this application.

[0017] In the diagram: 1. Housing; 2. Battery pack; 3. Loading assembly; 31. Electric cylinder; 32. Loading vertical rod; 4. Airtight transfer pipe; 5. Wiring harness conduit; 6. Displacement sensor; 7. Control system; 8. Water inlet; 9. Pressure relief valve; 10. Carpet layer. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present application.

[0019] To make the technical problem that this application aims to solve clearer, the causes of the technical problem will be analyzed in detail below: In existing technologies, battery pack 2 is typically exposed to an open environment or simple fixtures during durability testing. If battery pack 2 catches fire, emits smoke, or even explodes during cyclic loading due to internal short circuits or electrolyte leakage, the flames and toxic gases will spread directly to the test site, easily igniting surrounding equipment, damaging the factory, and causing serious personal injury to operators. There is a lack of real-time electrical condition monitoring methods; existing solutions only perform simple insulation resistance checks before and after the test, failing to continuously monitor changes in the insulation performance of battery pack 2 during loading. Because stepping loads cause repeated deformation of the top cover, this may gradually damage the internal insulation layer or terminal sealing structure of battery pack 2. This gradual damage cannot be detected in a single static pressure test and only becomes apparent during long-term durability testing. The lack of real-time monitoring means that early warnings and shutdowns cannot be initiated in the early stages of insulation degradation. Often, problems are only detected when a serious short circuit or fire occurs, missing the optimal response time. Furthermore, high-value equipment is tightly coupled with hazardous sources. In existing load endurance tests, precision and expensive drive components are typically rigidly connected to battery pack 2 and directly exposed to the test environment. If thermal runaway occurs in battery pack 2, flames and high temperatures will rapidly spread to these high-value components, causing irreversible damage and increasing test costs and repair cycles.

[0020] Existing technology distributes the testing processes—including tread pressure testing, airtightness testing, flatness (deformation) testing, and insulation performance testing—on different specialized equipment. After each test is completed, the battery pack 2 needs to be removed from the current workstation, transported to the next workstation for reinstallation, alignment, and wiring. This sequential workflow results in a significant amount of time being spent on disassembly, reassembly, transportation, and recalibration. Especially for the large and heavy battery pack 2, each transport requires the use of lifting equipment and multiple personnel, making it extremely inefficient.

[0021] Firstly, reference Figures 1 to 2 This application provides a battery pack trampling durability testing device, which includes: Box 1, which is a hollow structure, is used to house battery pack 2; Loading component 3 is located on the top surface of housing 1; the output end of loading component 3 passes through housing 1 and is located directly above battery pack 2. The airtightness transfer pipe 4 is installed on the housing 1, with one end connected to the pressure relief valve interface of the battery pack 2 and the other end connected to the external airtightness testing equipment. The wiring harness conduit 5 is installed on the housing 1, and one end is connected to the wiring harness interface of the battery pack 2 to lead out the high voltage line of the battery pack 2 and connect it to the external insulation testing equipment. Displacement sensor 6 is located on the upper cover of battery pack 2; The control system 7 is connected to the low-voltage communication lines of the loading component 3, the airtightness testing device, the insulation testing device, the displacement sensor 6, and the battery pack 2, respectively, to apply cyclic loads to the battery pack 2 and acquire test parameters.

[0022] By setting up this device, the key interfaces of the battery pack 2 are led out from the inside of the closed housing 1 to the outside through the airtight transfer pipe 4 and the wiring harness conduit 5. This allows the airtightness testing equipment and the insulation testing equipment to establish a connection with the battery pack 2 without opening the housing 1 or removing the battery pack 2. This achieves integrated loading, airtightness testing, and insulation monitoring, avoiding the cumbersome process of repeatedly disassembling and transferring the battery pack 2 between different workstations in the prior art, shortening the test cycle and improving efficiency. Secondly, the control system 7 is simultaneously connected to the loading component 3, the airtightness testing equipment, the insulation testing equipment, the displacement sensor 6, and the low-voltage communication line of the battery pack 2, forming a monitoring and control network. During the application of cyclic load by loading component 3, displacement sensor 6 provides real-time feedback on the deformation of the upper cover plate, airtightness testing equipment provides real-time feedback on the sealing status, insulation testing equipment monitors insulation resistance in real-time via low-voltage communication line, and control system 7 judges the status of battery pack 2 based on these multi-dimensional data. Once an abnormality occurs, control system 7 can immediately alert and take protective measures. The enclosure 1 itself acts as a physical isolation barrier, enclosing the dangerous battery pack 2 testing process inside, while all testing equipment is placed outside the enclosure 1 and connected by pipelines. This ensures testing accuracy and isolates personnel from potential hazards, solving the safety hazards of equipment damage and personnel injury that may occur due to test failure in existing technologies.

