Energy storage high-voltage box test system

Abstract

The utility model discloses an energy storage high-voltage box test system, which comprises a test tool, an upper computer and a to-be-tested high-voltage box, and is characterized in that the test tool comprises a plurality of test interfaces, and the test interfaces are connected with the high-voltage box and are used for detecting input and output digital quantity signals and communication channel signals of an LCU in a preset acquisition loop; input and output digital quantity signals, communication channel signals and collected data signals of the RCU are transmitted to an upper computer through a CAN interface so as to display a test result. According to the test system disclosed by the invention, the detection efficiency is improved through the test tool, the automatic test process can be realized, the manual operation time is shortened, and the test speed and efficiency are improved; meanwhile, by using the testing tool, errors caused by manual operation can be reduced, and the accuracy of a testing result is improved.

Description

Technical Field

[0001] This invention belongs to the field of energy storage equipment technology, and in particular relates to a high-voltage test system for energy storage boxes. Background Technology

[0002] An integrated energy storage cabinet is an integrated energy storage system that integrates core components such as batteries, battery management systems (BMS), power storage converters (PCS), and energy management systems (EMS) into a single outdoor cabinet. This design features high integration, standardization, ease of installation and maintenance, and can adapt to various application scenarios, such as frequency regulation of thermal power units, photovoltaic power consumption, peak shaving and valley filling, peak-valley electricity pricing, and microgrids.

[0003] The integrated energy storage cabinet boasts high integration and a small footprint, maximizing space utilization. Its standardized design facilitates mass production. For battery management, each battery cluster is managed individually, extending battery life and system reliability. Fire safety is paramount, with built-in smoke, temperature, and gas detectors, and a perfluorohexanone fire extinguishing system, ensuring safe system operation. It supports remote and local control, cloud platform monitoring, and the IEC61850 communication protocol, facilitating system management and maintenance.

[0004] The high-voltage box is a key component of an energy storage system. It connects the battery clusters and the power supply converter (PCS), managing the high-voltage battery system. It features functions such as acquiring battery cluster voltage and current, contactor control, and protection. It supports data status processing and charge / discharge control and management of battery packs within the same cluster. It also contains the internal power distribution circuits of the integrated energy storage cabinet, mainly including the power supply circuit for the liquid-cooled main unit and the internal lighting circuit. The high-voltage box houses DC molded case circuit breakers, DC contactors, DC fuses, current sensors, a main control module, a switching power supply, and miniature circuit breakers.

[0005] The energy storage high-voltage box uses an integrated wiring harness to connect all components, ensuring stable and reliable connections. It collects cell voltage and temperature data from all battery modules via an internal CAN interface, providing protection for the battery modules. Furthermore, it has the function of communicating with the PCS (Power Control System), and the main circuit is equipped with circuit breakers, fuses, and relays to manage the charging and discharging of the entire battery system, ensuring safe and reliable operation.

[0006] High-voltage energy storage boxes have complex structures and functions, and are highly integrated. Since high-voltage boxes within the same project are essentially identical and can be mass-produced, factory testing of the high-voltage boxes is crucial. A comprehensive testing system ensures the integrity of all functions and reliable operation of the high-voltage box. Currently, energy storage unit capacity is developing rapidly, and the number of individual cabinets is increasing. The Three Gorges Binhai 200MW / 400MWh string energy storage power station project has 1080 energy storage cabinets. Therefore, the design of testing fixtures for energy storage high-voltage boxes is particularly important. Summary of the Invention

[0007] To address the aforementioned shortcomings, this invention provides a high-voltage energy storage box testing system that improves testing efficiency. Through an automated testing process, it reduces manual operation time, increases testing speed and efficiency, and reduces human error by using testing fixtures, thereby improving the accuracy of test results.

[0008] A high-voltage energy storage box testing system includes a testing fixture, a host computer, and a high-voltage box under test. The testing fixture includes several testing interfaces connected to the high-voltage box. These interfaces are used to detect the input and output digital signals and communication channel signals of the LCU in a preset acquisition circuit, the input and output digital signals and communication channel signals of the RCU, and the acquired data signals. The data is then transmitted to the host computer via a CAN interface to display the test results.

