Rapid detection tool for high-voltage interlocking of power battery

Abstract

The utility model discloses a power battery high-voltage interlocking rapid detection tool, which belongs to the technical field of electric automobiles, and comprises a detection circuit and an insulating shell, the detection circuit is positioned in the insulating shell, and the detection circuit is a loop formed by a switch, a resistor, a power supply, a bulb, a loudspeaker and an amplifying circuit which are sequentially connected in series; a first connecting plug is arranged between the switch and the amplifying circuit, and a second connecting plug is arranged between the bulb and the loudspeaker; the first connecting plug and the second connecting plug are used for being connected with a low-voltage line plug of power battery high-voltage interlocking in an inserted mode; the amplification circuit is used for providing amplification current for the loudspeaker. During use, the lower end of the detection tool is held by a hand, the upper end is aligned with two low-voltage line plugs of power battery high-voltage interlocking for plugging, plugging is completed after the junction of the upper end and the lower end is in contact with the outer edge of a battery contact, detection operation can be completed by pressing the button, and operation is convenient.

Description

Technical Field

[0001] This utility model belongs to the field of electric vehicle technology, specifically relating to a rapid testing tool for high-voltage interlock of power batteries. Background Technology

[0002] High Voltage Interlock (HVIL) is a safety protection mechanism that checks the continuity of the entire high voltage system circuit by detecting low voltage signals, identifies circuit abnormalities, and disconnects the control devices at the high voltage input in a timely manner.

[0003] High-voltage interlocks have the following functions:

[0004] 1. Reflects whether the high-voltage circuit is loose: When the high-voltage circuit is loose, the resistance of the entire high-voltage interlock circuit will be abnormal. The system can detect this situation and provide alarm information to the vehicle controller before the high-voltage power is cut off, allowing time for countermeasures to be taken, thereby avoiding the loss of power to the vehicle and affecting passenger safety.

[0005] 2. Preventing Incomplete Circuitry: Before the vehicle is powered on and driven, the high-voltage interlock system detects the integrity of the circuit to prevent safety accidents caused by problems such as loose connections. If an incomplete circuitry is detected, the system will not be able to power on, avoiding potential safety hazards.

[0006] 3. Preventing safety accidents caused by human error: During the operation of a high-voltage system, without a high-voltage interlock design, manually disconnecting the high-voltage connection point may cause voltage breakdown and generate an electric arc, harming personnel and equipment around the break point. The high-voltage interlock system prevents the generation of electric arcs by disconnecting the power battery output when the connector is disconnected, thus protecting the safety of personnel and equipment.

[0007] Therefore, the high-voltage interlock system is crucial to the safety of new energy vehicles and is an extremely important component. Within the entire high-voltage circuit, there must be a power source, namely the power battery. Therefore, high-voltage interlock testing of the power battery is a necessary step.

[0008] Currently, common methods for testing high-voltage interlocking in power batteries include:

[0009] 1. EOL testing involves connecting an EOL device to the BMS bus and reading the high-voltage interlock signal to check if it is normal. However, EOL devices are inconvenient to carry or move, and they consume a lot of power, are expensive, and are complicated to operate.

[0010] 2. The resistance is tested using an instrument. This involves connecting the test leads to both ends of the low-voltage harness of the high-voltage interlock circuit and measuring the resistance value. Normally, the power battery is not located at the terminal resistance position of the high-voltage interlock circuit (the HCU is usually at the terminal resistance position). Therefore, if the resistance is zero, the high-voltage interlock is considered normal. However, the test leads must be relatively sharp at both ends; otherwise, they cannot be connected to the low-voltage harness terminals. This can easily lead to injury during operation, and the test leads may come into contact with the high-voltage positive and negative terminals, causing a hazard.