[0023] Furthermore, in one embodiment, a water inlet 8 is provided on the top of the box body 1; The housing 1 is equipped with a smoke sensor and a temperature sensor, both of which are connected to the control system 7 for injecting liquid into the housing 1 to submerge the battery pack 2 in the event of a fire or abnormal smoke.

[0024] In this embodiment, by setting a water inlet 8 on the top of the housing 1 and configuring a smoke sensor and a temperature sensor connected to the control system 7 inside the housing 1, the sensing and intervention function for abnormal fires or smoke emissions from the battery pack 2 is realized. When the sensors detect an abnormality, liquid can be injected into the housing 1 through the water inlet 8 to submerge the battery pack 2, allowing it to release electrical energy in a relatively safe manner. This nips a fire in its infancy, effectively preventing the flames from spreading to the outside of the housing, protecting the safety of surrounding equipment, factory buildings, and operators, and making up for the lack of active fire-fighting measures in the prior art.

[0025] Furthermore, in one embodiment, a pressure relief valve 9 is provided on the top of the housing 1; The housing 1 is equipped with a pressure sensor that is connected to the control system 7 to open the pressure relief valve 9 when the pressure inside the housing 1 reaches a preset threshold.

[0026] In this embodiment, by installing a pressure relief valve 9 on the top of the housing 1 and configuring a pressure sensor connected to the control system 7 inside the housing 1, real-time monitoring and automatic pressure relief of the internal pressure of the housing 1 are achieved. When the battery pack 2 undergoes a violent chemical reaction such as deflagration during the test, causing the internal pressure to rise sharply and reach a preset threshold, the pressure relief valve 9 can be opened to release the high-pressure gas, preventing the housing 1 from bursting or exploding due to overpressure, thereby avoiding secondary disasters, protecting the structural integrity of the housing 1 and the safety of surrounding equipment and personnel, and enhancing the safety guarantee capability of the test device under extreme failure conditions.

[0027] Furthermore, in one embodiment, the loading component 3 includes an electric cylinder 31 and a loading rod 32; The loading rod 32 is installed on the top surface of the housing 1. One end of the rod outside the housing 1 is connected to the output shaft of the electric cylinder 31, and the other end inside the housing 1 serves as the output end. The electric cylinder 31 is also connected to the control system 7 via signal.

[0028] In this embodiment, the electric cylinder 31 provides precise and controllable reciprocating linear motion, which can apply a stable cyclic load to the battery pack 2 according to the loading frequency, amplitude and number of times preset by the control system, and truly simulate the fatigue condition of repeated stepping by the user; the layout of the loading vertical rod 32 penetrating the box 1 makes the electric cylinder 31 located outside the box 1, physically isolated from the dangerous sources inside the box, reducing the risk of damage to the electric cylinder 31 due to thermal runaway of the battery pack 2; the signal connection between the control system 7 and the electric cylinder 31 realizes the automatic adjustment and real-time feedback control of the loading parameters, improving the accuracy of the test.

[0029] Furthermore, in one embodiment, the output end of the loading rod 32 may be detachably provided with a loading simulation head, which includes a flat-bottomed loading head and a pointed loading head.

[0030] In this embodiment, by detachably setting a loading simulation head at the output end of the loading vertical rod 32, and specifically defining the loading simulation head as a flat-bottomed loading head and a pointed-toe loading head, the simulation switching function for different shoe types is realized. The flat-bottomed loading head can simulate the stepping contact area and pressure distribution of ordinary shoe soles, while the pointed-toe loading head can simulate the concentrated load effect of high-heeled shoe soles. By changing the loading head, the two most typical stepping conditions in daily use can be covered, making the test conditions closer to real user scenarios, avoiding the verification blind spots caused by a single loading head, improving the comprehensiveness and simulation degree of stepping durability test, and thus more accurately evaluating the fatigue resistance performance of the battery pack 2 cover plate in actual use.

[0031] Furthermore, in one embodiment, one end of the loading rod 32 located outside the housing 1 is magnetically connected to the output shaft of the electric cylinder 31 via a magnetic adapter, so as to allow the electric cylinder 31 to disengage from the loading rod 32 immediately.

