Life cycle test equipment for battery management system

Abstract

The utility model relates to the technical field of battery management systems, in particular to life cycle test equipment for a battery management system, which comprises an upper computer, a simulation unit and a test unit, and is characterized in that the simulation unit comprises a high-voltage test box, a low-voltage test box, a battery simulation box and an environment simulation box; the testing unit comprises a high-precision measuring circuit, and the high-precision measuring circuit comprises a voltage input loop, a current input loop and a frequency input loop. Various complex conditions possibly encountered by the battery management system in practical application are fully covered by simulating various environmental conditions and working conditions, and measurement is performed through the test unit, so that the defects of the prior art are overcome, and high requirements of the fields of new energy automobiles, energy storage systems and the like on the test of the battery management system are met.

Description

Technical Field

[0001] The utility model relates to the technical field of battery management systems, and in particular to a battery management system life cycle test device. Background Technique

[0002] BMS, namely the battery management system, is a system for monitoring and controlling batteries. Its main purpose is to intelligently manage and maintain each battery unit, monitor the battery status, prevent overcharging and over-discharging of the battery, so as to extend the service life of the battery.

[0003] For example, CN106371024A involves a battery management system test device. The input voltage of the switching power supply is generally 12V, and the output voltage of the switching power supply is generally 0 - 5V. The output terminals of the N switching power supplies are connected in sequence in a way that the negative output terminal of one switching power supply is connected to the positive output terminal of the next switching power supply or the positive output terminal of one switching power supply is connected to the negative output terminal of the next switching power supply, so that the output voltages of the N switching power supplies can be superimposed to obtain a total voltage. In the present invention, the main controller measures the total voltage, and the slave controller measures the single-cell voltage. Since this tooling obtains the total voltage and the single-cell voltage by inputting a low-voltage 12V power supply, the probability of safety hazards is relatively small, and the problem of relatively high safety hazards when using a high-voltage power supply is solved. However, this test device can only simulate limited environmental conditions and working conditions, and cannot fully cover various complex situations that the battery management system may encounter in actual applications. This single test environment makes the test results limited and cannot fully reflect the performance and reliability of the battery management system.

[0004] In order to be able to simulate various environments and meet the high requirements for testing the battery management system, a battery management system life cycle test device is proposed. Content of the Utility Model

[0005] The purpose of the utility model is to provide a battery management system life cycle test device to solve the problems raised in the above background technique.

[0006] To achieve the above purpose, the utility model provides a battery management system life cycle test device, including a host computer, a simulation unit and a test unit. The simulation unit includes a high-voltage test box, a low-voltage test box, a battery simulation box and an environment simulation box; the test unit includes a high-precision measurement circuit, and the high-precision measurement circuit includes a voltage input loop, a current input loop and a frequency input loop.

[0007] The host computer is connected to the simulation unit and the test unit through the first communication module, controls the simulation unit to simulate the usage environment of the battery management system, measures the battery management system with the test unit, switches different circuits according to different test items, and finally outputs the test results through serial port data.

[0008] As a further improvement of this technical solution, the high-voltage test box includes a high-voltage power supply, a high-voltage relay, and an insulation resistance. The high-voltage power supply is connected to the high-voltage relay and the insulation resistance, and the high-voltage power supply, the high-voltage relay, and the insulation resistance are used to build a high-voltage circuit to simulate the high-voltage environment when the battery management system works.

[0009] As a further improvement of this technical solution, the low-voltage test box includes a low-voltage power supply, a main control unit, and a resistive load. The low-voltage power supply is used to provide the working power supply for the battery management system, and the resistive load is used to simulate the load required when the battery management system works.

[0010] As a further improvement of this technical solution, the main control unit includes a second communication module, an input measurement module, and an output module. The second communication module is responsible for sending the instructions of the host computer to the device, collecting the data collected by the device, and uploading the data to the host computer; the input measurement module is used to monitor the working parameters of the simulated battery management system; the output module is used to simulate the working signals of the battery management system.

[0011] As a further improvement of this technical solution, the battery simulation box includes a simulated battery and a simulated thermistor. The simulated battery is used to cooperate with the battery management system for charge and discharge and battery equalization operations; the simulated thermistor is used to simulate the temperature when the battery works.

[0012] As a further improvement of this technical solution, the environment simulation box includes high and low temperature, vibration table, salt spray test chamber, low air pressure test chamber, and impact test chamber.

