Automatic test system

Abstract

The utility model discloses an automatic test system which comprises a PCBA automatic test bench, a first test assembly is arranged on the PCBA automatic test bench, automatic operation of production test is controlled through an upper computer, no personnel participates in the whole test process, human intervention is reduced, test efficiency is improved, automatic burning of an MCU is achieved, and the test efficiency is improved. The production efficiency and the reliability are greatly improved by applying the control panel and the off-line burner, compared with an existing integrated equipment automatic test platform, the system cost is greatly reduced, the cost of traditional integrated equipment is high, the price of a single set of integrated equipment can reach million level, and the system cost is greatly reduced. Through the technical innovation of the cell simulator and the relay module and the like, the price of a single set is reduced to a ten thousand yuan level, the cost of the test system is greatly reduced, and through the arrangement of the relay module, the automatic switching of the current direction is realized, the current access point can be accurately controlled, and the test efficiency is improved. And the flexibility and the accuracy of current management are obviously improved.

Description

Technical Field

[0001] This utility model relates to the field of automated testing technology, and more specifically, to an automated testing system. Background Technology

[0002] The Battery Management System (BMS) is used for final confirmation after the Printed Circuit Board Assembly (PCBA) is manufactured. Conventional testing methods such as Automated Optical Inspection (AOI) and In-Circuit Test (ICT) are insufficient to fully detect internal electrical problems. Therefore, Functional Circuit Test (FCT) is employed for final verification. Existing BMS PCBA functional testing systems are mainly divided into two categories: one involves manual adjustment of analog sources, power supplies, and other equipment, in conjunction with a host computer to test the board's functionality; the other is an integrated equipment testing system. This type of system integrates multiple analog cell groups, various DC power supplies, signal generators, and oscilloscopes to achieve single-board functional testing.

[0003] Integrated automated testing systems typically cost over a million yuan per unit and cannot cover functional tests such as automated MCU (Microcontroller Unit) programming, cell voltage sampling channel leakage current detection, and power MOS function testing. Manual MCU programming is time-consuming, significantly impacting testing efficiency and increasing costs. Abnormal leakage current in the cell sampling channel can lead to battery performance degradation, inconsistent cell states, and safety hazards. Abnormal power MOS can cause overcharging and over-discharging of the battery pack, and in severe cases, even thermal runaway of the cells. Therefore, it is necessary to develop a new testing method that achieves full-function testing of the BMS PCBA at a lower cost, thereby improving testing efficiency and reducing costs. The goal of this innovation is to find a more cost-effective solution without compromising test quality to address the growing market demands and technological challenges.

[0004] A search revealed Chinese Patent Publication No. CN117572047A, which discloses a testing device and control method for a Battery Management System (BMS). This method integrates multiple devices, with a host computer communicating with these devices via a communication control board to control and test the tested battery board. Another search revealed Chinese Patent Publication No. CN221804218U, which discloses an automated testing system for a multi-cell battery management system. This automated testing system includes a control module and an execution module. The test PC runs the control module, while the execution module includes a battery simulator, a DC power supply, an electronic load, and a relay board. The control module controls the execution module to achieve voltage acquisition and charge / discharge function testing of the BMS.

[0005] However, the above-mentioned patents have certain shortcomings in practical use:

[0006] (1) Manual testing platforms have low testing efficiency and high testing costs;

[0007] (2) The BMS PCBA automated test platform cannot automatically program the MCU;

[0008] (3) The BMS PCBA automated test platform cannot automatically adjust the current access point of the board under test to achieve power MOS testing;

[0009] (4) The automated testing platform cannot test the leakage current of the cell voltage sampling channel;

[0010] (5) Existing automated testing platforms are expensive.

[0011] No effective solutions have yet been proposed to address the problems in the relevant technologies. Utility Model Content

[0012] In view of the problems in the related technologies, this utility model proposes an automated testing system to overcome the above-mentioned technical problems existing in the existing related technologies.

[0013] Therefore, the specific technical solution adopted by this utility model is as follows:

[0014] An automated testing system includes a PCBA automated test bench, on which a first test component is disposed, and a second test component is electrically connected to one side of the first test component, and the second test component is electrically connected to the first test component, and a device under test is electrically connected to one side of the second test component.

[0015] Furthermore, the first test component includes an industrial control PC and a DC power supply. The industrial control PC and DC power supply are set on the PCBA automated test bench. The industrial control PC is electrically connected to a CAN card and multiple offline programmers.