[0032] In this embodiment, a magnetic connection is achieved by setting a magnetic adapter between the loading vertical rod 32 and the output shaft of the electric cylinder 31. This allows the two to reliably transfer the load under normal operating conditions using magnetic attraction, while enabling immediate separation in emergencies such as a fire in the battery pack 2. When thermal runaway or deflagration occurs inside the housing 1, the control system 7 or external force can quickly separate the electric cylinder 31 from the loading vertical rod 32, thereby removing the electric cylinder 31 and its controller, along with other high-value accessories, from the danger zone to avoid damage from flames or high temperatures. This reduces the risk of equipment damage and economic losses, ensures the reuse of key components, and creates conditions for subsequent troubleshooting and test recovery.

[0033] Furthermore, in one embodiment, a carpet layer 10 is also included, which is laid on the surface of the upper cover plate of the battery pack 2; The displacement sensor 6 is a through-type travel sensor, whose measuring probe passes through the carpet layer 10 and directly contacts the top cover of the battery pack 2.

[0034] In this embodiment, by adding a carpet layer 10 laid on the surface of the upper cover of the battery pack 2, and setting the displacement sensor 6 as a penetrating stroke sensor, so that its measuring probe passes through the carpet layer 10 and directly contacts the upper cover, on the one hand, the setting of the carpet layer 10 simulates the covering state of the floor mats inside a real vehicle, so that the load applied by the loading component 3 is transmitted to the upper cover through the carpet layer 10, which is closer to the force conditions when the user actually steps on it, thus improving the authenticity of the test; on the other hand, the penetrating displacement sensor directly measures the deformation of the upper cover itself, eliminating the interference of the elastic deformation of the carpet layer on the measurement results, avoiding the error caused by carpet compression in traditional indirect measurement methods, thereby obtaining accurate and reliable deformation data, providing a precise basis for evaluating the durability performance of the battery pack 2.

[0035] Furthermore, in one embodiment, the bottom of the housing 1 is provided with a base for fixing the battery pack 2; The housing 1 is designed to be transparent so that the status of the battery pack 2 can be observed without opening the housing 1.

[0036] In this embodiment, by setting a base for fixing the battery pack 2 at the bottom of the housing 1 and designing the housing 1 to be transparent, on the one hand, the base can securely fix the battery pack 2 in a predetermined position inside the housing 1, preventing the battery pack 2 from shifting due to vibration or impact during cyclic loading, and ensuring that the loading component 3 is always aligned with the target loading area; on the other hand, the transparent housing 1 allows the operator to directly observe the appearance changes of the battery pack 2 during the test (such as whether the top cover is cracked, whether there is smoke or fire, etc.) without opening the housing 1, which avoids frequently opening the door to damage the sealed environment of the housing 1 and interrupt the test process, and also ensures the physical isolation of the operator from the hazard source, taking into account both safety and observation convenience.

[0037] Secondly, this application proposes a method for testing the durability of a battery pack under foot pressure, which includes: A cyclic load is applied to the battery pack 2 inside the housing 1 using the loading component 3; During the loading process, the deformation of the upper cover of the battery pack 2 is collected by the displacement sensor 6, the air tightness parameters of the battery pack 2 are detected by the air tightness detection equipment connected by the air tightness transfer pipe 4, the insulation resistance value of the battery pack 2 is detected in real time by the low-voltage communication line of the battery pack 2, and the insulation of the battery pack 2 is checked by the high-voltage line led out by the wire harness conduit 5 when the predetermined durability number is reached. The tread durability of the battery pack 2 is evaluated based on the deformation, airtightness parameters, and insulation resistance values ​​obtained from the control system 7.

[0038] By integrating cyclic loading, deformation acquisition, airtightness testing, real-time insulation resistance monitoring, and specialized insulation checks into a single test process, and relying on the device described in the first aspect to achieve synchronous execution of all operations within the closed state of enclosure 1, this method eliminates the serial operation mode of repeated disassembly and reassembly of battery pack 2 between different workstations in existing technologies. It realizes a parallel testing process of one-time clamping and full-item testing, shortening the test cycle and improving testing efficiency. On the other hand, by combining real-time monitoring of insulation resistance via low-voltage communication lines with specialized insulation checks of high-voltage lines at predetermined durability cycles, a continuous online early warning and phased evaluation insulation monitoring system is formed. This system can promptly capture abnormal signals in the early stages of insulation performance degradation and conduct timely evaluations to prevent safety accidents such as short circuits and fires caused by insulation failure. At the same time, the entire test process is carried out under the physical isolation protection of enclosure 1, ensuring that even in the event of extreme failure, the safety of personnel and equipment will not be endangered. It should be noted that the low-voltage communication line is connected to the control system 7, and its insulation resistance value is detected in real time through messages.