[0011] 3. Patent CN216870706U mentions a testing fixture. This fixture is characterized by its ability to measure the interlocking circuits of multiple batteries and determine the circuit's functionality through a judgment unit. However, in practice, testing one battery is no different from testing multiple batteries; both require the same number of insertions and removals. Furthermore, if the number of batteries measured changes, the fixture needs to adjust its resistance value, which is quite cumbersome. Additionally, this fixture is large and difficult to carry.

[0012] In summary, current high-voltage interlock testing methods and tooling cannot simultaneously achieve safety, portability, and economy. Utility Model Content

[0013] To address the shortcomings of existing testing fixtures in simultaneously achieving safety, portability, and cost-effectiveness, this invention provides a rapid testing fixture for high-voltage interlocking of power batteries. The fixture comprises a switch, resistor, power supply, light bulb, speaker, and amplifier circuit. Its outer shell is made of polymethyl methacrylate, making it thin, lightweight, and easy to carry. In use, the lower end of the fixture is held, and the upper end is aligned with the two low-voltage connectors of the high-voltage interlocking of the power battery. Connection is complete when the junction of the upper and lower ends contacts the outer edge of the battery contacts. Pressing the button completes the testing operation, making it easy to use.

[0014] This utility model is achieved through the following technical solution:

[0015] A rapid testing fixture for high-voltage interlock of a power battery includes a testing circuit and an insulating housing. The testing circuit is located inside the insulating housing and consists of a circuit composed of a switch, a resistor, a power supply, a light bulb, a speaker, and an amplifier circuit connected in series. A first connector is provided between the switch and the amplifier circuit, and a second connector is provided between the light bulb and the speaker. The first and second connectors are used to connect to the low-voltage connector of the high-voltage interlock of the power battery. The switch controls the conduction or disconnection of the entire circuit, the resistor protects the entire circuit, the power supply provides power to the entire circuit, the light bulb determines whether the circuit is normal, the speaker provides an alarm, and the amplifier circuit provides amplified current to the speaker.

[0016] Furthermore, the insulating housing is provided with switch mounting holes to expose the switch for easy operation by the operator.

[0017] Furthermore, the insulating outer shell is convex in shape and is made of polymethyl methacrylate.

[0018] Furthermore, the loudspeaker is an electric bell.

[0019] Furthermore, the amplifier circuit includes resistor R1, resistor R2, capacitor C, transistor, output voltage pin OUT, input voltage pin U0, and input voltage pin U1; one end of resistor R1 is connected to the positive terminal of input voltage pin U1 via a wire, and the other end is connected to the base of the transistor via a wire; the emitter output of the transistor is connected to the positive terminal of output voltage pin OUT, and the negative terminal of output voltage pin OUT is grounded; the positive terminal of input voltage pin U0 is connected to the collector of the transistor via resistor R2; the negative terminal of input voltage pin U0 and one end of capacitor C are both grounded, and the other end of capacitor C is connected to the collector of the transistor via a wire.

[0020] Furthermore, the resistor R1 is a base bias resistor, used to ensure the magnitude of the base current, thereby stabilizing the operating state of the transistor, ensuring that the transistor operates in the appropriate amplification region, and avoiding excessive saturation or cutoff.

[0021] Furthermore, the transistor is a PNP type transistor, and the switching on and off of the transistor is controlled by the base to amplify a weak signal into an electrical signal with a larger amplitude.

[0022] Furthermore, the resistor R2 is a collector resistor, which is used to ensure that R2 bears a certain voltage when the transistor is working, thereby providing the output voltage pin OUT with a suitable voltage, so as to ensure that the speaker works within a suitable voltage range.

[0023] Furthermore, the capacitor C is used to protect the safety of the entire circuit; when U1 is connected to the amplifier circuit, the amplifier circuit works, the transistor is turned on, and the speaker is powered on; when U1 is not connected to the amplifier circuit, the amplifier circuit does not work, the transistor is in the cut-off state, and the energy possessed by U0 does not perform external work, thereby saving energy.