[0013] As a further improvement of this technical solution, the measurement chip and the thermistor input circuit connected to the measurement chip, and the measurement chip is connected to the voltage input circuit, the current input circuit, and the frequency input circuit.

[0014] Compared with the prior art, the beneficial effects of the present utility model are:

[0015] In this battery management system life cycle test device, various environmental conditions and working conditions are simulated to comprehensively cover various complex situations that the battery management system may encounter in actual applications, and measurements are carried out through the test unit, overcoming the shortcomings of the prior art and meeting the high requirements for the testing of battery management systems in fields such as new energy vehicles and energy storage systems. Description of the Drawings

[0016] Figure 1 is a schematic diagram of the overall structure of the present utility model;

[0017] Figure 2 is the circuit of the high-voltage test box of the present utility model Figure 1 ;

[0018] Figure 3 is the circuit of the high-voltage test box of the present utility model Figure 2 ;

[0019] Figure 4 is the circuit diagram of the high-precision measurement of the present utility model. Specific embodiments

[0020] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described in conjunction with the accompanying drawings in the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present utility model without creative efforts shall fall within the protection scope of the present utility model.

[0021] In the description of the present utility model, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc. is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be construed as a limitation of the present utility model.

[0022] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, "a plurality" means two or more unless otherwise specifically defined.

[0023] With the rapid development and popularization of the new energy vehicle market, the BMS (Battery Management System) as a key technology in the fields of electric vehicles, energy storage systems, etc., its importance has become increasingly prominent. The BMS (Battery Management System) is not only responsible for the real-time monitoring and management of the battery, but also undertakes the important responsibilities of protecting the battery safety and ensuring the efficient operation of the battery. Therefore, the performance verification, reliability evaluation and safety guarantee of the BMS (Battery Management System) have become important concerns in the industry.

[0024] In the new energy vehicle industry chain, the performance and reliability of the BMS (Battery Management System) are directly related to the safety and service life of the battery, which in turn affects the performance of the whole vehicle and the user experience. To ensure that the BMS (Battery Management System) can meet various environmental conditions and working conditions requirements during actual operation, comprehensive and detailed tests are needed. As an important part of the life cycle test, it can simulate the state of the BMS (Battery Management System) under long-term and high-intensity operation, verify the stability and reliability of its performance indicators, and provide strong support for product design and improvement.

[0025] At present, there are already some BMS (Battery Management System) test devices on the market. They mainly test the performance of the BMS (Battery Management System) by simulating the actual working conditions of the battery. These devices usually include components such as battery simulators, temperature controllers, and data acquisition systems, which can simulate conditions such as the charging and discharging process and temperature change of the battery, and test various performance indicators of the BMS (Battery Management System). However, these devices still have some deficiencies in terms of test accuracy, environmental adaptability, and operation convenience.

[0026] Therefore, please refer to Figures 1 - 4 As shown, this embodiment provides a battery management system life cycle test device, including a host computer, a simulation unit, and a test unit.

[0027] The simulation unit includes a high-voltage test box, a low-voltage test box, a battery simulation box, and an environment simulation box.

[0028] The test unit includes a high-precision measurement circuit, and the high-precision measurement circuit includes a voltage input loop, a current input loop, and a frequency input loop.

[0029] The host computer connects the simulation unit and the test unit through the first communication module, controls the simulation unit to simulate the usage environment of the battery management system, and measures the battery management system with the test unit. It switches different loops according to different test items (voltage test, current test, frequency test), and finally outputs the test results through serial port data.

[0030] This embodiment simulates a variety of environmental conditions (including battery charging and discharging, temperature control, thermal management, fault diagnosis, etc.) and working conditions (including high and low temperature, vibration, salt spray, air pressure, shock, etc.) to comprehensively cover various complex situations that the BMS (Battery Management System) may encounter in actual applications, and measures through the test unit.

[0031] The high-voltage test box includes a high-voltage power supply, a high-voltage relay, and an insulation resistance. The high-voltage power supply is connected to the high-voltage relay and the insulation resistance, specifically as Figures 2 - 3As shown, a high-voltage power supply, a high-voltage relay, and an insulation resistance are used to build a high-voltage circuit to simulate the high-voltage environment when the BMS (Battery Management System) is working.

