Battery pack control box performance detection device and system

Abstract

The utility model relates to a battery pack control box performance detection device and system, and belongs to the technical field of power supply detection. The device comprises a high-voltage line control circuit board, a resistor used for simulating the identification resistor of the charging gun, and an industrial personal computer. The high-voltage line control circuit board is used for being connected with a high-voltage connector of a detected battery pack control box through a high-voltage detection wire harness. The internal resistance tester, the insulation and voltage resistance tester and the high-voltage direct-current power supply are electrically connected with the high-voltage line control circuit board respectively so as to connect different high-voltage loops in the tested battery pack control box according to selection of the high-voltage line control circuit board; the low-voltage direct-current power supply, the low-voltage signal analyzer, the voltage acquisition module and the resistor are respectively connected with a low-voltage connector of the detected battery pack control box through the low-voltage detection wire harness; the industrial personal computer is in communication connection with the internal resistance tester, the insulation and voltage resistance tester, the low-voltage signal analyzer and the voltage acquisition module, and the industrial personal computer is in control connection with the high-voltage line control circuit board, the high-voltage direct-current power supply and the low-voltage direct-current power supply.

Description

Technical Field

[0001] The utility model relates to a performance detection device and system for a battery pack control box, belonging to the technical field of power supply detection. Background Art

[0002] At present, there are more and more electric vehicles applying lithium-ion battery systems. While the output of lithium-ion battery systems is growing rapidly, seeking performance detection technologies with high efficiency and strong reliability is also the effort direction of each battery system manufacturing enterprise. A power supply system often consists of multiple battery packs and a control box. The control box mainly integrates components such as HVU (high-voltage detection module), DCDC (DC converter), BMU (main control unit), Hall, high-voltage circuit, and low-voltage circuit. After the control box is completed, it is necessary to detect the main performance of the control box. The main detection items include high-voltage circuit insulation withstand voltage detection, HVU function detection, DCDC function detection, Hall function detection, BMU communication function detection, analog quantity detection, resistance quantity detection, etc., to ensure that the performance of each component meets the requirements of the whole vehicle. The battery pack control box is an important part of the power supply system. Its structure is complex, and the internal components will vary with the needs of different vehicles. The performance safety and reliability of the battery pack control box directly affect whether the vehicle can be used normally. Therefore, for enterprises, it is particularly important to quickly and effectively detect the performance of the control box.

[0003] At present, for the performance detection of the battery pack control box, domestic power supply system manufacturing enterprises adopt a traditional multi-station and single-function detection scheme, set up independent detection workstations on the production line, and use auxiliary tools to confirm the results. The main problems are low efficiency, difficult operation, difficult traceability of process data, occupying more production line space, and easy mistakes in manual operation and the existence of electric shock risks.

[0004] The Chinese utility model patent with the authorization announcement number CN219871626U discloses a modular test device, which can be applied to the technical field of test systems. The modular test device includes a central control module, at least one function module and at least one test instrument; the function modules respectively correspond to corresponding test functions and are connected to the corresponding test instruments based on the test functions; the test functions are used to adjust the working state of the object under test or obtain the test parameters of the object under test in combination with the test instruments; the central control module is used to generate test instructions according to the target test plan and send the test instructions to the corresponding at least one function module, so that the function module realizes the corresponding test function and executes the test process corresponding to the target test plan. The above device not only ensures that the structure of the device itself is clear and easy to troubleshoot, but also facilitates the construction or adjustment of the device according to the test requirements, making the test device easy to assemble and maintain. This device can test multiple functions of the battery pack control box to a certain extent, but it cannot specifically detect the battery pack control box integrated with components such as HVU (high-voltage detection module), DCDC (DC converter), BMU (main control unit), Hall, high-voltage circuit, and low-voltage circuit, and cannot fully meet the detection requirements for this type of battery pack control box. Summary of the Utility Model

[0005] The purpose of the present utility model is to provide a performance detection device and system for a battery pack control box to solve the problem that it is difficult to improve the efficiency during the performance detection of the battery pack control box after completion on the production line.