[0016] Furthermore, the DC power supply is electrically connected to the main control board, which is electrically connected to multiple battery cell simulation boards. The CAN card and offline programmer are also electrically connected to the main control board.

[0017] Furthermore, the first test component also includes a relay module, one side of which is mounted on the main control board of the module, and the relay module is electrically connected to a DC power supply.

[0018] Furthermore, the second test component includes a pin test fixture, which is set on one side of the PCBA automated test bench, and a secondary control board is provided at one end of the pin test fixture.

[0019] Furthermore, the ejector pin test fixture is provided with symmetrically arranged connection test terminals, which are electrically connected to the main control board, the relay module and the device under test, respectively, and the secondary control board is electrically connected to the device under test.

[0020] Furthermore, the cell simulation board is electrically connected to the device under test via a pin test fixture.

[0021] The beneficial effects of this utility model are as follows:

[0022] (1) In response to the problems of the existing manual testing platform, the production test is automatically controlled by the host computer. The entire testing process is unmanned, reducing human intervention, improving testing efficiency, and realizing the automatic programming of MCU. By using the control board and offline programmer, the production efficiency and reliability are greatly improved.

[0023] (2) Compared with existing integrated equipment automated testing platforms, this invention greatly reduces system costs. Traditional integrated equipment is expensive, with a single set costing millions. However, this invention reduces the price of a single set to tens of thousands of yuan through technological innovations such as cell simulators and relay modules, greatly compressing the cost of the testing system. Furthermore, by setting up relay modules, not only can the automatic switching of current direction be realized, but the current access point can also be precisely controlled, significantly improving the flexibility and accuracy of current management.

[0024] (3) Compared with the existing integrated equipment automated test system, it integrates MCU automated programming function, cell sampling channel leakage current detection function and relay module control current access point function. These functions are not available in the current integrated equipment automated test platform. The introduction of these functions significantly improves test efficiency, ensures the stability and safety of the entire system, and by setting up multiple cell simulation boards, it can accurately simulate the working conditions of actual cells, which greatly reduces the test cost. At the same time, the AFE sampling and monitoring of output voltage also ensures the accuracy of the test. At the same time, the use of cell simulation boards and high voltage modules to detect the total voltage of the board under test makes the test efficient and economical while ensuring the stability and safety of the system. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of the first test component and the second test component of an automated testing system according to an embodiment of the present utility model;

[0027] Figure 2 This is a schematic diagram of the structure of the first test component of an automated testing system according to an embodiment of the present utility model;

[0028] Figure 3 This is a schematic diagram of the programming and testing process of an automated testing system according to an embodiment of the present utility model.

[0029] In the picture:

[0030] 1. PCBA automated test bench; 2. Ejector pin test fixture; 3. First test component; 301. Industrial control PC; 302. DC power supply; 303. CAN card; 304. Offline programmer; 305. Main control board; 306. Cell simulation board; 307. Relay module; 4. Second test component; 401. Secondary control board; 402. Connection test terminal; 5. Test device. Detailed Implementation

[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0032] Example 1;

[0033] like Figures 1-3 As shown, an automated testing system according to an embodiment of the present utility model includes a PCBA automated testing bench 1. A first testing component 3 is disposed on the PCBA automated testing bench 1. A second testing component 4 is electrically connected to one side of the first testing component 3 and is electrically connected to the first testing component 3. A test piece 5 is electrically connected to one side of the second testing component 4.

[0034] Example 2;

[0035] like Figures 1-3 As shown, according to an embodiment of the present invention, an automated testing system includes a first testing component 3 comprising an industrial control PC 301 and a DC power supply 302. The industrial control PC 301 and the DC power supply 302 are mounted on a PCBA automated testing bench 1. The industrial control PC 301 is electrically connected to a CAN card 303 and multiple offline programmers 304. The DC power supply 302 is electrically connected to a main control board 305. The main control board 305 is electrically connected to multiple battery cell simulation boards 306. The CAN card 303 and the offline programmers 304 are both electrically connected to the main control board 305.

[0036] The first test component 3 also includes a relay module 307, one side of which is mounted on the module main control board 305, and the relay module 307 is electrically connected to the DC power supply 302.

[0037] Industrial PC 301 communicates with main control board 305 and device under test 5 via CAN card 303. Industrial PC 2 is responsible for running industrial PC 301. Industrial PC 301 coordinates and controls the entire test system, including controlling the output signals of main control board 306, receiving and processing input signals collected by the system, and receiving the collected data sent by device under test 5.

