EOL test system of PACK or battery module

Abstract

The utility model provides an EOL test system of a PACK or a battery module, which belongs to the field of new energy automobile power electronic technology test and comprises a power supply circuit, a high voltage test circuit, a CC / CP / CC2 test circuit, an environment detector, a voltage itinerant detector, a temperature itinerant detector, a 485 module, an I / O module P1, an I / O module P2, an I / O module P3, a plurality of relays and an industrial personal computer. The power supply circuit comprises a 24V power supply module DS1 and a 24V power supply module DS2, the high-voltage test circuit comprises a withstand voltage tester, a universal meter and an internal resistance tester, the CC / CP / CC2 test circuit comprises a signal generator, a low-voltage direct-current source and a CAN box, and the 485 module is in communication connection with an environment detector, a voltage itinerant detector, a temperature itinerant detector, the low-voltage direct-current source and an industrial personal computer. The industrial personal computer is in communication connection with the withstand voltage tester, the universal meter, the internal resistance tester, the I / O module P1, the I / O module P2 and the I / O module P3. The industrial personal computer is connected with the signal generator and the CAN box for data exchange. All the testing devices are integrated into one testing system, and the testing requirements of the battery pack and the battery module can be met.

Description

TECHNICAL FIELD

[0001] The utility model relates to new energy automobile electric power electronic technology test field especially, a kind of EOL test system of PACK or battery module. BACKGROUND

[0002] Battery module and battery pack (PACK) are the core components of electric vehicle power system, they occupy an important position in electric vehicle industry chain, with the rapid development of electric vehicle industry and new market demand, there are new test requirements for it.Battery module and battery pack not only concern the normal operation of equipment, also involve safety issues, so the test of battery pack and battery module cannot be ignored: (1) battery pack is usually used as the power source of equipment, provides sustained stable power for equipment, the performance of battery pack is directly related to the running state of equipment, through test, can avoid the problems such as power failure and unstable operation of equipment in operation;(2) through test, whether there is short circuit and other safety hazards in battery pack can be found, safety accidents can be effectively avoided, equipment safety is guaranteed;(3) through test, performance problems and safety hazards can be found early, reduce maintenance frequency and downtime, improve the service life and stability of equipment, reduce the maintenance cost caused by equipment failure in later period.

[0003] But the EOL (End of Line) test system of battery module and battery pack in the market at present mainly uses manual test, whenever test a function, it needs to be connected to corresponding test equipment, there are problems: (1) battery pack and battery module cannot be tested simultaneously;(2) the efficiency of manual test of test personnel is low;(3) multiple models of battery pack cannot be tested simultaneously. UTILITY MODEL CONTENT

[0004] The technical problem to be solved by the utility model is how to integrate each test equipment into a test system, and compatible with the test requirements of battery pack and battery module.

[0005] The utility model discloses a PACK or battery module's EOL test system, including power supply circuit, high voltage test circuit, CC CP CC2 test circuit, environmental detector, voltage inspection appearance, temperature inspection appearance, 485 module, I / O module P1, I / O module P2, I / O module P3, a plurality of relays, industrial computer, the power supply circuit includes 24V power module DS1, 24V power module DS2, and high voltage test circuit includes voltage resistance tester, multimeter, internal resistance tester, and CC CP CC2 test circuit includes signal generator, low voltage DC source, CAN box, and the input of 24V power module DS1 and 24V power module DS2 all connects input power supply, and the output of 24V power module DS1 is connected to environmental detector, voltage inspection appearance, temperature inspection appearance, 485 module, I / O module P1, I / O module P2, I / O module P3 respectively, and the output of 24V power module DS2 is connected to a plurality of relays, and voltage inspection appearance is connected to I / O module P2, and temperature inspection appearance is connected to I / O module P2, I / O module P3, and signal generator, low voltage DC source are connected to I / O module P1, and CAN box is connected to I / O module P2, and 485 module is connected with environmental detector, voltage inspection appearance, temperature inspection appearance, low voltage DC source, industrial computer communication respectively, and industrial computer is connected with voltage resistance tester, multimeter, internal resistance tester, I / O module P1, I / O module P2, I / O module P3 communication respectively, and industrial computer is connected with signal generator, CAN box and carries out data exchange.

[0006] Preferably, the power supply circuit further comprises a circuit breaker QF1, a fuse FU1, an emergency stop switch EMG, and a push button switch SB1. The live wire of the circuit breaker QF1 is connected with the live wire of the input power supply, and the zero line of the circuit breaker QF1 is connected with the zero line of the input power supply. The live wire of the circuit breaker QF1 is connected with the fuse FU1 in series, and then connected to one end of the emergency stop switch EMG. The other end of the emergency stop switch EMG is connected to one end of the push button switch SB1. The other end of the push button switch SB1 is connected to the live wire input end of the 24V power module DS1 and the live wire input end of the 24V power module DS2. The zero line of the circuit breaker QF1 is connected to the zero line input end of the 24V power module DS1 and the zero line input end of the 24V power module DS2.

[0007] Preferably, the several relays include relays KA1-KA27, the ports CZ0-CZ21 of the I / O module P1 are connected to the positive output of the 24V power module DS2, one end of the relay coil KA1A is connected to the port Y0 of the I / O module P1, one end of the relay coils KA2A-KA22A is connected to the ports Y1-Y21 of the I / O module P1 respectively, the other ends of the relay coils KA1A-KA22A are connected to the negative output of the 24V power module DS2 respectively, one end of the relay coil KA23A is connected to the port Y10 of the I / O module P3, one end of the relay coil KA24A is connected to the port Y11 of the I / O module P3, one end of the relay coil KA25A is connected to the port Y12 of the I / O module P3, one end of the relay coil KA26A is connected to the port Y13 of the I / O module P3, one end of the relay coil KA27A is connected to the port Y14 of the I / O module P3, and the other ends of the relay coils KA23A-KA27A are connected to the negative output of the 24V power module DS2 respectively.

[0008] Preferably, the high-voltage test circuit further includes resistors R1, R2, R3, and a fuse FU2, the port LOW of the high-voltage tester is connected to one end of the fuse FU2, the other end of the fuse FU2 is connected to one end of the normally open contact of the relay KA27, one end of the normally open contact of the relay KA4, one end of the normally open contact of the relay KA5, and one end of the normally open contact of the relay KA6 respectively, the other end of the normally open contact of the relay KA27 is connected to the jack, the other end of the normally open contact of the relay KA4 is connected to one end of the resistor R1, the other end of the normally open contact of the relay KA5 is connected to one end of the resistor R2, the other end of the normally open contact of the relay KA6 is connected to one end of the resistor R3, the port HV of the high-voltage tester is connected to one end of the normally open contacts of the relays KA1-KA3, the other ends of the resistors R1-R3 are connected together and then connected to the other end of the normally open contact of the relay KA3, and the other ends of the normally open contacts of the relays KA1 and KA2 are connected to the jack.

[0009] The port HI of the multimeter is connected to one end of the normally open contact of the relay KA7, the normally open contact of the relay KA9, the normally open contact of the relay KA11, the normally open contact of the relay KA24, and the normally open contact of the relay KA26, and the other end of the normally open contact of the relay KA7, the normally open contact of the relay KA9, and the normally open contact of the relay KA11 is connected to the navigation plug. The port LO of the multimeter is connected to one end of the normally open contact of the relay KA8, the normally open contact of the relay KA10, the normally open contact of the relay KA12, the normally open contact of the relay KA23, and the normally open contact of the relay KA25, and the other end of the normally open contact of the relay KA8, the normally open contact of the relay KA10, and the normally open contact of the relay KA12 is connected to the navigation plug. The other end of the normally open contact of the relay KA23 is connected to the positive electrode of the heating film resistance port of the battery pack or battery module to be tested. The other end of the normally open contact of the relay KA24 is connected to the negative electrode of the heating film resistance port of the battery pack or battery module to be tested. The other end of the normally open contact of the relay KA25 is connected to the positive electrode of the auxiliary circuit port of the battery pack or battery module to be tested. The other end of the normally open contact of the relay KA26 is connected to the negative electrode of the auxiliary circuit port of the battery pack or battery module to be tested.