[0006] To achieve the above purpose, the solution of the present utility model includes:

[0007] A performance detection device for a battery pack control box of the present utility model includes an internal resistance tester, an insulation withstanding voltage tester, a high-voltage DC power supply, a low-voltage DC power supply, a low-voltage signal analyzer, a voltage acquisition module, and further includes: a high-voltage line control circuit board for selectively connecting different high-voltage circuits inside the battery pack control box to be tested, a resistor for simulating the identification resistance of a charging gun, and an industrial control computer;

[0008] The high-voltage line control circuit board is used to connect the high-voltage plug of the battery pack control box to be tested through a high-voltage detection wire harness. The internal resistance tester, the insulation withstanding voltage tester, and the high-voltage DC power supply are respectively electrically connected to the high-voltage line control circuit board to realize the connection of different high-voltage circuits inside the battery pack control box to be tested according to the selection of the high-voltage line control circuit board; the low-voltage DC power supply, the low-voltage signal analyzer, the voltage acquisition module, and the resistor are used to be respectively connected to the low-voltage plug of the battery pack control box to be tested through a low-voltage detection wire harness; the internal resistance tester, the insulation withstanding voltage tester, the low-voltage signal analyzer, and the voltage acquisition module are respectively communicatively connected to the industrial control computer, and the industrial control computer is controllably connected to the high-voltage line control circuit board, the high-voltage DC power supply, and the low-voltage DC power supply.

[0009] Furthermore, the high-voltage DC power supply is a programmable high-voltage DC power supply.

[0010] Furthermore, the low-voltage DC power supply is a programmable low-voltage DC power supply.

[0011] Furthermore, the high-voltage line control circuit board is connected to the industrial control computer through an RS-232 serial port or an RS-485 serial port.

[0012] Furthermore, the high-voltage line control circuit board, the internal resistance tester, the insulation withstanding voltage tester, the high-voltage DC power supply, the low-voltage DC power supply, the low-voltage signal analyzer, the voltage acquisition module, the resistor, and the industrial control computer are integrally installed in a cabinet.

[0013] A performance detection system for a battery pack control box of the present utility model includes an internal resistance tester, an insulation withstanding voltage tester, a high-voltage DC power supply, a low-voltage DC power supply, a low-voltage signal analyzer, and a voltage acquisition module, and further includes: a high-voltage line control circuit board for selectively connecting different high-voltage circuits inside the battery pack control box to be tested, a resistor for simulating the identification resistance of a charging gun, an industrial control computer, and a host computer connected to the industrial control computer;

[0014] The high-voltage line control circuit board is used to connect the high-voltage connector of the battery pack control box to be tested through a high-voltage detection wire harness. The internal resistance tester, the insulation withstanding voltage tester, and the high-voltage DC power supply are respectively electrically connected to the high-voltage line control circuit board to realize connecting different high-voltage circuits inside the battery pack control box to be tested according to the selection of the high-voltage line control circuit board; the low-voltage DC power supply, the low-voltage signal analyzer, the voltage acquisition module, and the resistor are used to be respectively connected to the low-voltage connector of the battery pack control box to be tested through a low-voltage detection wire harness; the internal resistance tester, the insulation withstanding voltage tester, the low-voltage signal analyzer, and the voltage acquisition module are respectively communicatively connected to the industrial control computer, and the industrial control computer is controllably connected to the high-voltage line control circuit board, the high-voltage DC power supply, and the low-voltage DC power supply.

[0015] Furthermore, the high-voltage DC power supply is a programmable high-voltage DC power supply.

[0016] Furthermore, the low-voltage DC power supply is a programmable low-voltage DC power supply.

[0017] Furthermore, the high-voltage line control circuit board is connected to the industrial control computer through an RS-232 serial port or an RS-485 serial port.

[0018] Furthermore, the high-voltage line control circuit board, the internal resistance tester, the insulation withstanding voltage tester, the high-voltage DC power supply, the low-voltage DC power supply, the low-voltage signal analyzer, the voltage acquisition module, the resistor, and the industrial control computer are integrally installed in a cabinet.

[0019] The beneficial effects of the present utility model are:

[0020] The present utility model is a combined invention. When detecting the performance of the battery pack control box, the following items are mainly detected: high-voltage circuit insulation withstand voltage detection, HVU function detection, DCDC function detection, Hall function detection, BMU communication function detection, analog quantity detection, resistance quantity detection, etc. The devices for realizing the above detection functions mainly include: insulation withstand voltage tester, internal resistance tester, programmable high-voltage DC power supply, programmable low-voltage DC power supply, low-voltage signal analyzer, high-voltage harness control circuit board, voltage acquisition module, resistor, etc. The present utility model provides a battery pack control box detection device and system that integrates the above detection devices with an industrial control computer, replacing the traditional multi-station and single-function detection scheme on the production line, and can solve the problem that it is difficult to improve the efficiency when detecting the performance of the battery pack control box after completion on the production line. Description of the Drawings