[0039] Furthermore, in one embodiment, the insulation check is triggered when the number of cycles of the loading component 3 counted by the control system 7 reaches a preset threshold. The control system 7 controls the insulation detection device to measure the insulation resistance of the high-voltage circuit of the battery pack 2. The measured insulation resistance value is compared with the insulation resistance value detected in real time by the low-voltage communication line to determine the trend of insulation performance degradation of the battery pack 2 in the long-term durability test.

[0040] In this embodiment, it is clarified that the insulation check is not performed randomly or continuously, but is precisely triggered when the number of cycles of the loading component 3 counted by the control system 7 reaches a preset threshold. For example, at key nodes such as 10%, 50%, and 100% of the total number of cycles in the durability test, a precise measurement is performed on the high-voltage circuit of the battery pack 2. This can capture the stage-by-stage changes in insulation performance under long-term fatigue accumulation, avoiding subtle degradation signals missed by real-time monitoring due to sampling frequency or accuracy limitations. Secondly, the insulation resistance value obtained by offline measurement is compared with the insulation resistance value detected in real-time by the low-voltage communication line. If the real-time monitoring value slowly decreases from the normal range of 500MΩ to 300MΩ at a certain stage, but is still above the safety threshold, and the offline measurement is 280MΩ, the two are close, so it can be judged that the insulation performance is showing a slow linear decay trend, and the test can continue; conversely, if the real-time monitoring value shows 300MΩ, but the offline measurement value drops sharply to 50MΩ, it indicates that there may be a lag or blind spot in the real-time monitoring, and local insulation breakdown may have occurred inside the battery pack 2, requiring immediate shutdown for investigation. This comparative analysis can effectively identify whether abnormal fluctuations detected in real-time monitoring are genuine performance degradation or sensor noise interference, thus enabling more accurate judgments. Finally, by tracking comparative data from multiple nodes over a long period, a decay curve of insulation resistance with the number of cycles can be plotted, quantitatively assessing the expected insulation life of battery pack 2 under fatigue conditions. For example, if the offline measurements for the first three nodes (10%, 50%, and 100%) are 480MΩ, 350MΩ, and 200MΩ respectively, showing a clear accelerated decay trend, it can be predicted in advance that the battery pack may experience insulation failure in subsequent tests, thus proactively terminating the test or strengthening safety protection measures before an accident occurs. This predictive judgment based on trend analysis improves the safety assurance level of the test compared to simply relying on a single threshold alarm.

[0041] The beneficial effects of this invention include: A battery pack tread durability testing device is proposed. The device connects the key interfaces of the battery pack 2 from the inside of the enclosed housing 1 to the outside via an airtightness transfer pipe 4 and a wiring harness conduit 5. This allows the airtightness testing equipment and insulation testing equipment to connect to the battery pack 2 without opening the housing 1 or removing the battery pack 2, achieving integrated loading, airtightness testing, and insulation monitoring. This avoids the cumbersome process of repeatedly disassembling and reassembling the battery pack 2 between different workstations in existing technologies, shortening the testing cycle and improving efficiency. Furthermore, the control system 7 is simultaneously connected to the loading component 3, the airtightness testing equipment, the insulation testing equipment, the displacement sensor 6, and the low-voltage communication line of the battery pack 2, forming a monitoring and... During the application of cyclic load by loading component 3, the displacement sensor 6 provides real-time feedback on the deformation of the upper cover plate, the airtightness testing device provides real-time feedback on the sealing status, and the insulation testing device monitors the insulation resistance in real-time via a low-voltage communication line. The control system 7 then judges the status of battery pack 2 based on these multi-dimensional data. If any abnormality occurs, the control system 7 can immediately alert and take protective measures. The enclosure 1 itself acts as a physical isolation barrier, enclosing the dangerous battery pack 2 testing process inside, while all testing equipment is placed outside the enclosure 1 and connected via pipelines. This ensures testing accuracy and isolates personnel from potential hazards, solving the safety risks of equipment damage and personnel injury that may occur due to test failure in existing technologies.