[0010] The positive electrode of the first test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA13. The positive electrode of the second test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA14. The negative electrode of the first test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA15. The negative electrode of the second test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA16. The other ends of the normally open contacts of the relay KA13 and the relay KA14 are connected to the navigation plug. The other ends of the normally open contacts of the relay KA15 and the relay KA16 are connected to the navigation plug.

[0011] Preferably, the CC / CP / CC2 test circuit further comprises resistors R7-R11, the positive signal output of the signal generator is connected to port CZ27 of I / O module P1, port Y27 of I / O module P1 is connected to port CP of the battery pack or battery module to be tested, the negative signal output of the signal generator is connected to port CZ28 of I / O module P1, port CZ29 of I / O module P1, port CZ30 of I / O module P1, one end of resistor R8, port Y28 of I / O module P1 is connected to one end of resistor R7, the other end of resistor R7 is connected to port CC2 of the battery pack or battery module to be tested through a jumper, port Y29 of I / O module P1 is connected to port PE of the battery pack or battery module to be tested through a jumper, port Y30 of I / O module P1 is connected to the other end of resistor R8, one end of resistor R9 after being connected to port CZ31, port Y31 of I / O module P1 is connected to the other end of resistor R9, one end of resistor R10 after being connected to port CZ32, port Y32 of I / O module P1 is connected to the other end of resistor R10, one end of resistor R11 after being connected to port CZ33, the other end of resistor R11 is connected to port Y33 of I / O module P1, and port Y33 of I / O module P1 is connected to port CC of the battery pack or battery module to be tested through a jumper.

[0012] Preferably, the positive output of the low-voltage DC source is connected to port CZ26, port CZ24, and port CZ22 of I / O module P1, the negative output of the low-voltage DC source is connected to port CZ23 and port CZ25 of I / O module P1, port Y26 of I / O module P1 is connected to the wake-up signal port of the battery pack or battery module to be tested through a jumper, port Y24 of I / O module P1 is connected to port K30L+ of the battery pack or battery module to be tested through a jumper, port Y22 of I / O module P1 is connected to port K15L+ of the battery pack or battery module to be tested through a jumper, port Y23 of I / O module P1 is connected to port K15L- of the battery pack or battery module to be tested through a jumper, and port Y25 of I / O module P1 is connected to port K30L- of the battery pack or battery module to be tested through a jumper.

[0013] Preferably, the positive electrode of the first signal port of the CAN box is connected to the port CZ0 of the I / O module P2, the negative electrode of the first signal port of the CAN box is connected to the port CZ1 of the I / O module P2, the positive electrode of the second signal port of the CAN box is connected to the port CZ2 of the I / O module P2, the negative electrode of the second signal port of the CAN box is connected to the port CZ3 of the I / O module P2, the port Y0 of the I / O module P2 is connected to the port CAN1-H of the battery pack or battery module to be tested through the aviation plug, the port Y1 of the I / O module P2 is connected to the port CAN1-L of the battery pack or battery module to be tested through the aviation plug, the port Y2 of the I / O module P2 is connected to the port CAN2-H of the battery pack or battery module to be tested through the aviation plug, and the port Y3 of the I / O module P2 is connected to the port CAN2-L of the battery pack or battery module to be tested through the aviation plug.

[0014] Preferably, the insulation test circuit further comprises resistors R4-R6, one end of the normally open contact of the relay KA17 is connected to the aviation plug, the other end of the normally open contact of the relay KA17 is connected to one end of the resistor R4, one end of the resistor R5 and one end of the resistor R6 respectively, the other end of the resistor R4 is connected to one end of the normally open contact of the relay KA18, the other end of the resistor R5 is connected to one end of the normally open contact of the relay KA19, the other end of the resistor R6 is connected to one end of the normally open contact of the relay KA20, the other ends of the normally open contacts of the relays KA18, KA19 and KA20 are connected to one end of the normally open contacts of the relays KA21 and KA22, the other end of the normally open contact of the relay KA21 is connected to the aviation plug, and the other end of the normally open contact of the relay KA22 is connected to the aviation plug, and the aviation plug is connected to the battery pack or battery module to be tested.

[0015] Preferably, the switch is further provided, the voltage withstand tester, the multimeter, the internal resistance tester, the I / O module P1, the I / O module P2 and the I / O module P3 are in communication connection with the switch, the switch is in communication connection with the industrial computer, the signal port of the voltage withstand tester is connected to the first signal port JHJ-LAN1 of the switch, the signal port of the multimeter is connected to the second signal port JHJ-LAN2 of the switch, the signal port of the internal resistance tester is connected to the third signal port JHJ-LAN3 of the switch, the signal port of the I / O module P1 is connected to the fourth signal port JHJ-LAN34 of the switch, the signal port of the I / O module P2 is connected to the fifth signal port JHJ-LAN5 of the switch, the signal port of the I / O module P3 is connected to the sixth signal port JHJ-LAN6 of the switch, the signal port of the 485 module is connected to the seventh signal port JHJ-LAN7 of the switch, and the eighth signal port JHJ-LAN8 of the switch is connected to the signal port of the industrial computer.

[0016] Preferably, the alarm lamp LED1, the alarm lamp LED2, the alarm lamp LED3 are further included, one end of the alarm lamp LED1 is connected to the output positive pole of the 24V power module DS1, the other end of the alarm lamp LED1 is connected to the output negative pole of the 24V power module DS1, one end of the alarm lamp LED2 is connected to the port Y16 of the I / O module P3, the other end of the alarm lamp LED2 is connected to the output negative pole of the 24V power module DS1, one end of the alarm lamp LED3 is connected to the port Y15 of the I / O module P3, the other end of the alarm lamp LED3 is connected to the output negative pole of the 24V power module DS1, and the port CZ16 and the port CZ15 of the I / O module P3 are both connected to the output positive pole of the 24V power module DS1.

[0017] The utility model discloses the advantages provided by the utility model are:

[0018] 1. The utility model discloses a whole circuit is simple, and the integration is convenient, and the compatibility is strong, can realize the test demand to battery package or battery module, replaces the corresponding test equipment that needs to use every test one item, greatly improves the efficiency of battery package or battery module factory test.

[0019] 2. The utility model discloses a safe and reliable power supply circuit, and the external 220V AC enters the test system inside through the circuit breaker QF1, and the fuse FU1 on the AC live wire is used for protecting the circuit to prevent damaging the internal circuit when overcurrent or short circuit, and the live wire is connected with the emergency stop switch EMG, when the test appears abnormity, the test personnel can manually press the emergency stop switch and protect, when the test personnel needs to power on the test system internal instrument, presses the button switch SB1, can power supply 24V power module DS1, 24V power module DS2 in the test system, and the internal instrument equipment power supply all come from 24V power module DS1, 24V power module DS2.

[0020] 3. The utility model discloses a high voltage test circuit, adds three resistors of different resistance values of resistance R1, resistance R2, resistance R3 in the positive pole loop of the voltage withstand tester and the negative pole loop for the Master calibration of the voltage withstand tester itself, adds a 1A fuse in the output positive pole loop of the voltage withstand tester for protection, prevents the short circuit damage of equipment caused by the failure of internal high voltage relay, and the multimeter is used for battery package and battery module total voltage test, CAN terminal resistance test, short circuit test, heating film resistance value test and auxiliary loop test, uses the relay to switch each channel, and the AC resistance tester is used for the ACR resistance value test of battery package (PACK) and battery module.

[0021] 4. The utility model discloses a CC / CP / CC2 test circuit, a resistance R7 is connected in series in the battery pack port CC2 and signal generator negative loop, is used for simulating CC2 signal voltage variation in direct current charging stake, is used for detecting whether CC2 function is normal. Four resistances R8-R11 are connected in series in the battery pack port CC and signal generator negative loop, and each resistance is connected in parallel on the DO channel of I / O module P1, is used for simulating that the AC charging stake CC signal informs battery pack that the charging cable capacity is at this time.