[0021] Figure 1 It is a schematic diagram of the component composition of the battery pack control box;

[0022] Figure 2 It is a schematic diagram of the composition of the battery pack control box performance detection device;

[0023] Figure 3 It is a schematic diagram of the application of the battery pack control box performance detection device. Detailed Embodiment

[0024] To make the purpose, technical solution and advantages of the present utility model clearer and more understandable, the present utility model will be further described in detail below with reference to the drawings and embodiments.

[0025] Overall concept of the present utility model:

[0026] As Figure 1 shown, the battery pack control box is the detection object of the detection device involved in the present utility model. The battery pack control box mainly includes the following components: 1. High-voltage circuit connector; 2. Low-voltage circuit connector; 3. Control box outer body; 4. Electrical components: BMU (main control unit), Hall sensor, DCDC (DC converter), HVU (high-voltage detection module). For this battery pack control box, the main detection items include: high-voltage circuit insulation withstand voltage detection, HVU function detection, DCDC function detection, Hall function detection, BMU communication function detection, analog quantity detection, resistance quantity detection, etc. The devices for realizing the above detection functions mainly include: insulation withstand voltage tester, internal resistance tester, programmable high-voltage DC power supply, programmable low-voltage DC power supply, low-voltage signal analyzer, high-voltage harness control circuit board, voltage acquisition module, resistor, etc. The main concept of the present utility model is to provide a battery pack control box detection device that integrates the above detection devices with an industrial control computer, replacing the traditional multi-station and single-function detection scheme on the production line.

[0027] Embodiment of a performance detection device for a battery pack control box, as follows Figure 2 shown

[0028] (1) In the figure, the number 1 points to the high-voltage circuit connector (high-voltage connector) of the battery pack control box, and the number 2 points to the low-voltage circuit connector (low-voltage connector). Before the detection starts, connect the high-voltage detection harness to the high-voltage connector of the battery pack control box to be tested. The high-voltage detection harness includes multiple groups of high-voltage power supply lines, and the high-voltage connector includes plug connectors corresponding to multiple different high-voltage circuits in the battery pack control box to be tested; connect the low-voltage detection harness to the low-voltage connector of the battery pack control box to be tested. The low-voltage detection harness includes signal lines, detection lines, low-voltage power supply lines, and low-voltage output lines.

[0029] (2) Develop the upper computer operation software based on.Net. The upper computer is connected to the industrial computer, and the industrial computer is connected to and communicates with the high-voltage line control circuit board to control the high-voltage line control circuit board to perform line switching. The industrial computer is connected to and controls the high-voltage DC power supply and the low-voltage DC power supply and respectively controls their on and off. The industrial computer is communicatively connected to devices such as an internal resistance tester, an insulation withstanding voltage tester, a low-voltage signal analyzer, and a voltage acquisition module and controls the above devices to perform corresponding detections. The internal resistance tester, the insulation withstanding voltage tester, and the high-voltage DC power supply are electrically connected to the high-voltage line control circuit board. The low-voltage DC power supply, the low-voltage signal analyzer, and the voltage acquisition module are connected to the battery pack control box to be tested through the low-voltage detection harness.

[0030] Among them, the specific communication method between the industrial computer and each device is determined according to each device itself; the high-voltage DC power supply and the low-voltage DC power supply can be controlled to be turned on and off by the industrial computer controlling a switch, or a programmable high-voltage DC power supply and a programmable low-voltage DC power supply that can be directly controlled by the industrial computer can be selected.

[0031] (3) The high-voltage line control circuit board is used to switch different high-voltage circuits. The internal resistance tester is used to detect the continuity of the high-voltage circuit. The insulation withstanding voltage tester is used to detect the insulation performance of the battery pack control box shell in each high-voltage circuit. The high-voltage DC power supply is used to provide high voltage for the battery pack control box under the control of the industrial computer for detection. The low-voltage DC power supply is used to provide low voltage for the battery pack control box under the control of the industrial computer for detection. The low-voltage signal analyzer is used to send instructions to the DCDC and detect whether the functions of the BMU, Hall sensor, and HVU in the low-voltage circuit are normal. The voltage acquisition module is used to read whether the output voltage of the DCDC is normal. A resistor is connected to the BMU pin to simulate the identification resistor of the whole vehicle or the charging gun.