[0024] Compared with the prior art, the advantages of this utility model are as follows:

[0025] 1. Portability: The testing fixture of this utility model consists only of a switch, resistor, power supply, light bulb, speaker, and amplifier circuit. The outer shell is made of polymethyl methacrylate, which is thin, lightweight, and easy to carry.

[0026] 2. Safety: The testing fixture of this utility model has only two connection points, and the relative distance between them is fixed and consistent with the distance from the low-voltage line. Therefore, there is no possibility of accidentally touching the positive and negative poles of the high voltage at the same time. The outer shell is made of polymethyl methacrylate, which is an insulating material, further improving safety.

[0027] 3. Easy to operate; when using, hold the lower end of the testing fixture and align the upper end with the two low-voltage wire plugs of the high-voltage interlock of the power battery. The connection is considered complete when the junction of the upper and lower ends contacts the outer edge of the battery contacts. Press the button to complete the testing operation.

[0028] 4. Convenient for judgment: There is no need to go through the tedious process of checking messages and comparing their meanings. You can judge whether the high-voltage interlock circuit is normal simply by whether the tool light is on or whether the tool rings.

[0029] 5. Energy saving; unlike dedicated cabinets that require a 220V power supply, or other fixtures that require a dedicated stable voltage for the controller, this fixture only needs two AA batteries to operate. Attached Figure Description

[0030] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0031] Figure 1 This is a schematic diagram of the overall structure of a high-voltage interlock rapid testing fixture for power batteries according to this utility model;

[0032] Figure 2 This is a structural schematic diagram of a high-voltage interlock rapid testing fixture for power batteries according to the present invention;

[0033] Figure 3 This is a schematic diagram of an amplifier circuit;

[0034] Figure 4 This is a schematic diagram illustrating the use of a high-voltage interlock rapid testing fixture for power batteries according to this utility model.

[0035] Figure 5 This is a flowchart illustrating the use of a high-voltage interlock rapid testing fixture for power batteries according to this utility model.

[0036] In the diagram: 1. Switch; 2. Resistor; 3. Power supply; 4. Light bulb; 5. Speaker; 6. Amplifier circuit; 7. First connector; 8. Second connector. Detailed Implementation

[0037] To clearly and completely describe the technical solution and its specific working process of this utility model, the specific embodiments of this utility model are as follows, in conjunction with the accompanying drawings:

[0038] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0039] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0040] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0041] Example 1

[0042] like Figure 1 and Figure 2The diagram shows a structural schematic of a rapid testing fixture for high-voltage interlocking of a power battery according to this utility model. The testing fixture includes a testing circuit and an insulating shell. The testing circuit is located inside the insulating shell and consists of a circuit composed of a switch, a resistor, a power supply, a light bulb, a speaker, and an amplifier circuit connected in series. A first connector is provided between the switch and the amplifier circuit, and a second connector is provided between the light bulb and the speaker. The first and second connectors are used to connect to the low-voltage connector of the high-voltage interlocking of the power battery. The switch is used to control the conduction or disconnection of the entire circuit, the resistor is used to protect the entire circuit, the power supply is used to provide power to the entire circuit, the light bulb is used to determine whether the circuit is normal, the speaker is used to provide an alarm, and the amplifier circuit is used to provide amplified current to the speaker.

[0043] The following describes in detail the various components involved in this embodiment;

[0044] In this embodiment, the switch is a normally open push-button switch, facilitating pressing before and during use. During operation, the switch connects or disconnects the contacts in the circuit, allowing or disallowing current flow. The "closed" state of the switch makes the circuit conductive, allowing current to flow; the "open" state of the switch makes the circuit non-conductive, forming an open circuit and disallowing current flow. It serves to connect / disconnect the appliance from the power supply.