[0022] 5. The utility model discloses three aluminum shell resistances R4, resistance R5, resistance R6 are added on PACK+, PACK- and GND, simulate adding the resistance of different resistance value between PACK+ to GND and PACK- to GND, can detect battery pack insulation function. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 The schematic diagram of the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0024] Figure 2 The circuit diagram of the power supply circuit part in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0025] Figure 3 The circuit diagram of the power supply circuit part in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0026] Figure 4 The circuit diagram of the power supply circuit part in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0027] Figure 5 The circuit diagram of the high voltage test circuit in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0028] Figure 6 The circuit diagram of the CC / CP / CC2 test circuit part in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0029] Figure 7 The circuit diagram of the CC / CP / CC2 test circuit part in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0030] Figure 8 The circuit diagram of the insulation test circuit in the EOL test system of the PACK or battery module provided for the embodiment of the utility model is shown in the figure.

[0031] Figure 9 An interface connection diagram of the voltage monitoring instrument in the EOL test system of the PACK or battery module provided for an embodiment of this utility model;

[0032] Figure 10 An interface connection diagram of the temperature monitoring instrument in the EOL testing system of the PACK or battery module provided for an embodiment of this utility model;

[0033] Figure 11 A schematic diagram showing the connection between the voltage detector, temperature detector, and battery module in the EOL testing system for a PACK or battery module provided in an embodiment of this utility model.

[0034] Figure 12 An interface connection diagram of the switch in the EOL test system of the PACK or battery module provided for an embodiment of this utility model;

[0035] Figure 13 An interface connection diagram of the industrial control computer in the EOL testing system of the PACK or battery module provided for an embodiment of this utility model;

[0036] In the diagram: 1 Environmental monitoring instrument, 2 Withstand voltage tester, 3 Multimeter, 4 Internal resistance tester, 5 Signal generator, 6 Low voltage DC power supply, 7 Industrial computer, 8 Aviation connector, 9 Monitor, 10 Bar scanner. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model are described clearly and completely below with reference to specific embodiments and accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0038] like Figure 1 As shown, this embodiment provides an EOL testing system for a PACK or battery module, including a power supply circuit, a high voltage test circuit, a CC / CP / CC2 test circuit, an insulation test circuit, an environmental detector 1, a voltage detector, a temperature detector, a 485 module, I / O modules P1, P2, and P3, several relays, and an industrial control computer 7.

[0039] like Figure 2 As shown, the power supply circuit includes circuit breaker QF1, fuse FU1, emergency stop switch EMG, push-button switch SB1, 24V power module DS1, and 24V power module DS2, as follows. Figure 5 As shown, the high-voltage test circuit includes a withstand voltage tester 2, a multimeter 3, and an internal resistance tester 4, as follows:Figure 6 As shown, the CC / CP / CC2 test circuit includes a signal generator 5, a low-voltage DC source 6, a CAN box, a 24V power module DS1 and a 24V power module DS2, which are used to convert the input alternating current into 24V direct current to power the environmental detector, the voltage inspection instrument, the temperature inspection instrument, the 485 module, the I / O module P1, the I / O module P2, the I / O module P3, and a plurality of relays in the test system. The voltage inspection instrument is connected to the I / O module P2, the temperature inspection instrument is connected to the I / O module P2 and the I / O module P3, the signal generator and the low-voltage DC source are connected to the I / O module P1, the CAN box is connected to the I / O module P2, the environmental detector is used for collecting external environmental temperature, the voltage inspection instrument is used for collecting battery module single cell voltage, the temperature inspection instrument is used for collecting battery module single cell temperature, the withstand voltage tester is used for AC and DC withstand voltage test and insulation resistance test, the multimeter is used for battery pack or battery module total voltage test and internal contactor state test, the signal generator is used for simulating CP signal, the low-voltage DC source is used for providing battery pack (PACK) low-voltage power supply and wake-up signal, the CAN box is used for system and battery pack (PACK) BMS communication, and the industrial computer is used for system software control and data recording.

[0040] Continuing to refer to Figure 2 , in the power supply circuit, the live wire and the zero wire of the circuit breaker QF1 are connected with the live wire and the zero wire of the input power supply respectively, the live wire of the circuit breaker QF1 is connected to one end of the emergency stop switch EMG in series with the fuse FU1, the other end of the emergency stop switch EMG is connected to one end of the button switch SB1, the other end of the button switch SB1 is connected to the live wire input end of the 24V power module DS1 and the live wire input end of the 24V power module DS2, and the zero wire of the circuit breaker QF1 is connected to the zero wire input end of the 24V power module DS1 and the zero wire input end of the 24V power module DS2, as shown in Figure 3 , the output end of the 24V power module DS1 is connected to the environmental detector, the voltage inspection instrument, the temperature inspection instrument, the 485 module, the I / O module P1, the I / O module P2 and the I / O module P3 respectively, as shown in Figure 4 , the output end of the 24V power module DS2 is connected to the coils of a plurality of relays respectively, the other end of the button switch SB1 is also connected to the withstand voltage tester, the multimeter, the internal resistance tester, the signal generator, the low-voltage DC source and the industrial computer respectively, the 485 module is in communication connection with the environmental detector, the voltage inspection instrument, the temperature inspection instrument, the low-voltage DC source and the industrial computer respectively, the industrial computer is in communication connection with the withstand voltage tester, the multimeter, the internal resistance tester, the I / O module P1, the I / O module P2 and the I / O module P3 respectively, and the industrial computer is connected with the signal generator and the CAN box for data exchange.

[0041] The EOL testing system for PACK or battery modules of this utility model also includes a switch, a withstand voltage tester, a multimeter, an internal resistance tester, I / O modules P1, P2, and P3, which are communicatively connected to the switch. The switch is communicatively connected to an industrial control computer. Figure 12 and Figure 13 As shown, the switch model is TL-SF1008, and the industrial computer model is IPC3000. The signal port of the withstand voltage tester is connected to the first signal port JHJ-LAN1 of the switch; the signal port of the multimeter is connected to the second signal port JHJ-LAN2 of the switch; the signal port of the internal resistance tester is connected to the third signal port JHJ-LAN3 of the switch; the signal port of I / O module P1 is connected to the fourth signal port JHJ-LAN34 of the switch; the signal port of I / O module P2 is connected to the fifth signal port JHJ-LAN5 of the switch; the signal port of I / O module P3 is connected to the sixth signal port JHJ-LAN6 of the switch; the signal port of the 485 module is connected to the seventh signal port JHJ-LAN7 of the switch; and the eighth signal port JHJ-LAN8 of the switch is connected to the signal port of the industrial computer. Through LAN communication between the switch and the industrial computer, after the tester completes the test harness connection, automatic testing can be performed according to the written test process documents. The host computer will automatically record all test data and test steps and automatically upload them to the backend.

[0042] The relay QF1 is model BKN 2P C16A, the fuse FU1 is model RS308-PV-3E15A, the emergency stop switch EMG is model CE4T-10R-02, the push-button switch SB1 is model LB22C-P20Z / ER220V / S / L, the 24V power module DS1 is model LRS-75-24, and the 24V power module DS2 is model LRS-150-24. (See reference...) Figure 1The main control circuit further comprises several sockets, the socket is a 5-hole socket, the model of the 5-hole socket is DZ47X510, the firewire of the 5-hole socket is connected to the other end of the button switch SB1, the zero line of the 5-hole socket is connected to the zero line of the circuit breaker QF1, the voltage resistance tester, the multimeter, the internal resistance tester, the signal generator, the low-voltage direct current source and the industrial computer are respectively connected to the 5-hole socket to turn on the power supply. The sockets are eight, which are sockets CZ1-CZ8, and in specific use, the power port of the voltage resistance tester can be connected to the socket CZ1 through the power line, the power port of the multimeter can be connected to the socket CZ2 through the power line, the power port of the internal resistance tester can be connected to the socket CZ3 through the power line, the power port of the signal generator can be connected to the socket CZ4 through the power line, the power port of the low-voltage direct current source can be connected to the socket CZ5 through the power line, the power port of the switch can be connected to the socket CZ6 through the power line, the power port of the industrial computer can be connected to the socket CZ7 through the power line, and the socket CZ8 can be used as a spare socket.