[0038] The industrial control PC 301 supplies power and downloads programs to the offline programmer 302 via a USB-Type C cable. The programming signal of the offline programmer 304 is controlled by the main control board 305 and then automatically programs the MCU of the board under test 5 via the SWD protocol.

[0039] The DC power supply 302 is used for current calibration and power MOS testing. The industrial control PC 301 communicates with the main control board 306 via CAN protocol. The main control board 306 then controls the output of the DC power supply 302 via RS232 protocol. The industrial control PC 301 controls the relay module 307 on the main control board 306 via CAN to switch the current direction and switch the B-, P-, and P+ access points, thus completing the functional testing of the charge and discharge current and power MOS of the device under test 5.

[0040] The main control board 306 integrates RS232, RS485, LAN, and daisy-chain communication detection functions to detect the communication status of the BMS PCBA. It also integrates dry contact input / output and DIDO analog input / output detection functions, and can detect the fan control and feedback, relay control and feedback, LED light board and other functions of the device under test 5.

[0041] The cell simulation board 306 is used to simulate the voltage output of series-connected cells. Each cell simulation board 306 can simulate 32 series-connected 3.3V cells. The cell simulation boards 306 are cascaded through daisy-chain communication to realize the simulation of 32*n series-connected cells. The industrial control PC 301 communicates with the main control board 305 through the CAN protocol, and then obtains data such as the simulated cell voltage and leakage current through daisy-chain communication.

[0042] Example 3;

[0043] like Figures 1-3 As shown, according to an embodiment of the present invention, an automated testing system includes a second testing component 4 comprising a pin test fixture 2 for fixing the test piece 5 and achieving its electrical connection with the PCBA automated testing bench 1. The pin test fixture 2 is disposed on one side of the PCBA automated testing bench 1. A secondary control board 401 is disposed at one end of the pin test fixture 2. The pin test fixture 2 is provided with symmetrically arranged connection test terminals 402, which are electrically connected to the main control board 305, the relay module 307 and the test piece 5, respectively. The secondary control board 401 is electrically connected to the test piece 5. The cell simulation board 306 is electrically connected to the test piece 5 through the pin test fixture 2.

[0044] The secondary control board 401 uses a 39K resistor to simulate the equivalent resistance of a 10kΩ 25℃ NTC at -8℃ and the equivalent resistance of a 100kΩ 25℃ NTC at 46℃, and integrates a high-voltage module to support the cluster-level BMS 1000V total voltage function detection. The secondary control board 401 also integrates multiple 10m current analog outputs for the current analog input function detection of the board under test.

[0045] To facilitate understanding of the above-mentioned technical solutions of this utility model, the working principle or operation method of this utility model in actual process will be described in detail below.

[0046] In summary, the above-mentioned technical solution of this utility model is as follows:

[0047] 1. Start the test

[0048] First, the BMS PCBA to be tested needs to be placed in a dedicated ejector pin test fixture. This fixture can ensure a stable electrical connection between the device under test 5 and the PCBA automated test bench 1. Then, the tester starts the test through the host computer software on the industrial control PC301. The industrial control PC301 will communicate with the main control board 305 and the device under test 5 through the CAN protocol and execute the corresponding commands according to the preset test steps.

[0049] 2. Burning function test

[0050] Before testing, the industrial PC301 downloads the programming file to the offline programmer 304 via a Type-C cable (e.g., ...). Figure 3 As shown, during the programming process, the industrial control PC 301 sends a programming command to the main control board 305. The main control board 304 then controls the start pin of the offline programmer 304 to work, thereby triggering the offline programmer 304 to automatically complete the erasure, programming, and verification of the MCU. After successful programming, the offline programmer 304 sends an acknowledgment signal to the main control board 305 based on the verification result. The industrial control PC 301 then determines whether the programming was successful.

[0051] 3. Communication circuit function test

[0052] This invention can cover testing of multiple communication protocols including CAN, RS485, RS232, LAN, and daisy chain. The industrial PC 301 sends test commands via the CAN protocol, and the main control board 305 sends data to the device under test 5 via the corresponding communication interface. After receiving the data, the device under test 5 replies with the same data to the main control board 305. Finally, the main control board 305 compares the data to determine the result and sends the test result to the industrial PC 301 via the CAN protocol.

[0053] 4. DIDO and dry contact input / output function test

[0054] BMS boards are typically designed with DIDO and dry contact input / output signals for peripheral device control and status acquisition. For testing the input signals of the board under test (DUT), the industrial PC301 sends a test command to the main controller, which then manipulates the relays. The DUT 5 reads the state of the input signal, and finally, the industrial PC301 uses the CAN protocol to read the input signal state to determine the test result. For testing the output signals, the industrial PC301 sends a test command to the DUT, the DUT 5 changes its output state, and the main control board 305 reads the output state of the DUT 5.

