A battery high-voltage distribution box current precision detection system

Abstract

The utility model relates to a kind of battery high voltage distribution box current precision detection system, it includes cabinet, control panel, pull-out operation platform and detection mechanism.Control panel integrates touch screen and operating member, pull-out operation platform is built-in replaceable test tool, its conductive probe and measured distribution box copper sheet elastic contact;Detection mechanism includes programmable ac and dc power supply, electronic load tester, high-precision ammeter, power analyzer, main control host computer and CAN communication module, instrument and test tool are interconnected by serial port and CAN bus and main control host computer respectively.This detection system uses integrated detection equipment of integrated cabinet, through replaceable tool adaptation multiple model distribution box, test parameter closed-loop control is realized in combination with serial port and CAN bus communication, using sensing grating and position proximity switch ensures operation safety, solve the problem that traditional detection system is poor in compatibility, low efficiency and many security risks.

Description

Technical Field

[0001] This utility model relates to the field of battery system testing technology, specifically to a battery high-voltage distribution box current accuracy testing system. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the battery high-voltage distribution box (BDU), as a key component of the battery system, directly affects the vehicle's safety and range performance through its current accuracy and reliability. Traditional testing equipment has the following problems:

[0003] (1) Poor compatibility: The fixed tooling design cannot be adapted to multiple models of distribution boxes, requiring repeated purchase of equipment, which is costly;

[0004] (2) Complex operation: The independent control interface of the testing instrument leads to complicated parameter configuration, a lot of manual intervention, and low efficiency;

[0005] (3) Insufficient safety: The lack of real-time location monitoring and safety interlock mechanism makes it easy to cause equipment damage or personal injury due to misoperation; (4) Limited accuracy: The discrete connection between the traditional ammeter and the power supply is easily affected by contact resistance, resulting in a large test error. Utility Model Content

[0006] The technical problem this utility model aims to solve is to overcome the shortcomings of traditional battery high-voltage distribution box testing equipment, such as poor compatibility, complex operation, insufficient safety, and limited accuracy. It provides a current accuracy testing system based on modular integration and sensor-based collaborative control. This system adopts an integrated cabinet design and utilizes replaceable tooling on a pull-out operating table, a standardized interface for the CAN communication module, and a safety interlock design between the sensing grating and the proximity switch. This enables rapid adaptation to multiple distribution box models, closed-loop adjustment of test parameters, and proactive protection against operational risks, thus solving the problems of poor compatibility, low testing efficiency, complex operation, and numerous safety hazards associated with traditional solutions.

[0007] This high-voltage distribution box current accuracy testing system includes a cabinet, a control panel and a pull-out operating platform mounted on the front panel of the cabinet, and a testing mechanism housed within the cabinet. The control panel features a touchscreen display, operating components, and a protective cover covering the operating area. The pull-out operating platform includes a replaceable fixture storage area, on which a test fixture for mounting the distribution box under test is detachably installed. The test fixture is equipped with conductive probes for securing the input and output copper contacts of the distribution box. The testing mechanism includes a programmable AC / DC converter. The system includes a programmable AC / DC power supply, an electronic load performance tester, a high-precision AC / DC ammeter, a high-precision power analyzer, a CAN communication module, and a host computer. All components are fixedly mounted on a bracket inside the cabinet. The programmable AC / DC power supply, electronic load performance tester, high-precision AC / DC ammeter, and high-precision power analyzer are connected to the host computer via a standardized serial port. The test fixture is also connected to the host computer via the CAN communication module.

[0008] Specifically, the operating components include a power switch, a start test button, a stop test button, a USB interface, and an emergency stop switch. The touch screen and the operating components are connected to the input terminal of the host computer.

[0009] Specifically, the conductive probe of the test fixture adopts a spring-loaded pin structure, and the end of the test fixture is provided with gold-plated contacts to form multi-point elastic contact with the copper sheet of the distribution box under test.

[0010] Specifically, the programmable AC / DC power supply and electronic load performance tester are connected to the copper plates at the input and output ends of the test fixture, respectively. The high-precision AC / DC ammeter is connected in series in the circuit under test, and the high-precision power analyzer is connected in parallel in the circuit under test. The high-precision AC / DC ammeter and the high-precision power analyzer are serially connected to the host computer and transmit current and power parameters through serial communication.

[0011] The optimized cabinet is equipped with sensing gratings on both sides, a proximity switch inside the cabinet, and a magnetic sensor below the detection pull-out operating table.