[0043] The models of the I / O module P1, the I / O module P2 and the I / O module P3 are all SRND-WM-36DO, the several relays provided by the utility model have a total of 27, which are all high-voltage dry reed relays, and the model is LRL-101-100PCV-P0. Figure 4, including relays KA1-KA27, the ports CZ0-CZ21 of the I / O module P1 are connected to the positive output of the 24V power module DS2, one end of the relay coil KA1A is connected to the port Y0 of the I / O module P1, similarly, one end of the relay coils KA2A-KA22A is connected to the ports Y1-Y21 of the I / O module P1 respectively, the other end of the relay coils KA1A-KA22A is connected to the negative output of the 24V power module DS2 respectively, one end of the relay coil KA23A is connected to the port Y10 of the I / O module P3, one end of the relay coil KA24A is connected to the port Y11 of the I / O module P3, one end of the relay coil KA25A is connected to the port Y12 of the I / O module P3, one end of the relay coil KA26A is connected to the port Y13 of the I / O module P3, one end of the relay coil KA27A is connected to the port Y14 of the I / O module P3, the other end of the relay coils KA23A-KA27A is connected to the negative output of the 24V power module DS2 respectively. The circuit breaker QF1 is a 2P miniature circuit breaker, model BKN 2P C16A, the external 220V AC power enters the test system through the circuit breaker QF1, the fuse FU1 on the AC live line is used to protect the circuit from damage due to overcurrent or short circuit, the emergency stop switch EMG is connected in series on the live line, when the test is abnormal, the test personnel can manually press the emergency stop switch for protection, when the test personnel needs to power on the internal instruments of the test system, press the button switch SB1 to power on the 24V power module DS1, the 24V power module DS2 and the eight 5-hole sockets, the internal instrument equipment power supply comes from the 24V power module DS1, the 24V power module DS2 and the 5-hole socket. The I / O module P1, the I / O module P2 and the I / O module P3 are used to control the low-voltage signal connection between the internal instrument equipment and the battery pack (PACK) and the battery module and the coil action of the high-voltage reed relay.

[0044] With reference to Figure 3Still include alarm lamp LED1, alarm lamp LED2, alarm lamp LED3, three alarm lamps of the utility model are three color alarm lamps, wherein, alarm lamp LED1 is red, alarm lamp LED2 is green, alarm lamp LED3 is white, one end of alarm lamp LED1 is connected to the output terminal positive pole of 24V power module DS1, the other end of alarm lamp LED1 is connected to the output terminal negative pole of 24V power module DS1, one end of alarm lamp LED2 is connected to the port Y16 of I / O module P3, the other end of alarm lamp LED2 is connected to the output terminal negative pole of 24V power module DS1, one end of alarm lamp LED3 is connected to the port Y15 of I / O module P3, the other end of alarm lamp LED3 is connected to the output terminal negative pole of 24V power module DS1, the port CZ16 and the port CZ15 of I / O module P3 are all connected to the output terminal positive pole of 24V power module DS1.

[0045] The model of the voltage resistance tester is TOS9301, the model of the universal meter is 34465A, and the model of the internal resistance tester is BT3563A, as shown in Figure 5As shown, the high-voltage test circuit further comprises resistors R1, R2, R3, a fuse FU2, the model of which is C10G1. The port LOW of the voltage tester is connected to one end of the fuse FU2, the other end of the fuse FU2 is connected to one end of the normally open contact of the relay KA27, one end of the normally open contact of the relay KA4, one end of the normally open contact of the relay KA5, one end of the normally open contact of the relay KA6, respectively, the other end of the normally open contact of the relay KA27 is connected to the aviation plug 8 through a copper bar, the other end of the normally open contact of the relay KA4 is connected to one end of the resistor R1, the other end of the normally open contact of the relay KA5 is connected to one end of the resistor R2, the other end of the normally open contact of the relay KA6 is connected to one end of the resistor R3, the port HV of the voltage tester is connected to one end of the normally open contact of the relays KA1-KA3, the other ends of the resistors R1-R3 are connected together and then connected to the other end of the normally open contact of the relay KA3, the other end of the normally open contact of the relay KA1 is connected to the aviation plug through a copper bar, the other end of the normally open contact of the relay KA2 is connected to the aviation plug through a copper bar, the port HI of the multimeter is connected to one end of the normally open contact of the relay KA7, the normally open contact of the relay KA9, the normally open contact of the relay KA11, the normally open contact of the relay KA24, the normally open contact of the relay KA26, the other end of the normally open contact of the relay KA7 is connected to the aviation plug through a copper bar, the other end of the normally open contact of the relay KA9 is connected to the aviation plug through a copper bar, the other end of the normally open contact of the relay KA11 is connected to the aviation plug through a copper bar, the port LO of the multimeter is connected to one end of the normally open contact of the relay KA8, the normally open contact of the relay KA10, the normally open contact of the relay KA12, the normally open contact of the relay KA23, the normally open contact of the relay KA25, the other end of the normally open contact of the relay KA8 is connected to the aviation plug through a copper bar, the other end of the normally open contact of the relay KA10 is connected to the aviation plug through a copper bar, the other end of the normally open contact of the relay KA12 is connected to the aviation plug through a copper bar, the other end of the normally open contact of the relay KA23 is connected to the positive electrode of the heating film resistance port of the battery pack to be tested, the other end of the normally open contact of the relay KA24 is connected to the negative electrode of the heating film resistance port of the battery pack to be tested, the other end of the normally open contact of the relay KA25 is connected to the positive electrode of the auxiliary circuit port of the battery pack to be tested, the other end of the normally open contact of the relay KA26 is connected to the negative electrode of the auxiliary circuit port of the battery pack to be tested, the positive electrode of the first test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA13, the positive electrode of the second test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA14, the negative electrode of the first test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA15, the negative electrode of the second test port of the internal resistance tester is connected to one end of the normally open contact of the relay KA16, the other ends of the normally open contacts of the relays KA13 and KA14 are connected together and then connected to the aviation plug through a copper bar, the other ends of the normally open contacts of the relays KA15 and KA16 are connected together and then connected to the aviation plug through a copper bar.

[0046] The test system integrates a voltage withstand tester for AC voltage withstand and insulation impedance test of battery pack (PACK) and battery module. A high-voltage dry reed relay is used in the test loop to switch the positive battery pack (PACK) and the positive and negative electrodes of the battery module of the voltage withstand tester, and a 1A fuse is added in the positive output loop of the voltage withstand tester for protection, to prevent the voltage withstand tester from being damaged by short circuit caused by failure of the internal high-voltage relay. In addition, R1 (RIP52-100M-J), R2 (RIP52-50M-J) and R3 (RIP52-5M-J) are added in the positive and negative loops of the voltage withstand tester for Master calibration of the voltage withstand tester itself. The test system also integrates a high-precision six-and-a-half-digit multimeter for total voltage test, CAN terminal resistance test, short circuit test, heating film resistance test and auxiliary loop test of the battery pack (PACK) and the battery module. A high-voltage dry reed relay is used to switch each channel, and the system also integrates an AC resistance tester for ACR resistance test of the battery pack (PACK) and the battery module.

[0047] The signal generator is model DG821, the low-voltage DC source is model PA5010, and the CAN box is model USBCANFD-200U, as shown in Figure 6 and Figure 7 The CC / CP / CC2 test circuit further includes resistors R7-R11. The positive signal output of the signal generator is connected to port CZ27 of I / O module P1, port Y27 of I / O module P1 is connected to port CP of the battery pack to be tested, the negative signal output of the signal generator is connected to port CZ28 of I / O module P1, port CZ29 of I / O module, port CZ30 of I / O module P1, one end of resistor R8, port Y28 of I / O module P1 is connected to one end of resistor R7, the other end of resistor R7 is connected to port CC2 of the battery pack to be tested through a terminal block, port Y29 of I / O module P1 is connected to port PE of the battery pack to be tested through a terminal block, port Y30 of I / O module P1 is connected to the other end of resistor R8, one end of resistor R9 after being connected to port CZ31, port Y31 of I / O module P1 is connected to the other end of resistor R9, one end of resistor R10 after being connected to port CZ32, port Y32 of I / O module P1 is connected to the other end of resistor R10, one end of resistor R11 after being connected to port CZ33, the other end of resistor R11 is connected to port Y33 of I / O module P1, and port Y33 of I / O module P1 is connected to port CC of the battery pack to be tested through a terminal block.