[0009] Preferably, the high-voltage box includes an LCU local controller and an RCU. Both the LCU and RCU have a CAN communication interface, a 485 communication interface, and several DI / DO interfaces. The CAN communication interfaces are connected to form a CAN communication channel, and the 485 communication interfaces are connected to form a 485 communication channel. The DI / DO interfaces are used to input and output digital signals. The RCU's DI / DO interface is connected to one or more of the following: PCS dry contacts, high-voltage box DC circuit breaker, main contactor, and fuse. The data acquisition interface acquires one or more of the following data: total positive voltage, total negative voltage, and Hall current. The LCU's DI / DO interface is connected to one or more of the following: water immersion signal, fire signal, emergency stop signal, and access control signal.

[0010] Preferably, the test fixture includes a test interface, which includes one or more of the following: P1 BMU connector, P2 DI / DO connector, P3 water immersion / fire protection connector, P4 PCS connector, and P5 commissioning and spare connector. Specifically, P1 is used to connect the RCU to the slave control unit BMU, P2 is used to connect the high-voltage box indicator light and emergency stop signal, P3 is used to connect the LCU water immersion / fire protection signal, P4 is used to connect the PCS dry contact, and P5 is used to connect the host computer.

[0011] Preferably, the P1 BMU connector has low-voltage output and low-voltage input interfaces. The CAN communication interface of the low-voltage output interface is connected to pins 3 and 4 of the RCU's D port, and the slave power supply interface is connected to pin 5 of the RCU's D port. At the same time, the slave power supply + / - interface, the encoding IO1 interface, and the CAN communication interface are respectively connected to the BMU's power supply port, IO port, and CAN communication interface.

[0012] Preferably, the P2 DI / DO connector has several DO interfaces and several DI interfaces, wherein DO1 is connected to the running indicator light, DO2 is connected to the fault indicator light, DO3 is connected to the alarm indicator light, DI1 is connected to the access control signal, DI2 is connected to the backup signal, and DI3 is connected to the emergency stop signal.

[0013] Preferably, the P3 water immersion / fire protection connector has a 485 communication interface, a water immersion detector interface, a fire protection dry contact port, and a spare port. The P3 485 communication interface is connected to the LCU's 485A1-B1, the water immersion detector interface is connected to pins 2 and 3 of the water immersion transmitter SJ, the fire protection dry contact port is connected to the LCU's DI5 and 6 pins, and the spare port is connected to the LCU's DI4 and 7 pins. At the same time, the access control, spare, and emergency stop signals of the P2 DO interface are all connected to the fire protection dry contact port and the spare port.

[0014] Preferably, the P4 PCS connector has a CAN communication interface, a PCS dry contact output interface, and a 485 communication interface. The CAN communication interface of P4 is connected to pins 12 and 24 of the RCU B port; the PCS dry contact output interface is connected to pins 15 and 31 of the RCU C port, and is also connected to the water immersion detector interface of P3; the 485A2-B2 pins of P4 are connected to the 485A2-B3 pins of the LCU, and are also connected to the 485A1-B1 pins of P3.

[0015] Preferably, the P5 debugging and spare connector has a main control CAN1 debugging port, a main control CAN2 debugging port, an LCU CAN1 port, and an RCU 485 port. The main control CAN1 debugging port is connected to the CAN communication interface of P4 and is also connected to the host computer for communication. The main control CAN2 debugging port is connected to pins 3 and 6 of P1. The LCU CAN1 port is connected to the CAN1_H and CAN1_L of the LCU and is also connected to the host computer for communication. The RCU 485 port is connected to the 485A1-B1 and A2-B3 of the RCU.

[0016] As a preferred option, the high-voltage box panel is also equipped with network port 1, network port 2 and USB interface. Network port 1 is connected to the LAN interface of the RCU, and network port 2 is connected to the host computer via network cable. The USB flash drive storing the test program is inserted into the USB interface to burn the test program.