[0012] This utility model discloses a battery high-voltage distribution box current accuracy detection system, which overcomes the shortcomings of traditional battery high-voltage distribution box testing equipment, such as poor compatibility, complex operation, insufficient safety, and limited accuracy. It adopts an integrated cabinet design and achieves rapid adaptation of multiple distribution boxes, closed-loop adjustment of test parameters, and active protection against operational risks through replaceable tooling of the pull-out operating table, standardized interface of CAN communication module, and safety interlock design of sensing grating and position proximity switch. It solves the problems of poor compatibility, low testing efficiency, complex operation, and many safety hazards of traditional solutions. Attached Figure Description

[0013] The following description, in conjunction with the accompanying drawings, further illustrates the battery high-voltage distribution box current accuracy detection system of this utility model:

[0014] Figure 1 This is a 3D structural diagram of the current accuracy detection system for the high-voltage distribution box of this battery.

[0015] Figure 2 This is a 3D structural diagram of the current accuracy detection system for the high-voltage distribution box of this battery (pull-out control panel in the pulled-out state).

[0016] Figure 3 This is a partial structural diagram of the test fixture described in the battery high-voltage distribution box current accuracy detection system;

[0017] Figure 4 This is a wireframe diagram illustrating the logical structure and connection principle of the detection mechanism in the high-voltage distribution box current accuracy detection system for this battery.

[0018] In the picture:

[0019] 1-Cabinet;

[0020] 2-Control panel; 21-Touch display screen; 22-Operating element; 23-Protective cover; 221-Power switch; 222-Start test button; 223-Stop test button; 224-USB interface; 225-Emergency stop switch;

[0021] 3-Pull-out operating table; 31-Replaceable tooling storage area; 32-Test tooling; 33-Sensing grating; 34-Position proximity switch; 35-Magnetic sensor; 321-Conductive probe;

[0022] 4-Testing organization; 41-Programmable AC / DC power supply; 42-Electronic load performance tester; 43-High-precision AC / DC ammeter; 44-High-precision power analyzer; 45-CAN communication module; 46-Main control host computer. Detailed Implementation

[0023] 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 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. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0024] In the description of this utility model, it should be understood that the terms "left", "right", "front", "rear", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0025] The present invention will be further described below with specific embodiments, but the scope of protection of the present invention is not limited to the following embodiments.

[0026] Implementation method 1: such as Figures 1 to 4 As shown, this battery high-voltage distribution box current accuracy testing system includes a cabinet 1, a control panel 2 and a pull-out operating table 3 mounted on the front panel of the cabinet 1, and a testing mechanism 4 mounted inside the cabinet. The control panel 2 is equipped with a touch screen 21, operating components 22, and a protective cover 23 covering the operating area. The pull-out operating table 3 has a replaceable tooling placement area 31, on which a test fixture 32 for loading the distribution box under test is detachably mounted. The test fixture 32 is equipped with conductive probes 321 for securing the input and output copper plates of the distribution box to elastic contact. The testing mechanism 4 includes a programmable AC / DC power supply 41. The system includes an electronic load performance tester 42, a high-precision AC / DC ammeter 43, a high-precision power analyzer 44, a CAN communication module 45, and a main control host computer 46. The programmable AC / DC power supply 41, electronic load performance tester 42, high-precision AC / DC ammeter 43, high-precision power analyzer 44, CAN communication module 45, and main control host computer 46 are all fixedly installed on the internal support of cabinet 1. The programmable AC / DC power supply 41, electronic load performance tester 42, high-precision AC / DC ammeter 43, and high-precision power analyzer 44 are connected to the main control host computer 46 via a standardized serial port. The test fixture 32 is connected to the main control host computer 46 via the CAN communication module 45. Through modular integrated design, the core test instruments such as the programmable AC / DC power supply and electronic load are fixed on the internal support of the cabinet. Combined with the quick fixture replacement function of the pull-out operating table 3, compatible testing of multiple power distribution boxes can be achieved. The CAN communication module 45, in conjunction with the standardized serial interface, communicates and transmits data, solving the problems of complex interfaces and poor expandability of traditional equipment. The design of the protective cover 23 and the flexible probe 321 ensures both operational safety and the stability of the electrical connection, thereby improving both testing accuracy and efficiency.

[0027] Implementation method 2: such as Figure 2As shown, the current accuracy detection system for the high-voltage distribution box of this battery includes the following components: the operating unit 22 comprises a power switch 221, a start test button 222, a stop test button 223, a USB interface 224, and an emergency stop switch 225. The touch screen 21 and the operating unit 22 are connected to the input terminal of the main control host computer 46. By integrating operating components such as the power switch 221 and the emergency stop switch 225, operators can quickly cut off the power or terminate the test process in an emergency, avoiding the risk of equipment overload or misoperation. The USB interface 224 supports external data export, facilitating offline analysis of test results. The multi-button start / stop design simplifies the human-machine interaction logic, lowers the operating threshold, and is especially suitable for high-frequency testing scenarios on production lines. The remaining structures and components are as described in Embodiment 1 and will not be described again.