[0048] The test system integrates a signal generator for simulating PWM signals on the CP line, and can adjust the voltage, duty cycle and frequency of the PWM signal according to customer requirements. The negative electrode of the signal generator is connected to the battery pack (PACK) PE. A 1K resistor R7 (RJ 3W 1KΩ) is connected in series in the loop between the battery pack CC2 and the negative electrode of the signal generator for simulating the change of the CC2 signal voltage in the direct current charging pile, and for detecting whether the CC2 function is normal. Four resistors R8 (RJ 3W 100Ω) / R9 (RJ 3W 220Ω) / R10 (RJ 3W 680Ω) / R11 (RJ 3W 1.5kΩ) are connected in series in the loop between the battery pack CC and the negative electrode of the signal generator, and each resistor is connected in parallel to the DO channel of the I / O module P1. By controlling the action of the DO channel, different resistance values are switched to simulate the AC charging pile CC signal informing the battery pack of the capacity of the charging cable at this time.

[0049] The positive output of the low-voltage DC source is connected to the port CZ26, port CZ24 and port CZ22 of the I / O module P1. The negative output of the low-voltage DC source is connected to the port CZ23 and port CZ25 of the I / O module P1. The port Y26 of the I / O module P1 is connected to the wake-up signal port of the battery pack to be tested through a terminal block. The port Y24 of the I / O module P1 is connected to the port K30L+ of the battery pack to be tested through a terminal block. The port Y22 of the I / O module P1 is connected to the port K15L+ of the battery pack to be tested through a terminal block. The port Y23 of the I / O module P1 is connected to the port K15L- of the battery pack to be tested through a terminal block. The port Y25 of the I / O module P1 is connected to the port K30L- of the battery pack to be tested through a terminal block, for providing low-voltage power supply for the BMS inside the battery pack, and can simulate BMS overvoltage and undervoltage test by modifying different voltages. The low-voltage DC source output is connected to the I / O module, and the output is controlled through the DO channel.

[0050] The positive electrode of the first signal port of the CAN box is connected to the port CZ0 of the I / O module P2, the negative electrode of the first signal port of the CAN box is connected to the port CZ1 of the I / O module P2, the positive electrode of the second signal port of the CAN box is connected to the port CZ2 of the I / O module P2, the negative electrode of the second signal port of the CAN box is connected to the port CZ3 of the I / O module P2, the port Y0 of the I / O module P2 is connected to the port CAN1-H of the battery pack to be tested through a jack, the port Y1 of the I / O module P2 is connected to the port CAN1-L of the battery pack to be tested through a jack, the port Y2 of the I / O module P2 is connected to the port CAN2-H of the battery pack to be tested through a jack, the port Y3 of the I / O module P2 is connected to the port CAN2-L of the battery pack to be tested through a jack, for communication with the battery pack (PACK) BMS, the CAN box contains two channels, which can simultaneously meet the requirements of BMS communication and vehicle communication, the CAN channel is also turned on through the DO channel, and both channels are connected in parallel to the multimeter for CAN terminal resistance test.

[0051] As shown in Figure 8 , and referring to Figure 5 , the insulation test circuit includes resistors R4-R6, one end of the normally open contact of the relay KA17 is connected to the jack through a copper bar, the other end of the normally open contact of the relay KA17 is connected to one end of the resistor R4, one end of the resistor R5 and one end of the resistor R6 respectively, the other end of the resistor R4 is connected to one end of the normally open contact of the relay KA18, the other end of the resistor R5 is connected to one end of the normally open contact of the relay KA19, the other end of the resistor R6 is connected to one end of the normally open contact of the relay KA20, the other ends of the normally open contacts of the relays KA18, KA19 and KA20 are connected to one end of the normally open contacts of the relays KA21 and KA22, the other end of the normally open contact of the relay KA21 is connected to the jack through a copper bar, the other end of the normally open contact of the relay KA22 is connected to the jack through a copper bar, and the jack is connected to the battery pack to be tested to test the insulation performance of the battery pack. By adding three aluminum shell resistors R4 (RX24 50W 32K) / R5 (RX24 50W 96K) / R6 (RX24 50W 160K) on PACK+, PACK- and GND, resistors of different resistance values are added between PACK+ and GND and between PACK- and GND, which are used for detecting the insulation function of the battery pack, and all low-voltage signals of the battery pack are connected to the test system through the only En 24P jack.

[0052] The model of the environmental detector is JCJ 175A0A24CN, the model of the voltage patrol instrument is AMC16Z-FD16, the model of the temperature patrol instrument is DAQM-4207, and the model of the 485 module is ZLAN5443A,

[0053] As Figure 9 shown, and with reference to Figure 11, the port U1- of the voltage inspector is connected to the port Y4 of the I / O module P2, the port CZ4 of the I / O module P2 is connected to the port V- of the battery module to be measured through the aviation plug, the port U1+ of the voltage inspector is connected to the port U2- and then connected to the port Y5 of the I / O module P2, the port CZ5 of the I / O module P2 is connected to the port V1+ of the battery module to be measured through the aviation plug, the port U2+ of the voltage inspector is connected to the port U3- and then connected to the port Y6 of the I / O module P2, the port CZ6 of the I / O module P2 is connected to the port V2+ of the battery module to be measured through the aviation plug, the port U3+ of the voltage inspector is connected to the port U4- and then connected to the port Y7 of the I / O module P2, the port CZ7 of the I / O module P2 is connected to the port V3+ of the battery module to be measured through the aviation plug, the port U4+ of the voltage inspector is connected to the port U5- and then connected to the port Y8 of the I / O module P2, the port CZ8 of the I / O module P2 is connected to the port V4+ of the battery module to be measured through the aviation plug, the port U5+ of the voltage inspector is connected to the port U6- and then connected to the port Y9 of the I / O module P2, the port CZ9 of the I / O module P2 is connected to the port V5+ of the battery module to be measured through the aviation plug, the port U6+ of the voltage inspector is connected to the port U7- and then connected to the port Y10 of the I / O module P2, the port CZ10 of the I / O module P2 is connected to the port V6+ of the battery module to be measured through the aviation plug, the port U7+ of the voltage inspector is connected to the port U8- and then connected to the port Y11 of the I / O module P2, the port CZ11 of the I / O module P2 is connected to the port V7+ of the battery module to be measured through the aviation plug, the port U8+ of the voltage inspector is connected to the port U9- and then connected to the port Y12 of the I / O module P2, the port CZ12 of the I / O module P2 is connected to the port V8+ of the battery module to be measured through the aviation plug, the port U9+ of the voltage inspector is connected to the port U10- and then connected to the port Y13 of the I / O module P2, the port CZ13 of the I / O module P2 is connected to the port V9+ of the battery module to be measured through the aviation plug, the port U10+ of the voltage inspector is connected to the port U11- and then connected to the port Y14 of the I / O module P2, the port CZ14 of the I / O module P2 is connected to the port V10+ of the battery module to be measured through the aviation plug, the port U11+ of the voltage inspector is connected to the port U12- and then connected to the port Y15 of the I / O module P2, the port CZ15 of the I / O module P2 is connected to the port V11+ of the battery module to be measured through the aviation plug, the port U12+ of the voltage inspector is connected to the port U13- and then connected to the port Y16 of the I / O module P2, the port CZ16 of the I / O module P2 is connected to the port V12+ of the battery module to be measured through the aviation plug, the port U13+ of the voltage inspector is connected to the port U14- and then connected to the port Y17 of the I / O module P2, the port CZ17 of the I / O module P2 is connected to the port V13+ of the battery module to be measured through the aviation plug,The port U14+ of the voltage inspector is connected with the port U15-, and then connected to the port Y18 of the I / O module P2, the port CZ18 of the I / O module P2 is connected to the port V14+ of the battery module to be measured through a plug, the port U15+ of the voltage inspector is connected with the port U16-, and then connected to the port Y19 of the I / O module P2, the port CZ19 of the I / O module P2 is connected to the port V15+ of the battery module to be measured through a plug, the port U15+ of the voltage inspector is connected to the port Y20 of the I / O module P2, and the port CZ20 of the I / O module P2 is connected to the port V16+ of the battery module to be measured.