[0045] The resistor is a pure resistor, serving to protect the entire circuit. The circuit exists in two states: one where current flows through the amplifier circuit and the speaker, and another where current does not flow through the amplifier circuit and the speaker. If the amplifier circuit and the speaker are short-circuited by the high-voltage interlock circuit of the power battery, the current in the entire circuit will increase. To prevent damage to the high-voltage interlock circuit and burnout of the bulb, a pure resistor is added to protect the circuit.

[0046] The power source provides power to the entire circuit. Since the speaker and bulb require little energy, only dry cell batteries are needed, which also improves the portability and economy of the entire tooling.

[0047] The purpose of the light bulb is to allow the user to quickly determine whether the entire circuit is normal, thus serving a self-test function. If the light does not illuminate after the user presses the switch, it indicates an open circuit, and the fixture needs to be repaired before further use. This prevents the speaker from remaining silent due to circuit damage, which could lead the user to mistakenly believe the high-voltage interlock circuit is normal, resulting in erroneous test results.

[0048] The amplifier circuit provides amplified current to the speaker. If the high-voltage interlock circuit is damaged, the current cannot flow through the high-voltage interlock circuit and can only flow through the speaker, causing the alarm to sound. Users can easily and quickly determine whether the high-voltage interlock circuit is normal.

[0049] As Figure 3 shown, the amplifier circuit of this embodiment will be introduced in detail below. The amplifier circuit includes a resistor R1, a resistor R2, a capacitor C, a triode, an output voltage pin OUT, an input voltage pin U0, and an input voltage pin U1. One end of the resistor R1 is connected to the positive pole of the input voltage pin U1 through a wire, and the other end is connected to the base of the triode through a wire. The emitter output of the triode is connected to the positive pole of the output voltage pin OUT, and the negative pole of the output voltage pin OUT is grounded. The positive pole of the input voltage pin U0 is connected to the collector of the triode through the resistor R2. The negative pole of the input voltage pin U0 and one end of the capacitor C are both grounded, and the other end of the capacitor C is connected to the collector of the triode through a wire.

[0050] The triode is a PNP type triode, which controls the on and off of the triode through the base and is used to amplify a weak signal into an electrical signal with a larger amplitude value.

[0051] Among them, R1 is the base bias resistor, which can ensure the magnitude of the base current, thus stabilizing the working state of the triode, ensuring that the triode works in a suitable amplification region, and avoiding over-saturation or truncation. R2 is the collector resistor, which can ensure that when the triode works, R2 bears a certain voltage, so as to give the output voltage pin OUT a suitable voltage to ensure that the speaker works within a suitable voltage range. The capacitor C is used to protect the safety of the entire circuit; when U1 is connected to the amplifier circuit, the amplifier circuit works, the triode conducts, and the speaker is powered on; when U1 is not connected to the amplifier circuit, the amplifier circuit does not work, the triode is in the cut-off state, and the energy possessed by U0 does not do external work, thus saving energy.

[0052] During use, the relative relationship between the high-voltage interlock quick detection tooling of this embodiment and the battery is as Figure 4 shown. The overall detection tooling presents a "convex" shape. During use, the upper end of the tooling is embedded into the high-voltage interlock port of the power battery. If the junction between the upper and lower ends of the tooling is not flush with the outside of the battery, it is considered that the insertion is not firm. At this time, the detection switch should not be pressed, and the docking should continue until the junction between the upper and lower ends of the tooling is flush with the outside of the battery.

[0053] The lower end of the tooling is exposed outside, and the switch on it needs to be pressed or disconnected during use; the bulb on it is used to indicate the working state. If the light is not on, it means that there is an open circuit in the entire tooling and the working state is abnormal. At this time, the tooling should be pulled out for repair; the tooling shell is made of polymethyl methacrylate (insulating material) and plays a protective role. The user performs the plugging and unplugging operations through the lower part of the tooling exposed outside.