[0042] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0043] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A battery pack trampling durability testing device, characterized in that, It includes: The housing (1) is a hollow structure designed to house the battery pack (2). A loading component (3) is disposed on the top surface of the housing (1); the output end of the loading component (3) passes through the housing (1) and is located directly above the battery pack (2); An airtight transfer pipe (4) is installed on the box (1), with one end connected to the pressure relief valve interface of the battery pack (2) and the other end connected to an external airtightness testing device. The wiring harness conduit (5) is installed on the housing (1) and one end is connected to the wiring harness interface of the battery pack (2) to lead out the high voltage line of the battery pack (2) and connect it to the external insulation testing equipment. Displacement sensor (6), which is located on the upper cover of battery pack (2); The control system (7) is connected to the low-voltage communication lines of the loading component (3), the airtightness detection device, the insulation detection device, the displacement sensor (6), and the battery pack (2) respectively, for applying cyclic loads to the battery pack (2) and acquiring test parameters.

2. The battery pack trampling durability testing device as described in claim 1, characterized in that: The top of the box (1) is provided with a water inlet (8); The housing (1) is equipped with a smoke sensor and a temperature sensor, and both the smoke sensor and the temperature sensor are connected to the control system (7) for signaling to remind the operator to inject liquid into the housing (1) to submerge the battery pack (2) in case of fire or abnormal smoke.

3. The battery pack trampling durability testing device as described in claim 1, characterized in that: The top of the housing (1) is provided with a pressure relief valve (9); The housing (1) is equipped with a pressure sensor that is connected to the control system (7) to remind the operator to open the pressure relief valve (9) when the pressure inside the housing (1) reaches a preset threshold.

4. The battery pack trampling durability testing device as described in claim 1, characterized in that: The loading component (3) includes an electric cylinder (31) and a loading rod (32); The loading rod (32) passes through the top surface of the housing (1), with one end outside the housing (1) connected to the output shaft of the electric cylinder (31) and the other end inside the housing (1) serving as the output end; and the electric cylinder (31) is connected to the control system (7) via signal.

5. The battery pack trampling durability testing device as described in claim 4, characterized in that: The output end of the loading vertical rod (32) may be detachably equipped with a loading simulation head, which includes a flat-bottomed loading head and a pointed loading head.

6. The battery pack trampling durability testing device as described in claim 4, characterized in that: One end of the loading rod (32) located outside the housing (1) is magnetically connected to the output shaft of the electric cylinder (31) via a magnetic adapter, so that the electric cylinder (31) can be immediately disengaged from the loading rod (32).

7. The battery pack trampling durability testing device as described in claim 1, characterized in that: It also includes a carpet layer (10) which is laid on the surface of the top cover of the battery pack (2); The displacement sensor (6) is a penetrating stroke sensor, whose measuring probe passes through the carpet layer (10) and directly contacts the top cover of the battery pack (2).

8. The battery pack trampling durability testing device as described in claim 1, characterized in that: The bottom of the housing (1) is provided with a base for fixing the battery pack (2); The housing (1) is made of transparent material so that the status of the battery pack (2) can be observed without opening the housing (1).

9. A method for testing the stamping durability of a battery pack, characterized in that, It includes: Provide a battery pack tread durability testing device as described in claim 1; The loading component (3) is used to apply a cyclic load to the battery pack (2) inside the housing (1); During the loading process, the deformation of the upper cover of the battery pack (2) is collected by the displacement sensor (6), the air tightness parameters of the battery pack (2) are detected by the air tightness detection device connected by the air tightness transfer pipe (4), the insulation resistance value of the battery pack (2) is detected in real time by the low-voltage communication line of the battery pack (2), and the insulation of the battery pack (2) is checked by the high-voltage line led out by the wire harness conduit (5) when the predetermined durability number is reached. The treading durability of the battery pack (2) is evaluated based on the deformation amount, the airtightness parameter and the insulation resistance value obtained by the control system (7).

10. The battery pack trampling durability test method as described in claim 9, characterized in that, The insulation check is triggered when the number of cycles of the loading component (3) counted by the control system (7) reaches a preset threshold. The control system (7) controls the insulation detection device to measure the insulation resistance of the high-voltage circuit of the battery pack (2). The measured insulation resistance value is compared with the insulation resistance value detected in real time by the low-voltage communication line to determine the trend of insulation performance degradation of the battery pack (2) in the long-term durability test.

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