[0017] Preferably, the energy storage high-voltage box test system also includes several indicator lights HL. The high-voltage box is also equipped with a lighting module. Indicator light HL1 is connected to the lighting module as a normal indicator of the lighting circuit. Indicator lights HL3 and HL4 are respectively connected between VIN+ / - of the RCU and 24V+ / - of the LCU as power indicator lights. HL11 and HL12 are respectively used as operation indicator lights and fault indicator lights, and are connected to DO1 and DO2 of the P2 DI / DO connector respectively. HL13 is connected between the circuit formed by DC circuit breaker KM1 and fuse FU1 and the circuit formed by DC circuit breaker KM2 and Hall sensor, and is connected to DO3 of the P2 DI / DO connector as an alarm indicator light.

[0018] The beneficial effects of this invention are:

[0019] (1) The energy storage high-voltage box testing system disclosed in this invention improves testing efficiency. Through an automated testing process, it reduces the time spent on manual operation and increases the speed and efficiency of testing. The high-voltage box fixture can complete the test within 5 minutes, while traditional manual testing takes 30 minutes;

[0020] (2) The energy storage high-voltage box test system disclosed in this invention is easy to operate: the test tooling system interface is simple, and the operator can easily set up the test and interpret the results, which simplifies the operation process;

[0021] (3) The energy storage high-voltage box testing system disclosed in this invention has high accuracy: by using testing fixtures, human error is reduced, and the accuracy of test results is improved. The system displays the functional test results intuitively through indicator lights;

[0022] (4) The energy storage high-voltage box test system disclosed in this invention reduces costs: the automated test fixtures reduce the need for manual inspection, thereby reducing inspection costs and also reducing potential cost losses due to inspection errors;

[0023] (5) The energy storage high-voltage box testing system disclosed in this invention improves production quality: Through comprehensive testing and fault analysis, the testing fixture helps to improve the production quality of energy storage high-voltage boxes and ensure that the products meet safety and performance standards before leaving the factory.

[0024] (6) The present invention discloses convenient maintenance: the high-voltage box tooling system is designed with the convenience of maintenance in mind. The test tooling can be adjusted according to the project and can adapt to the test requirements of different projects. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below.

[0026] Figure 1This is a schematic diagram of the test fixture connection according to an embodiment of the present invention;

[0027] Figure 2 This is a test electrical diagram of the main circuit of a test fixture according to an embodiment of the present invention;

[0028] Figure 3 This is a test electrical diagram of the test fixture control circuit according to an embodiment of the present invention;

[0029] Figure 4 This is a test fixture BMU slave control test electrical diagram according to an embodiment of the present invention.

[0030] Figure 5 This is a test electrical diagram of the RCU main control test fixture according to an embodiment of the present invention. Detailed Implementation

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

[0032] Example

[0033] This invention discloses a high-voltage energy storage box testing system, including a testing fixture, a host computer, and a high-voltage box under test. The testing fixture includes several testing interfaces, which are connected to the high-voltage box and used to detect the input and output digital signals and communication channel signals of the LCU in the preset acquisition circuit, the input and output digital signals and communication channel signals of the RCU, and the acquired data signals, and transmit them to the host computer through the CAN interface to display the test results.

[0034] Test fixture components:

[0035] The high-voltage box test fixture consists of test software, test wiring harness, indicator lights, and slave control unit (BMU). The LCU local controller and RCU master control module, pre-installed in the high-voltage box, have preset test programs downloaded at the factory. Then, the test wiring harness plug of the test fixture is inserted into the corresponding socket on the high-voltage line, and the test is performed according to the test requirements.

[0036] like Figure 1-4 The diagram shows the connection of the test fixture. The test fixture includes a test interface, indicator lights, and a slave control unit (BMU). The test interface includes a P1 BMU connector, a P2 DI / DO connector, a P3 water immersion / fire protection connector, a P4 PCS connector, and a P5 debugging and spare connector.