[0054] As shown in Figure 10 , and referring to Figure 11The port IN0- of the temperature detector is connected to the port Y22 of the I / O module P2, the port IN0+ of the temperature detector is connected to the port Y21 of the I / O module P2, the port IN1- of the temperature detector is connected to the port Y24 of the I / O module P2, the port IN1+ of the temperature detector is connected to the port Y23 of the I / O module P2, the port IN2- of the temperature detector is connected to the port Y26 of the I / O module P2, the port IN2+ of the temperature detector is connected to the port Y25 of the I / O module P2, the port IN3- of the temperature detector is connected to the port Y28 of the I / O module P2, the port IN3+ of the temperature detector is connected to the port Y27 of the I / O module P2, the port IN4- of the temperature detector is connected to the port Y30 of the I / O module P2, the port IN4+ of the temperature detector is connected to the port Y29 of the I / O module P2, the port IN5- of the temperature detector is connected to the port Y32 of the I / O module P2, the port IN5+ of the temperature detector is connected to the port Y31 of the I / O module P2, the port IN6- of the temperature detector is connected to the port Y34 of the I / O module P2, the port IN6+ of the temperature detector is connected to the port Y33 of the I / O module P2, the port IN7+ of the temperature detector is connected to the port Y35 of the I / O module P2, the port IN7- of the temperature detector is connected to the port Y0 of the I / O module P3, the port IN8+ of the temperature detector is connected to the port Y1 of the I / O module P3, the port IN8- of the temperature detector is connected to the port Y2 of the I / O module P3, the port IN9+ of the temperature detector is connected to the port Y3 of the I / O module P3, the port IN9- of the temperature detector is connected to the port Y4 of the I / O module P3, the port IN10+ of the temperature detector is connected to the port Y5 of the I / O module P3, the port IN10- of the temperature detector is connected to the port Y6 of the I / O module P3, the port IN11+ of the temperature detector is connected to the port Y7 of the I / O module P3, the port IN11- of the temperature detector is connected to the port Y8 of the I / O module P3, when collecting the temperature of the battery module, the ports CZ21-CZ35 of the I / O module P2 are connected to the ports NTC1+ and NTC1- to the ports NTC8+ of the battery module through the aviation plug, and the ports CZ0-CZ8 of the I / O module P3 are connected to the ports NTC8- and NTC9+ to the ports NTC12+ and NTC12- of the battery module through the aviation plug.

[0055] As Figure 13Also shown, there is a display 9 and a bar scanner 10, the model of the display is B2213E-2, the model of the bar scanner is OH4503, the port HDMI of the display is connected to the port HIMI of the industrial computer, the USB power supply port of the bar scanner is connected to the port USB3 of the industrial computer, through the integrated bar scanner, the host computer can automatically identify the battery pack (PACK) and the battery module product series by scanning the bar code and call the corresponding test process and test record, which greatly simplifies the operation steps of the test personnel.

[0056] With reference to the accompanying drawings Figure 1 , the test system further comprises a cabinet body, the 24V power module DS1, the 24V power module DS2, the voltage patrol instrument, the temperature patrol instrument, the voltage resistance tester, the universal meter, the internal resistance tester, the 485 module, the I / O module P1, the I / O module P2, the I / O module P3, a plurality of relays, the signal generator, the low-voltage direct current source, the CAN box, the switch, the industrial computer are integrated in the cabinet body, the alarm lamp LED1, the alarm lamp LED2, the alarm lamp LED3 and the environment detector are all located on the top of the cabinet body, the emergency stop switch EMG and the button switch SB1 are located on the panel of the cabinet body, the display is connected in the middle of the cabinet body, and the bar scanner is located on the side panel of the cabinet body.

[0057] Working principle: the utility model is through the integration of each independent test equipment in a cabinet body, through the wiring connection setting, the overall circuit is simple, convenient integration, strong compatibility, can realize the test demand of battery pack or battery module, the specific test object and test item content are selected according to the demand, instead of the existing test of each project needs to use the corresponding test equipment, greatly improves the efficiency of battery pack or battery module factory test.

[0058] According to the actual test work, the test items usually include: PACK communication test, voltage resistance test and insulation resistance test, ACR test, total voltage test, single cell voltage and maximum voltage difference test, single cell temperature and maximum temperature difference test, insulation function test, HVIL function test, CC / CP / CC2 detection, heating film resistance test, short circuit detection test, auxiliary loop test, etc. The principles of the above tests using the test system are described below:

[0059] PACK communication function test is mainly to test the communication function of battery pack (PACK) BMS CAN. The host computer receives and analyzes the CAN frame sent by the BMS system through the CAN box, judges whether the communication function is normal, and judges whether the PACK communication function is normal according to whether the message information is within a reasonable range. Control I / O module P1 and I / O module P2 DO0 / DO1 conduction, control the low-voltage DC power supply to run and output to BMS for power supply; receive and analyze the CAN frame message sent by the BMS system through the CAN box; message information judgment, transmission to industrial computer for judgment.

[0060] The pressure and insulation test is mainly to test the insulation resistance of the output positive and output negative of the battery pack (PACK) and the battery module main loop to the shell. The test principle of the output positive to the shell is: 1) control the high-voltage dry yellow relay KA1A and KA27A to conduct through I / O module P1D00 and I / O module P3DO14; 2) set the voltage and test time of the pressure tester to select the corresponding test mode AC / DC / IR; 3) control the pressure tester to run; 4) get test data and results, DO channel is disconnected;

[0061] The test principle of the output negative to the shell is: 1) control the high-voltage dry yellow relay KA1A and KA27A to conduct through I / O module P1D01 and I / O module P3DO14; 2) set the voltage and test time of the pressure tester to select the corresponding test mode AC / DC / IR; 3) control the pressure tester to run; 4) get test data and results, DO channel is disconnected.

[0062] ACR test is mainly to test the AC resistance value between the output positive and output negative of the battery pack (PACK) and the battery module main loop. Control high-voltage dry yellow relay KA13A / KA14A / KA15A / KA16A to conduct through I / O module P1D012 / D013 / D014 / D015; control the internal resistance tester to run; get test data and results.

[0063] Total pressure test is mainly to test the output voltage precision of the battery pack (PACK) and the battery module main loop. Control high-voltage dry yellow relay KA7A and KA8A to conduct through I / O module P1D06 and D07, select the DC mode of the multimeter, get test data, and transmit to the industrial computer for judgment.

[0064] The single cell voltage and maximum voltage difference test is mainly to measure the single cell voltage accuracy of the battery pack (PACK) and the battery module and whether the single cell voltage difference meets the requirements. When used for battery pack (PACK) test: control I / O module P1D022 / DO23 and I / O module P2DO0 / DO1 to be on; control the low-voltage DC power supply to run and output power to the BMS; accept all single cell voltage values through the CAN box; calculate the maximum temperature difference by the host computer, and determine the result; control the DC power supply to stop running, and the DO channel is disconnected; when used for battery pack module test: control I / O module P2DO4 to DO20 to be on, and measure all single cell voltage values through the voltage inspection instrument; transmit to the industrial computer for judgment.

[0065] The single cell temperature and maximum temperature difference test is mainly to measure the single cell temperature accuracy of the battery pack (PACK) and the battery module and whether the single cell temperature difference meets the requirements. When used for battery pack (PACK) test: control I / O module P1D022 / DO23 and P2DO0 / DO1 to be on; control the low-voltage DC power supply to run and output power to the BMS; accept all single cell temperature values through the CAN box; calculate the maximum temperature difference by the host computer, and determine the result; control the DC power supply to stop running, and the DO channel is disconnected; when used for battery pack module test: control I / O module P2DO21 to DO35 to be on and I / O module P3DO0 to DO8 to be on; measure all single cell temperature values through the temperature inspection instrument; transmit to the industrial computer for judgment.