[0032] The operation method of a performance detection device for a battery pack control box of the present utility model when detecting a battery pack control box is as follows:

[0033] Before the detection starts, connect the high-voltage detection harness to the high-voltage connector of the battery pack control box, and connect the low-voltage detection harness to the low-voltage connector of the battery pack control box. When performing the performance detection of the battery pack control box, configure the detection items (such as the detection sequence, detection time, detection parameters, etc.) through the host computer software, and start the detection automatically by operating the host computer software.

[0034] During the detection process, the host computer automatically sends instructions through the industrial control computer to make the high-voltage DC power supply provide high voltage. According to the actual detection requirements, the on-off of the high-voltage DC power supply can be controlled by sending instructions to the switch through the industrial control computer. More preferably, a programmable high-voltage DC power supply is selected, and the on-off of the programmable high-voltage DC power supply is directly controlled by sending instructions from the industrial control computer to the programmable high-voltage DC power supply. The high-voltage value is generally 230V according to the actual situation of the whole vehicle and the battery pack.

[0035] A battery pack control box often contains multiple high-voltage circuits. Connecting the high-voltage detection harness to the high-voltage connector of the battery pack control box means connecting multiple high-voltage circuits. The industrial control computer automatically sends instructions to the high-voltage circuit control circuit board to switch the high-voltage circuit, switch to a high-voltage circuit to be detected, and successively call the internal resistance tester and the insulation withstand voltage tester for detection and obtain relevant data such as corresponding voltage and current. The on-off of the current circuit and the insulation withstand voltage performance of the battery pack control box are judged by comparing the obtained voltage, current and other relevant data with the set detection parameters. Among them, the communication method between the industrial control computer and the high-voltage harness circuit board is generally RS-232 serial communication or RS-484 serial communication. In actual situations, the specific communication method is determined according to the high-voltage circuit control circuit board equipment itself.

[0036] In the low-voltage circuit, similarly, the host computer software is used to make the industrial control computer automatically send instructions to make the low-voltage DC power supply provide low voltage. According to the actual detection requirements, the on-off of the low-voltage DC power supply can be controlled by sending instructions to the switch through the industrial control computer. More preferably, a programmable low-voltage DC power supply is selected, and the on-off of the programmable low-voltage DC power supply is directly controlled by sending instructions from the industrial control computer to the programmable low-voltage DC power supply. The low-voltage value is generally 12V or 24V according to the actual situation of the whole vehicle and the battery pack.

[0037] Operate the host computer software to make the industrial control computer automatically send instructions to the low-voltage signal analyzer through the board. The low-voltage signal analyzer performs the following tasks: detect the communication function, analog quantity, and resistance quantity of the BMU; read the detection information of the HVU; read the detection information of the Hall sensor; send instructions to the DCDC. After obtaining the above-mentioned detection data through the low-voltage signal analyzer, compare it with the set detection parameters to judge whether the functions of the BMU, HVU, and Hall sensor in the battery pack control box are normal. Among them, the BMU can be connected to multiple resistors through different pins to simulate the identification resistors of the whole vehicle or the charging gun.

[0038] The voltage acquisition module is a board card connected to the industrial control computer. This board card can read the output voltage of the DCDC. After obtaining the voltage data, it compares with the set detection parameters to determine whether the function of the DCDC in the battery pack control box is normal.

[0039] After the detection is completed, the detection data is automatically saved.

[0040] Embodiment of the battery pack control box performance detection system:

[0041] This embodiment provides a battery pack control box performance detection system, including the battery pack control box performance detection device introduced in the embodiment of the battery pack control box performance detection device and the upper computer. The upper computer is connected to the industrial control computer in the battery pack control box performance detection device and can control the battery pack control box performance detection device to automatically detect the battery pack control box through the upper computer. The battery pack control box performance detection device has been introduced clearly enough in the embodiment of the battery pack control box performance detection device and will not be elaborated here.

[0042] In summary, the present utility model integrates devices such as a high-voltage line control circuit board, an internal resistance tester, an insulation withstanding voltage tester, a high-voltage DC power supply, a low-voltage DC power supply, a low-voltage signal analyzer, a voltage acquisition module, a resistor, and an industrial control computer into one cabinet, and realizes the automatic detection of the performance of the battery pack control box through the battery pack control box performance detection system. After the integration of the battery pack control box detection device, as Figure 3 shown, in the figure, serial number 1 points to the detection device cabinet, serial number 2 points to the instrument integration, serial number 3 points to the connection of high-voltage and low-voltage wire harnesses, and serial number 4 points to the battery pack control box under test in the production line.