[0032] The low-voltage test box includes a low-voltage power supply, a main control unit, and a resistive load. The low-voltage power supply is used to provide the working power supply for the BMS (Battery Management System), and the resistive load is used to simulate the loads required when the BMS (Battery Management System) is working, such as the main fuse, high-voltage interlock, etc.

[0033] The main control unit includes a second communication module, an input measurement module, and an output module. Among them,

[0034] The second communication module is responsible for sending the instructions of the upper computer to the device, collecting the data collected by the device, and uploading the data to the upper computer;

[0035] The input measurement module is used to monitor parameters such as voltage, current, and frequency when simulating the operation of the BMS (Battery Management System);

[0036] The output module is used to output voltage signals and frequency signals to simulate various signals when the BMS (Battery Management System) is working, such as ignition signals, collision signals, etc.

[0037] The battery simulation box includes a simulated battery and a simulated thermistor. The simulated battery is usually composed of dozens to hundreds (determined according to different battery management systems) of simulated battery cells connected in series, and is used to cooperate with the BMS (Battery Management System) for charge and discharge and battery equalization operations;

[0038] The simulated thermistor is composed of multiple resistors of 10KΩ to 120KΩ and can be freely switched by the upper computer, and is used to simulate the temperature when the battery is working.

[0039] The environment simulation box includes the following devices:

[0040] a. High and low temperature: Using a high and low temperature box device, it can generate a controllable high temperature or low temperature environment and follow national standards such as GB / T2423.2 (High Temperature Test Method) and GB / T 2423.3 (Low Temperature Test Method), etc.;

[0041] b. Vibration table: Through devices such as a vibration table, a periodic mechanical vibration is applied to the product to simulate the vibration environment that may be encountered during transportation, use, or installation, and follow national standards such as GB / T 2423.10 (Vibration Test Method), etc.;

[0042] c. Salt spray test box: Using a salt spray test box, salt spray is sprayed under high temperature and high humidity conditions to simulate the corrosion and erosion effects in the marine environment and evaluate the anti-corrosion performance of the product, and follow national standards such as GB / T 10125 (Salt Spray Test), etc.;

[0043] d. Low-pressure test chamber. Use the low-pressure test chamber to simulate special environmental conditions such as high altitude by reducing the ambient air pressure, and evaluate the adaptability of the product. Conduct the test in accordance with national standards such as GB / T 2423.6 (Low-pressure test method).

[0044] e. Shock test chamber. Use the shock test chamber to subject the product to shocks by applying impact forces to evaluate its tolerance and seismic resistance. Conduct the test in accordance with national standards such as GB / T 2423.5 (Shock test method).

[0045] The test unit also includes a measurement chip and a thermistor input circuit connected to the measurement chip. The measurement chip is connected to the voltage input circuit and the frequency input circuit.

[0046] The circuit structure and circuit schematic diagram are as Figure 4 shown. Use a measurement module developed based on a high-precision multimeter SoC (System on Chip) with a 24-bit ADC. The multimeter SOC (System on Chip) is a chip integrated with multiple functional modules. It integrates an analog-to-digital converter (ADC), a microcontroller (MCU), a memory, and other peripheral interfaces and circuits to meet the requirements of high-precision and multi-functional measurements.

[0047] The measurement chip IC2 controls the voltage input circuit, the frequency input circuit, and the thermistor input circuit through a switching module to switch functions and ranges. The circuit structure of the switching module is as follows:

[0048] Pin A1 of the measurement chip IC2 is connected to resistor R4. Resistor R4 is connected to resistor R9 and potentiometer R10. Resistor R9 is connected to switch S6. Switch S6 is connected to pin A5 of the measurement chip IC2. Potentiometer R10 is connected to switch S4.

[0049] Pin A2 of the measurement chip IC2 is connected to capacitor C19 and also to resistor R5. Resistor R5 is connected to switch S5, the emitter of transistor Q1, and the other end of switch S4. The base of transistor Q1 is connected to the collector of transistor Q1 and also to the base of transistor Q2 and the collector of transistor Q2.

[0050] Pin A3 of the measurement chip IC2 is connected to capacitor C13. Pin A4 of the measurement chip IC2 is connected to the other end of capacitor C13 and also to the other end of capacitor C19.

[0051] Pin P10 of the measurement chip IC2 is connected to resistor R14. Resistor R14 is connected to capacitor C16 and also to resistors R15 and R20. Capacitor C16 is connected to the other end of switch S5.

[0052] The switching module switches functions and ranges through switches S4, S5, and S6.