[0037] The high-voltage box includes an LCU local controller and an RCU. Both the LCU and RCU have a CAN communication interface, a 485 communication interface, and several DI / DO interfaces. The CAN communication interfaces are connected to form a CAN communication channel, and the 485 communication interfaces are connected to form a 485 communication channel. The DI / DO interfaces are used to input and output digital signals. The RCU's DI / DO interface is connected to one or more of the following: PCS dry contacts, high-voltage box DC circuit breaker, main contactor, and fuse. The data acquisition interface acquires one or more of the following data: total positive voltage, total negative voltage, and Hall current. The LCU's DI / DO interface is connected to one or more of the following: water immersion signal, fire signal, emergency stop signal, and access control signal.

[0038] The connection between the test fixture and the high-voltage box is as follows:

[0039] The P1 BMU connector features low-voltage output and low-voltage input interfaces for connecting the RCU and BMU. The low-voltage output interface's CAN communication interface (pins 3 and 6) connects to pins 3 and 4 of the RCU's D port, and the slave power supply - (pin 4) connects to pin 5 of the RCU's D port. Simultaneously, the slave power supply + / - (pins 1 and 4), encoding IO1 (pin 2), and CAN communication interface (pins 3 and 6) connect to the power supply port (pins 1 and 4), IO port (pin 5), and CAN communication interface (pins 3 and 6) of #1 BMU, respectively. The low-voltage input interface's slave power supply + (pin 7) connects to pin 6 of the RCU's D port, and simultaneously, the slave power supply + / - (pins 7 and 10), encoding IO2 (pin 11), and CAN communication interface (pins 3 and 6) connect to...

[0040] The #2BMU has a power supply port (pins 1 and 4), an I / O port (pin 2), and a CAN communication interface (pins 3 and 6).

[0041] The P2 DI / DO connector has several DO interfaces and several DI interfaces. DO1 connects to the operation indicator light, DO2 connects to the fault indicator light, DO3 connects to the alarm indicator light, DI1 connects to the access control signal, DI2 connects to the backup signal, and DI3 connects to the emergency stop signal.

[0042] The P3 water immersion / fire protection connector features a 485 communication interface, a water immersion detector interface, a fire protection dry contact port, and a spare port. The P3's 485 communication interface connects to the LCU's 485A1 B1 pin; the water immersion detector interface connects to pins 2 and 3 of the water immersion transmitter SJ pin; the fire protection dry contact port connects to the LCU's DI5 and 6 pins; and the spare port connects to the LCU's DI4 and 7 pins. Simultaneously, the access control, spare, and emergency stop signals of the P2DO interface are all connected to the fire protection dry contact port and the spare port.

[0043] The P4 PCS connector features a CAN communication interface, a PCS dry contact output interface, and a 485 communication interface. Specifically, the P4's CAN communication interface connects to pins 12 and 24 of the RCU B port; the PCS dry contact output interface connects to pins 15 and 31 of the RCU C port, and also corresponds to the P3's water immersion detector interface; P4's 485A2-B2 pins connect to LCU's 485A2-B3 pins, and also correspond to P3's 485A1-B1 pins.

[0044] The P5 debug and spare connector has a main control CAN1 debug port, a main control CAN2 debug port, an LCU CAN1 port, and an RCU 485 port. The main control CAN1 debug port connects to the P4's CAN communication interface (pins 1 and 2, i.e., CAN1_H and CAN1_L), and also connects to the host computer for communication. The main control CAN2 debug port connects to pins 3 and 6 of the P1. The LCU CAN1 port connects to the LCU's CAN1_H and CAN1_L, and also connects to the host computer for communication. The RCU's 485 port connects to the RCU's 485A1-B1 and A2-B3 ports.

[0045] Meanwhile, the high-voltage box panel is also equipped with network port 1, network port 2 and USB interface. Network port 1 is connected to the LAN interface of RCU, and network port 2 is connected to the host computer through network cable. The USB flash drive storing test programs and test records is inserted into the USB interface to realize the burning of test programs.

[0046] like Figure 1-2 As shown, connecting the test fixture to the high-voltage box enables the testing of the following five items:

[0047] 1) Lighting circuit test: With external power supply, close the lighting circuit miniature circuit breaker QF1. The lighting circuit indicator light HL1 on the high voltage box should light up, and the external lighting should work normally.