[0066] The insulation function test is mainly to test the insulation function of the battery pack. The output positive pole to GND insulation function test principle is: 1) control I / O module P1D022 / DO23 and P2DO0 / DO1 to be on; 2) control the low-voltage DC power supply to run and output power to the BMS; 3) control high-voltage dry yellow relay KA21A / KA17A to be on through I / O module P1DO20 / DO16; 4) control high-voltage dry yellow relays KA18A / KA19A / KA20A to be on respectively through I / O module P1DO17 / DO18 / D019 to enter the aluminum shell resistance in series, 5) read the BMS insulation state through the CAN box; transmit to the industrial computer for judgment, and the output negative pole to GND insulation function test principle is similar to the output positive pole to GND insulation function test principle.

[0067] The HVIL test is mainly to test the high-voltage interlock function of the battery pack. Control I / O module P1D022 / DO23 and P2DO0 / DO1 to be on; control the low-voltage DC power supply to run and output power to the BMS; control P1DO34 to be on; read the BMS interlock state through the CAN box, transmit to the industrial computer for judgment, and the DO channel is disconnected.

[0068] The CC / CP / CC2 detection test mainly detects whether the fast charging and slow charging functions of the battery pack are normal. By controlling the I / O module P1D022 / DO23 and P2DO0 / DO1 to be conductive, controlling the low-voltage direct-current source to run and output power to the BMS, and controlling the I / O module P1D028 / DO29 to be conductive, a 1K resistor is transmitted between CC2 and PE, the BMS CC2 connection state is read through the CAN box, and transmitted to the industrial computer for judgment, realizing the fast charging signal CC2 test.

[0069] The I / O module P1D022 / DO23 and P2DO0 / DO1 are controlled to be conductive, the low-voltage direct-current source is controlled to run and output power to the BMS, the I / O module P1D028 / DO29 is controlled to be conductive, the signal generator output waveform type / duty ratio / frequency is set and controlled to run, and the BMS CP signal state is read through the CAN box; transmitted to the industrial computer for judgment, realizing the slow charging signal CP test.

[0070] The I / O module P1D022 / DO23 and P2DO0 / DO1 are controlled to be conductive, the low-voltage direct-current source is controlled to run and output power to the BMS, the I / O module P1D028 / DO29 is controlled to be conductive, and the I / O module P1D031 / D032 / D033 / D034 is controlled to be conductive in the CC and PE loop according to the test requirements. R8 / R9 / R10 / R11 is inserted into the resistor, the BMS CC signal state is read through the CAN box, and transmitted to the industrial computer for judgment, realizing the slow charging signal CC test.

[0071] The heating film resistance test mainly tests whether the heating film can work normally. By testing whether the resistance of the heating film is the set value, it is judged whether it is normal. By controlling the I / O module P2D010 / DO11 to be conductive, the high-voltage dry yellow relay KA23A / KA24A is controlled to be conductive, the multimeter mode is selected as resistance mode, and the test data is transmitted to the industrial computer for judgment.

[0072] The short circuit test mainly tests whether there is a short circuit between the output positive and output negative of the battery pack, the output positive and the shell, and the output negative and the shell. By controlling the I / O module P1D06 / DO7 to be conductive, the high-voltage dry yellow relay KA7A / KA8A is controlled to be conductive, the multimeter mode is selected as resistance mode, the test data is obtained, and transmitted to the industrial computer for judgment, realizing the short circuit test between the output positive and the output negative; by controlling the I / O module P1D08 / DO9 to be conductive, the high-voltage dry yellow relay KA9A / KA10A is controlled to be conductive, the multimeter mode is selected as resistance mode, the test data is obtained, and transmitted to the industrial computer for judgment, realizing the short circuit test between the output positive and the shell; by controlling the I / O module P1D010 / DO11 to be conductive, the high-voltage dry yellow relay KA11A / KA12A is controlled to be conductive, the multimeter mode is selected as resistance mode, the test data is obtained, and transmitted to the industrial computer for judgment, realizing the short circuit test between the output negative and the shell.

[0073] The auxiliary circuit test mainly tests whether the on-off of the PACK auxiliary power supply interface contactor is normal, and in the two states of the on-off of the contactor, whether the terminal voltage of the PACK auxiliary power supply interface is a set value is tested to determine whether it is normal.

[0074] It should be noted that the data transmission to the industrial computer, the judgment and calculation process of the industrial computer belong to the prior art.

[0075] The above examples are only used to illustrate the technical solutions of the utility model, and not to limit them; although the utility model has been described in detail with reference to the foregoing examples, those skilled in the art should understand that the technical solutions recorded in the foregoing examples can still be modified, or some technical features can be replaced equivalently; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the utility model.

Claims

1. An EOL testing system for a PACK or battery module, characterized in that: The system includes a power supply circuit, a high-voltage test circuit, a CC / CP / CC2 test circuit, an environmental monitoring instrument, a voltage monitoring instrument, a temperature monitoring instrument, a 485 module, I / O modules P1, P2, and P3, several relays, and an industrial computer. The power supply circuit includes 24V power modules DS1 and DS2. The high-voltage test circuit includes a withstand voltage tester, a multimeter, and an internal resistance tester. The CC / CP / CC2 test circuit includes a signal generator, a low-voltage DC power supply, and a CAN bus. The input terminals of both 24V power modules DS1 and DS2 are connected to the power supply. The output terminal of 24V power module DS1 is connected to the environmental monitoring instrument, voltage monitoring instrument, temperature monitoring instrument, and 485 module. The system consists of five modules: I / O modules P1, P2, and P3. The output of the 24V power supply module DS2 is connected to several relays. A voltage monitor is connected to I / O module P2, and a temperature monitor is connected to I / O modules P2 and P3. A signal generator and a low-voltage DC power supply are connected to I / O module P1, and a CAN box is connected to I / O module P2. The 485 module communicates with the environmental monitoring instrument, voltage monitor, temperature monitor, low-voltage DC power supply, and industrial computer. The industrial computer communicates with a withstand voltage tester, multimeter, internal resistance tester, I / O modules P1, P2, and P3. The industrial computer also exchanges data with the signal generator and CAN box.

2. The EOL testing system for PACK or battery module according to claim 1, characterized in that: The power supply circuit also includes a circuit breaker QF1, a fuse FU1, an emergency stop switch EMG, and a push-button switch SB1. The live wire and neutral wire of the circuit breaker QF1 are connected to the live wire and neutral wire of the input power supply, respectively. The live wire of the circuit breaker QF1 is connected in series with the fuse FU1 and then connected to one end of the emergency stop switch EMG. The other end of the emergency stop switch EMG is connected to one end of the push-button switch SB1. The other end of the push-button switch SB1 is connected to the live wire input terminal of the 24V power module DS1 and the live wire input terminal of the 24V power module DS2. The neutral wire of the circuit breaker QF1 is connected to the neutral wire input terminal of the 24V power module DS1 and the neutral wire input terminal of the 24V power module DS2.

3. The EOL testing system for PACK or battery module according to claim 2, characterized in that: Several relays, including relays KA1-KA27, are connected to ports CZ0-CZ21 of I / O module P1, which are all connected to the positive output terminal of 24V power module DS2. One end of relay coil KA1A is connected to port Y0 of I / O module P1, one end of relay coils KA2A-KA22A is connected to ports Y1-Y21 of I / O module P1, and the other end of relay coils KA1A-KA22A is connected to the negative output terminal of 24V power module DS2. One end of relay coil KA23A... One end of relay coil KA24A is connected to port Y10 of I / O module P3, one end of relay coil KA25A is connected to port Y12 of I / O module P3, one end of relay coil KA26A is connected to port Y13 of I / O module P3, one end of relay coil KA27A is connected to port Y14 of I / O module P3, and the other ends of relay coils KA23A-KA27A are respectively connected to the negative terminal of the output terminal of 24V power module DS2.