[0053] The current input circuit includes diodes D1, D2, resistor R11 connected to resistor R13, and switch S7;

[0054] Resistor R13 is connected to pin A6 of measurement chip IC2. The negative electrode of diode D2 is connected to the positive electrode of diode D4 and also to the negative electrode of diode D5. The negative electrode of diode D4 is connected to the positive electrode of diode D3 and also to the positive electrode of diode D1. The negative electrode of diode D3 is connected to the positive electrode of diode D5 and also to the COM terminal;

[0055] Resistor R11 is connected to switch S8 and also to resistor R22. Switch S8 is connected to the other end of switch S7 and also to fuse F1. Resistor R22 is connected to resistor R23 and also to fuse F2;

[0056] In addition, a display screen LCD for visually displaying the measurement results is connected to measurement chip IC2,

[0057] And measurement chip IC2 is connected to resistor R4 through pin P31 / TXD, then connected to optocoupler IC4 through resistor R4. Optocoupler IC4 is connected to the VDD terminal. Measurement chip IC2 is connected to the host computer through optocoupler IC4 for communication and data transmission.

[0058] A temperature sensor is integrated in the measurement module to monitor the working temperature of the module in real time, and perform segmented calibration for different temperature ranges, which can reduce the influence of temperature drift on the measurement accuracy; a PTC (thermistor) is integrated on the module, which can monitor the real-time temperature of the module, enabling the module to calibrate different temperature ranges to achieve the purpose of reducing temperature drift.

[0059] Switch different circuits according to different test items (voltage test, current test, frequency test), and finally output the test results through serial port data.

[0060] In summary, this embodiment simulates various environmental conditions and working conditions to comprehensively cover various complex situations that the battery management system may encounter in actual applications, and measures through the test unit, overcoming the shortcomings of the prior art and meeting the high requirements for testing the battery management system in fields such as new energy vehicles and energy storage systems.

[0061] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and the descriptions in the specification are only preferred examples of the present invention and are not used to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed. The scope of protection claimed by the present invention is defined by the appended claims and their equivalents.

Claims

1. A battery management system life cycle test device, characterized in that: It includes a host computer, an analog unit, and a test unit. The analog unit includes a high-voltage test box, a low-voltage test box, a battery simulation box, and an environment simulation box; the test unit includes a high-precision measurement circuit, and the high-precision measurement circuit includes a voltage input loop, a current input loop, and a frequency input loop. The host computer is connected to the analog unit and the test unit through a first communication module, controls the analog unit to simulate the usage environment of the battery management system, and uses the test unit to measure the battery management system, switches different loops according to different test items, and finally outputs the test results through serial port data.

2. The battery management system life cycle test device according to claim 1, wherein: The high-voltage test box includes a high-voltage power supply, a high-voltage relay, and an insulation resistance. The high-voltage power supply is connected to the high-voltage relay and the insulation resistance. The high-voltage power supply, the high-voltage relay, and the insulation resistance are used to build a high-voltage loop to simulate the high-voltage environment when the battery management system works.

3. The battery management system life cycle test device according to claim 1, characterized in that: The low-voltage test box includes a low-voltage power supply, a main control unit, and a resistive load, where: The low-voltage power supply is used to provide a working power supply for the battery management system. The resistive load is used to simulate the load required when the battery management system works.

4. The battery management system life cycle test device according to claim 3, wherein: The main control unit includes a second communication module, an input measurement module, and an output module, where: The second communication module is responsible for sending instructions from the host computer to the device, collecting data collected by the device, and uploading the data to the host computer. The input measurement module is used to monitor the working parameters of the simulated battery management system. The output module is used to simulate the working signal of the battery management system.

5. The battery management system life cycle test device according to claim 1, characterized in that: The battery simulation box includes a simulated battery and a simulated thermistor, where: The simulated battery is used to cooperate with the battery management system for charge and discharge and battery equalization operations. The simulated thermistor is used to simulate the temperature when the battery works.

6. The battery management system life cycle test device according to claim 1, characterized in that: The environment simulation box includes high and low temperatures, a vibration table, a salt spray test chamber, a low-pressure test chamber, and an impact test chamber.

7. The battery management system life cycle test device according to claim 1, wherein: The test unit further includes a measurement chip and a temperature-sensitive resistor input loop connected to the measurement chip. The measurement chip is connected to the voltage input loop, the current input loop, and the frequency input loop.

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