[0048] 2) DC power supply test: When the miniature circuit breaker of the switching power supply circuit is closed, the power indicator light HL3 of the LCU local controller and the power indicator light HL4 of the RCU main control module on the high voltage box should light up.

[0049] 3) Digital input / output interface test, mainly including LCU local controller input and output digital signals such as access control, AC molded housing position, water immersion signal, emergency stop signal, fire protection, AC molded housing trip signal, etc. The LCU checks whether the output interface is normal by running the test program, and lights up the operation indicator HL11, alarm indicator HL12, and fault indicator HL13 according to the output combination of the test table.

[0050] 4) LCU local controller peripheral device communication interface test, including main control fire signal channels, RS485 and CAN communication channels, and Ethernet communication test. The host computer reads the LCU peripheral interface data to determine if the above communication interfaces are functioning correctly.

[0051] 5) RCU main control module peripheral testing, including input / output digital signal channels of high-voltage box DC circuit breaker, main contactor, fuse, etc., measurement of total positive voltage, total negative voltage, Hall current, and testing of CAN and Ethernet communication. The above functions are determined by reading the RCU communication interface data connected to the LCU from the host computer.

[0052] Test tooling materials

[0053] The high-voltage test fixture includes the following materials:

[0054]

[0055] Test USB flash drive creation:

[0056] LCU local controller testing requires the creation of a program flashing card. The necessary materials and steps for creating the card are as follows:

[0057] Serial Number materials quantity illustrate 1 USB flash drive (2GB or larger) 1 Used for storing test programs 2 Test program 1 Test tooling program 3 balenaEtcher 1 USB flash drive burning tool

[0058] 1) Prepare the test program LCU100-TEST-V1.x-20xxxxxx.raw.gz;

[0059] 2) Insert the USB flash drive into the computer, and then open the burning software BalenaEtcher;

[0060] 3) Select the image and USB drive in the software, and click "burn". Wait for the burning process to complete.

[0061] Test process

[0062] The testing process uses four LED indicators on the LCU local controller and three status lights on the test fixture to indicate the test results. During offline testing, the test fixture is connected to an external power supply, and all connector plugs are inserted into the corresponding sockets on the high-voltage box. The test computer is then powered on and the test USB drive is inserted. The LCU local controller will automatically enter test mode and begin testing. Any problem encountered during the test will cause it to stop, and the test content will be indicated by the four internal indicator lights on the LCU local controller and the three external status lights on the high-voltage box. The test procedure and error messages are explained below:

[0063]

[0064]

[0065] The design of the high-voltage box testing system for energy storage cabinets can significantly improve the speed and quality of high-voltage box offline testing, enhance the automation level of energy storage system production, and bring about an overall improvement in the efficiency of energy storage systems.

[0066] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A testing system for an energy storage high-voltage box, characterized in that, The test fixture includes a test tool, a host computer, and a high-voltage box under test. The test tool includes several test interfaces, which are connected to the high-voltage box. These interfaces are used to detect the input and output digital signals and communication channel signals of the LCU in the preset acquisition circuit, the input and output digital signals and communication channel signals of the RCU, and the acquired data signals. The data is then transmitted to the host computer via the CAN interface to display the test results.

2. The energy storage high-voltage box testing system according to claim 1, characterized in that, The high-voltage box includes an LCU local controller and an RCU. Both the LCU and RCU have a CAN communication interface, a 485 communication interface, and several DI / DO interfaces. The CAN communication interfaces are connected to form a CAN communication channel, and the 485 communication interfaces are connected to form a 485 communication channel. The DI / DO interfaces are used to input and output digital signals. The RCU's DI / DO interface is connected to one or more of the following: PCS dry contacts, high-voltage box DC circuit breaker, main contactor, and fuse. The data acquisition interface acquires one or more of the following data: total positive voltage, total negative voltage, and Hall current. The LCU's DI / DO interface is connected to one or more of the following: water immersion signal, fire signal, emergency stop signal, and access control signal.