4. The EOL testing system for PACK or battery module according to claim 3, characterized in that: The high-voltage test circuit also includes resistors R1, R2, and R3, and fuse FU2. The LOW port of the withstand voltage tester is connected to one end of fuse FU2. The other end of fuse FU2 is connected to one end of the normally open contact of relay KA27, one end of the normally open contact of relay KA4, one end of the normally open contact of relay KA5, and one end of the normally open contact of relay KA6. The other end of the normally open contact of relay KA27 is connected to the aviation connector. The other end of the normally open contact of relay KA4 is connected to one end of resistor R1. The other end of the normally open contact of relay KA5 is connected to one end of resistor R2. The other end of the normally open contact of relay KA6 is connected to one end of resistor R3. The HV port of the withstand voltage tester is connected to one end of the normally open contacts of relays KA1-KA3. The other ends of resistors R1-R3 are connected to the other end of the normally open contact of relay KA3. The other ends of the normally open contacts of relays KA1 and KA2 are connected to the aviation connector. Connect the multimeter's port HI to one end of the normally open contacts of relays KA7, KA9, KA11, KA24, and KA26. Connect the other end of the normally open contacts of relays KA7, KA9, and KA11 to a connector. Connect the multimeter's port LO to one end of the normally open contacts of relays KA8, KA10, KA12, KA23, and KA25. The other end of normally open contact 8, normally open contact KA10, and normally open contact KA12 are connected to the aviation connector; the other end of normally open contact KA23 is connected to the positive terminal of the heating film resistor port of the battery pack or battery module under test; the other end of normally open contact KA24 is connected to the negative terminal of the heating film resistor port of the battery pack or battery module under test; the other end of normally open contact KA25 is connected to the positive terminal of the auxiliary circuit port of the battery pack or battery module under test; and the other end of normally open contact KA26 is connected to the negative terminal of the auxiliary circuit port of the battery pack or battery module under test. The positive terminal of the first test port of the internal resistance tester is connected to one end of the normally open contact of relay KA13. The positive terminal of the second test port of the internal resistance tester is connected to one end of the normally open contact of relay KA14. The negative terminal of the first test port of the internal resistance tester is connected to one end of the normally open contact of relay KA15. The negative terminal of the second test port of the internal resistance tester is connected to one end of the normally open contact of relay KA16. The other ends of the normally open contacts of relay KA13 and KA14 are connected to the aviation connector. The other ends of the normally open contacts of relay KA15 and KA16 are connected to the aviation connector.

5. The EOL testing system for PACK or battery module according to claim 1, characterized in that: The CC / CP / CC2 test circuit also includes resistors R7-R11. The positive output of the signal generator is connected to port CZ27 of I / O module P1. Port Y27 of I / O module P1 is connected to port CP of the battery pack or battery module under test. The negative output of the signal generator is connected to ports CZ28, CZ29, and CZ30 of I / O module P1, and one end of resistor R8. Port Y28 of I / O module P1 is connected to one end of resistor R7. The other end of resistor R7 is connected to port CC2 of the battery pack or battery module under test via a connector. Port Y29 is connected to port PE of the battery pack or battery module under test via an air connector. Port Y30 of I / O module P1 is connected to port CZ31 and then to the other end of resistor R8 and one end of resistor R9. Port Y31 of I / O module P1 is connected to port CZ32 and then to the other end of resistor R9 and one end of resistor R10. Port Y32 of I / O module P1 is connected to port CZ33 and then to the other end of resistor R10 and one end of resistor R11. The other end of resistor R11 is connected to port Y33 of I / O module P1. Port Y33 of I / O module P1 is connected to port CC of the battery pack or battery module under test via an air connector.

6. The EOL testing system for PACK or battery module according to claim 1, characterized in that: The positive output of the low-voltage DC power supply is connected to ports CZ26, CZ24, and CZ22 of I / O module P1, and the negative output of the low-voltage DC power supply is connected to ports CZ23 and CZ25 of I / O module P1. Port Y26 of I / O module P1 is connected to the wake-up signal port of the battery pack or battery module under test via an air connector. Port Y24 of I / O module P1 is connected to port K30L+ of the battery pack or battery module under test via an air connector. Port Y22 of I / O module P1 is connected to port K15L+ of the battery pack or battery module under test via an air connector. Port Y23 of I / O module P1 is connected to port K15L- of the battery pack or battery module under test via an air connector. Port Y25 of I / O module P1 is connected to port K30L- of the battery pack or battery module under test via an air connector.

7. The EOL testing system for PACK or battery module according to claim 1, characterized in that: The positive terminal of the first signal port of the CAN box is connected to port CZ0 of I / O module P2, the negative terminal of the first signal port of the CAN box is connected to port CZ1 of I / O module P2, the positive terminal of the second signal port of the CAN box is connected to port CZ2 of I / O module P2, and the negative terminal of the second signal port of the CAN box is connected to port CZ3 of I / O module P2. Port Y0 of I / O module P2 is connected to port CAN1-H of the battery pack or battery module under test via an air connector. Port Y1 of I / O module P2 is connected to port CAN1-L of the battery pack or battery module under test via an air connector. Port Y2 of I / O module P2 is connected to port CAN2-H of the battery pack or battery module under test via an air connector. Port Y3 of I / O module P2 is connected to port CAN2-L of the battery pack or battery module under test via an air connector.

8. The EOL testing system for PACK or battery module according to claim 3, characterized in that: It also includes an insulation test circuit, which includes resistors R4-R6. One end of the normally open contact of relay KA17 is connected to the aviation connector. The other end of the normally open contact of relay KA17 is connected to one end of resistor R4, one end of resistor R5, and one end of resistor R6. The other end of resistor R4 is connected to one end of the normally open contact of relay KA18. The other end of resistor R5 is connected to one end of the normally open contact of relay KA19. The other end of resistor R6 is connected to one end of the normally open contact of relay KA20. The other ends of the normally open contacts of relays KA18, KA19, and KA20 are connected together and then connected to one end of the normally open contacts of relays KA21 and KA22. The other end of the normally open contact of relay KA21 is connected to the aviation connector. The other end of the normally open contact of relay KA22 is connected to the aviation connector. The aviation connector receives the battery pack or battery module under test.

9. The EOL testing system for PACK or battery module according to claim 1, characterized in that: It also includes a switch, a withstand voltage tester, a multimeter, an internal resistance tester, I / O modules P1, P2, and P3, which communicate with the switch. The switch communicates with the industrial control computer. The signal port of the withstand voltage tester is connected to the first signal port JHJ-LAN1 of the switch, the signal port of the multimeter is connected to the second signal port JHJ-LAN2 of the switch, the signal port of the internal resistance tester is connected to the third signal port JHJ-LAN3 of the switch, the signal port of I / O module P1 is connected to the fourth signal port JHJ-LAN34 of the switch, the signal port of I / O module P2 is connected to the fifth signal port JHJ-LAN5 of the switch, the signal port of I / O module P3 is connected to the sixth signal port JHJ-LAN6 of the switch, the signal port of the 485 module is connected to the seventh signal port JHJ-LAN7 of the switch, and the eighth signal port JHJ-LAN8 of the switch is connected to the signal port of the industrial control computer.

10. The EOL testing system for a PACK or battery module according to claim 1, characterized in that: It also includes alarm lights LED1, LED2, and LED3. One end of alarm light LED1 is connected to the positive output terminal of the 24V power module DS1, and the other end of alarm light LED1 is connected to the negative output terminal of the 24V power module DS1. One end of alarm light LED2 is connected to port Y16 of I / O module P3, and the other end of alarm light LED2 is connected to the negative output terminal of the 24V power module DS1. One end of alarm light LED3 is connected to port Y15 of I / O module P3, and the other end of alarm light LED3 is connected to the negative output terminal of the 24V power module DS1. Ports CZ16 and CZ15 of I / O module P3 are both connected to the positive output terminal of the 24V power module DS1.

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