[0055] Ultimately, the industrial control PC301 will determine the test results based on the status of the input signals read from the main control board 305.

[0056] 5. Cell voltage sampling function test

[0057] The industrial PC 301 sends test commands via the CAN protocol. After receiving the commands, the main control board 305 supplies power to the cell simulation board 306 and reads the actual voltage output of the cell simulation board 306 via a daisy chain. The device under test 5 collects cell voltage data. The industrial PC 301 obtains the cell voltage collected by the cell simulation board 306 and the device under test 5 via the CAN protocol. The industrial PC 301 judges the test results based on the acquisition error.

[0058] 6. Cell temperature sampling function test

[0059] The battery cell temperature sampling harness of the test device 5 is connected to the auxiliary control board 401 inside the ejector test fixture 2. The industrial control PC 301 sends test commands through the CAN protocol. The test device 5 collects the battery cell temperature and sends it to the industrial control PC 301 through the CAN protocol. The industrial control PC 301 judges the test result based on the acquisition error.

[0060] 7. Leakage current detection of battery cell sampling channel

[0061] Each cell board outputs a cell voltage channel with a current sampling resistor connected in series. The main control board 305 uses AFE (Analog Front End) to simulate the front end and daisy-chain communication to collect the voltage before and after the resistor, and then calculates the channel leakage current. If an abnormal leakage current is detected, the main control board 305 will transmit this abnormal information to the industrial control PC301 via the CAN protocol.

[0062] 8. Charge / discharge current loop and power MOSFET testing

[0063] The industrial control PC 301 sends test commands via the CAN protocol. The main control board 305, based on these commands, controls the current source output status and relay group status via the RS232 protocol, thereby controlling the output direction and current input point (e.g., DC power supply 302). Figure 2 As shown in the figure, the industrial control PC301 finally reads the current data collected by the device under test 5 through the CAN protocol to determine whether the charging and discharging circuit and power MOS are abnormal.

[0064] 9. Functional test of analog signal detection circuit

[0065] The board under test 5 collects the analog signal output by the secondary control board and reports it to the industrial control PC301 via the CAN protocol. The industrial control PC301 then judges the test results.

[0066] 10. Total voltage test of the tested component at 5Bat (cell end) and PACK (external end of battery pack).

[0067] The device under test (DUT) 5 is powered by the cell simulation board 306. When testing the total voltage, DUT 5 reports the Bat and Pack terminal voltages collected by the industrial control PC 301 via the CAN protocol. The industrial control PC 301 judges the test results based on the sampling error.

[0068] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An automated testing system, comprising a PCBA automated test bench (1), characterized in that: The PCBA automated test bench (1) is provided with a first test component (3), a second test component (4) is electrically connected to one side of the first test component (3), and the second test component (4) is electrically connected to the first test component (3). The test device (5) is electrically connected to one side of the second test component (4).

2. The automated testing system according to claim 1, characterized in that, The first test component (3) includes an industrial control PC (301) and a DC power supply (302). The industrial control PC (301) and the DC power supply (302) are mounted on the PCBA automated test bench (1). The industrial control PC (301) is electrically connected to a CAN card (303) and multiple offline programmers (304).

3. The automated testing system according to claim 2, characterized in that, The DC power supply (302) is electrically connected to the main control board (305), and the main control board (305) is electrically connected to multiple battery cell simulation boards (306). The CAN card (303) and the offline programmer (304) are both electrically connected to the main control board (305).

4. The automated testing system according to claim 3, characterized in that, The first test component (3) also includes a relay module (307), one side of which is disposed on the module main control board (305), and the relay module (307) is electrically connected to the DC power supply (302).

5. An automated testing system according to claim 4, characterized in that, The second test component (4) includes a pin test fixture (2), which is disposed on one side of the PCBA automated test bench (1), and a sub-control board (401) is disposed at one end of the pin test fixture (2).

6. An automated testing system according to claim 5, characterized in that, The ejector pin test fixture (2) is provided with symmetrically arranged connection test terminals (402), and the connection test terminals (402) are electrically connected to the main control board (305), the relay module (307) and the test device (5) respectively. The auxiliary control board (401) is electrically connected to the test device (5).

7. An automated testing system according to claim 6, characterized in that, The cell simulation board (306) is electrically connected to the test piece (5) via a pin test fixture (2).

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