Claims

1. A battery pack control box performance detection device, including an internal resistance tester, an insulation withstand voltage tester, a high-voltage DC power supply, a low-voltage DC power supply, a low-voltage signal analyzer, and a voltage acquisition module, characterized in that: It also includes: a high-voltage line control circuit board for selecting and connecting different high-voltage circuits in the control box of the battery pack under test, a resistor for simulating the charging gun identification resistor, and an industrial computer; The high-voltage line control circuit board is used to connect the high-voltage connector of the battery pack control box under test through a high-voltage detection harness; the internal resistance tester, insulation withstand voltage tester, and high-voltage DC power supply are respectively electrically connected to the high-voltage line control circuit board to achieve connection of different high-voltage circuits in the battery pack control box under test according to the selection of the high-voltage line control circuit board; the low-voltage DC power supply, low-voltage signal analyzer, voltage acquisition module, and resistor are used to be connected to the low-voltage connector of the battery pack control box under test through a low-voltage detection harness; the internal resistance tester, insulation withstand voltage tester, low-voltage signal analyzer, and voltage acquisition module are respectively connected to the industrial computer for communication, and the industrial computer controls the connection of the high-voltage line control circuit board, the high-voltage DC power supply, and the low-voltage DC power supply.

2. The battery pack control box performance detection device according to claim 1, characterized in that: The high-voltage direct current power supply is a programmable high-voltage direct current power supply.

3. The battery pack control box performance detection device according to claim 1, characterized in that: The low-voltage DC power supply is a programmable low-voltage DC power supply.

4. The battery pack control box performance detection device according to claim 1, characterized in that: The high-voltage line control circuit board is connected to the industrial computer via an RS-232 serial port or an RS-485 serial port.

5. The battery pack control box performance detection device according to claim 1, characterized in that: The high-voltage line control circuit board, internal resistance tester, insulation withstand voltage tester, high-voltage DC power supply, low-voltage DC power supply, low-voltage signal analyzer, voltage acquisition module, resistor, and industrial computer are integrated and installed in a cabinet.

6. A battery pack control box performance detection system, comprising an internal resistance tester, an insulation withstand voltage tester, a high-voltage DC power supply, a low-voltage DC power supply, a low-voltage signal analyzer, and a voltage acquisition module, characterized in that: It also includes: a high-voltage line control circuit board for selecting and connecting different high-voltage circuits in the control box of the battery pack under test, a resistor for simulating the charging gun identification resistor, an industrial computer and a host computer connected to the industrial computer; The high-voltage line control circuit board is used to connect the high-voltage connector of the battery pack control box under test through a high-voltage detection harness; the internal resistance tester, insulation withstand voltage tester, and high-voltage DC power supply are respectively electrically connected to the high-voltage line control circuit board to achieve connection of different high-voltage circuits in the battery pack control box under test according to the selection of the high-voltage line control circuit board; the low-voltage DC power supply, low-voltage signal analyzer, voltage acquisition module, and resistor are used to be connected to the low-voltage connector of the battery pack control box under test through a low-voltage detection harness; the internal resistance tester, insulation withstand voltage tester, low-voltage signal analyzer, and voltage acquisition module are respectively connected to the industrial computer for communication, and the industrial computer controls the connection of the high-voltage line control circuit board, the high-voltage DC power supply, and the low-voltage DC power supply.

7. The battery pack control box performance detection system according to claim 6, characterized in that: The high-voltage direct current power supply is a programmable high-voltage direct current power supply.

8. The battery pack control box performance detection system according to claim 6, characterized in that: The low-voltage DC power supply is a programmable low-voltage DC power supply.

9. The battery pack control box performance detection system according to claim 6, characterized in that: The high-voltage line control circuit board is connected to the industrial computer via an RS-232 serial port or an RS-485 serial port.

10. The battery pack control box performance detection system according to claim 6, characterized in that: The high-voltage line control circuit board, internal resistance tester, insulation withstand voltage tester, high-voltage DC power supply, low-voltage DC power supply, low-voltage signal analyzer, voltage acquisition module, resistor, and industrial computer are integrated and installed in a cabinet.

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