3. The energy storage high-voltage box testing system according to claim 1, characterized in that, The test fixture includes a test interface, which includes one or more of the following: P1 BMU connector, P2 DI / DO connector, P3 water immersion / fire protection connector, P4 PCS connector, and P5 debugging and spare connector. Specifically, P1 is used to connect the RCU to the slave control unit BMU, P2 is used to connect the high-voltage box indicator light and emergency stop signal, P3 is used to connect the LCU water immersion / fire protection signal, P4 is used to connect the PCS dry contact, and P5 is used to connect the host computer.

4. The energy storage high-voltage box testing system according to claim 3, characterized in that, The P1 BMU connector has low-voltage output and low-voltage input interfaces. The CAN communication interface of the low-voltage output interface is connected to pins 3 and 4 of the RCU's D port, and the slave power supply interface is connected to pin 5 of the RCU's D port. At the same time, the slave power supply + / - interface, the encoding IO1 interface, and the CAN communication interface are connected to the BMU's power supply port, IO port, and CAN communication interface, respectively.

5. The energy storage high-voltage box testing system according to claim 4, characterized in that, The P2 DI / DO connector has several DO interfaces and several DI interfaces. DO1 connects to the running indicator light, DO2 connects to the fault indicator light, DO3 connects to the alarm indicator light, DI1 connects to the access control signal, DI2 connects to the backup signal, and DI3 connects to the emergency stop signal.

6. The energy storage high-voltage box testing system according to claim 5, characterized in that, The P3 water immersion / fire protection connector has a 485 communication interface, a water immersion detector interface, a fire protection dry contact port, and a spare port. The P3's 485 communication interface connects to the LCU's 485A1-B1 connector, the water immersion detector interface connects to pins 2 and 3 of the water immersion transmitter SJ connector, the fire protection dry contact port connects to pins DI5 and 6 of the LCU connector, and the spare port connects to pins DI4 and 7 of the LCU connector. At the same time, the access control, spare, and emergency stop signals of the P2 DO interface are all connected to the fire protection dry contact port and the spare port.

7. The energy storage high-voltage box testing system according to claim 6, characterized in that, The P4 PCS connector has a CAN communication interface, a PCS dry contact output interface, and a 485 communication interface. The P4 CAN communication interface connects to pins 12 and 24 of the RCU B port; the PCS dry contact output interface connects to pins 15 and 31 of the RCU C port, and also connects to the P3 water immersion detector interface; the P4 485A2-B2 pins connect to the LCU 485A2-B3 pins, and also connect to the P3 485A1-B1 pins.

8. The energy storage high-voltage box testing system according to claim 7, characterized in that, The P5 debugging and spare connector has a main control CAN1 debugging port, a main control CAN2 debugging port, an LCU CAN1 port, and an RCU 485 port. The main control CAN1 debugging port is connected to the CAN communication interface of P4 and also to the host computer for communication. The main control CAN2 debugging port is connected to pins 3 and 6 of P1. The LCU CAN1 port is connected to the CAN1_H and CAN1_L ports of the LCU and also to the host computer for communication. The RCU 485 port is connected to the 485A1-B1 and A2-B3 ports of the RCU.

9. The energy storage high-voltage box testing system according to claim 8, characterized in that, The high-voltage box panel is also equipped with network port 1, network port 2 and USB interface. Network port 1 is connected to the LAN interface of RCU, and network port 2 is connected to the host computer via network cable.

10. The energy storage high-voltage box testing system according to any one of claims 1-9, characterized in that, The energy storage high-voltage box test system also includes several indicator lights HL. The high-voltage box is also equipped with a lighting module. Indicator light HL1 is connected to the lighting module as a normal indicator of the lighting circuit. Indicator lights HL3 and HL4 are respectively connected between VIN+ / - of the RCU and 24V+ / - of the LCU as power indicator lights. HL11 and HL12 are respectively used as operation indicator lights and fault indicator lights, and are connected to DO1 and DO2 of the P2 DI / DO connector respectively. HL13 is connected between the circuit formed by DC circuit breaker KM1 and fuse FU1 and the circuit formed by DC circuit breaker KM2 and Hall sensor, and is connected to DO3 of the P2 DI / DO connector as an alarm indicator light.

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