[0054] As Figure 5 shown, the usage method of a high-voltage interlock quick detection tooling for a power battery in this embodiment is as follows:

[0055] Before use, perform a self-test. Press the switch and hold it for 3 seconds to check if the light turns on normally and the bell works properly. If either of them fails to work properly, check if the battery voltage is sufficient and if there are any abnormalities in the circuit. Then, correct the circuit according to the inspection results, such as replacing the battery, reconnecting broken points, or replacing components.

[0056] During operation, first hold the lower end of the testing fixture and align the upper end with the two low-voltage connectors of the high-voltage interlock of the power battery. The fixture is considered securely connected once the lower end touches the high-voltage interlock connector. After connection, press the switch and hold for 3 seconds. Check for a bell to determine if the high-voltage interlock circuit is functioning correctly: If it rings, the high-voltage interlock circuit has not short-circuited the speaker circuit, meaning the circuit resistance is not low enough to short-circuit the speaker circuit, indicating a disconnection or malfunction in the high-voltage interlock circuit. If there is no bell but the indicator light illuminates, the high-voltage interlock circuit has short-circuited the speaker, meaning the internal circuit is connected, indicating a normal high-voltage interlock circuit.

[0057] After completing the inspection, remove the tooling and complete all testing steps.

[0058] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0059] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable way without contradiction. In order to avoid unnecessary repetition, this utility model will not describe the various possible combinations separately.

[0060] Furthermore, various different embodiments of this utility model can be combined in any way, as long as they do not violate the spirit of this utility model, they should also be regarded as the content disclosed by this utility model.

Claims

1. A rapid testing fixture for high-voltage interlock of power batteries, characterized in that, The testing fixture includes a testing circuit and an insulating housing. The testing circuit is located inside the insulating housing and consists of a circuit composed of a switch, a resistor, a power supply, a light bulb, a speaker, and an amplifier circuit connected in series. A first connector is provided between the switch and the amplifier circuit, and a second connector is provided between the light bulb and the speaker. The first and second connectors are used to connect to the low-voltage connector of the high-voltage interlocking power battery. The switch is used to control the conduction or disconnection of the entire circuit, the resistor is used to protect the entire circuit, the power supply is used to provide power to the entire circuit, the light bulb is used to determine whether the circuit is normal, the speaker is used to provide an alarm, and the amplifier circuit is used to provide amplified current to the speaker.

2. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 1, characterized in that, The insulating housing is provided with switch mounting holes to expose the switch for easy operation by the operator.

3. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 1, characterized in that, The insulating outer shell is convex in shape and is made of polymethyl methacrylate.

4. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 1, characterized in that, The loudspeaker is an electric bell.

5. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 1, characterized in that, The amplifier circuit includes resistor R1, resistor R2, capacitor C, transistor, output voltage pin OUT, input voltage pin U0, and input voltage pin U1. One end of resistor R1 is connected to the positive terminal of input voltage pin U1 via a wire, and the other end is connected to the base of the transistor via a wire. The emitter of the transistor is connected to the positive terminal of output voltage pin OUT, and the negative terminal of output voltage pin OUT is grounded. The positive terminal of input voltage pin U0 is connected to the collector of the transistor via resistor R2. The negative terminal of input voltage pin U0 and one end of capacitor C are both grounded, and the other end of capacitor C is connected to the collector of the transistor via a wire.

6. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 5, characterized in that, The resistor R1 is a base bias resistor, used to ensure the base current magnitude, thereby stabilizing the working state of the transistor, ensuring that the transistor operates in the amplification region, and avoiding excessive saturation or cutoff.

7. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 5, characterized in that, The transistor is a PNP type transistor, and its on / off state is controlled by the base to amplify weak signals into amplitude electrical signals.

8. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 5, characterized in that, The resistor R2 is a collector resistor, used to ensure that R2 bears the voltage when the transistor is working, thereby providing the output voltage pin OUT with voltage, so as to ensure that the speaker works within the voltage range.

9. The rapid testing fixture for high-voltage interlock of a power battery as described in claim 5, characterized in that, The capacitor C is used to protect the entire circuit.

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