[0028] Implementation method 3: such as Figure 3 As shown, the conductive probe 321 of the test fixture 32 in the high-voltage distribution box current accuracy detection system of this battery adopts a spring-loaded pin structure. The end of the test fixture 32 is provided with gold-plated contacts, forming multi-point elastic contact with the copper sheet of the distribution box under test. The spring-loaded pin structure adapts to the positional deviation of the copper sheet through elastic deformation, and the gold-plated contacts reduce contact resistance, ensuring the stability of signal transmission during high-current testing. The multi-point contact design avoids test interruptions caused by single-point contact failure, making it particularly suitable for long-term durability testing of high-voltage distribution boxes. For some models, the gold-plated layer utilizes oxidation-resistant properties to extend the probe's lifespan and reduce maintenance frequency. The remaining structures and components are as described in Embodiment 1 and will not be repeated.

[0029] Implementation method 4: such as Figure 4 As shown, in this battery high-voltage distribution box current accuracy detection system, the programmable AC / DC power supply 41 and the electronic load performance tester 42 are connected to the input and output copper plates of the test fixture 32, respectively. The high-precision AC / DC ammeter 43 is connected in series in the circuit under test, and the high-precision power analyzer 44 is connected in parallel in the circuit under test. The high-precision AC / DC ammeter 43 and the high-precision power analyzer 44 are serially connected to the main control host computer 46 and transmit current and power parameters through serial communication. The high-precision AC / DC ammeter 43 is connected in series in the circuit under test to collect current, and the high-precision power analyzer 44 collects power by monitoring the circuit voltage in parallel through a voltage probe. The main control host computer 46 coordinates the work of each module and transmits test commands, adjusts the output voltage of the programmable AC / DC power supply 41 and the load parameters of the electronic load performance tester 42; the main control host computer receives test data and generates current accuracy judgment results, and stores test curves. The feedback control design enables high accuracy in power output fluctuation compensation and low load simulation error, achieving high-precision dynamic adjustment. The newly added parameter testing component can be directly connected to the CAN network without modifying the main control host computer firmware's modular expansion capabilities. The remaining structures and components are as described in Implementation Method 1 and will not be repeated.

[0030] Implementation method 5: such as Figure 2 As shown, the high-voltage distribution box current accuracy detection system of this battery has sensing gratings 33 on both sides of the cabinet 1, a proximity switch 34 inside the cabinet 1, and a magnetic sensor 35 below the pull-out operating platform 3. These are used to monitor the pull-out and retracted status and position of the pull-out operating platform in real time. The signal output terminal of the sensing grating 33 is connected to the input terminal of the main control computer 46, used to monitor the positional anomalies of the operating platform, the test fixtures on it, and the distribution box under test in real time, and transmit offset data to the main control computer 46 to prevent locking. The trigger terminals of the proximity switch 34 and the magnetic sensor 35 are connected to the lock control terminal of the main control computer 46, used to detect the pull-out status of the operating platform and trigger a locking command when fully closed, and trigger the main control computer to cut off the power supply when not closed, preventing personnel from accidentally touching high-voltage components and avoiding electrical safety hazards caused by human negligence. The remaining structures and components are as described in Embodiment 1 and will not be repeated.

[0031] During testing: The pull-out operating table 3 is pulled out, the distribution box under test is installed in the test fixture 32, and then the pull-out operating table 3 is pushed in and locked. The main control host computer 46 issues a command, and the programmable AC / DC power supply 41 outputs the set voltage to the input terminal of the distribution box. The electronic load performance tester 42 simulates the load condition. The high-precision AC / DC ammeter 43 is connected in series to collect the input current, and the high-precision power analyzer 44 is connected in parallel to monitor the circuit voltage. The sampled data is sent to the main control host computer 46 through a serial port connection. The distribution box under test in the test fixture 32 is awakened and sends product data from its internal Hall sensors and other sensors. The data is transmitted to the main control host computer 46 via the CAN communication module 45. The host computer compares and analyzes the sampled data with the product data.

[0032] This battery high-voltage distribution box current accuracy detection system overcomes the shortcomings of existing energy-consuming loads that can only provide fixed power values ​​and cannot achieve continuous adjustment. Through the collaborative architecture of discrete power switching of relay group and continuous adjustment of chopper circuit, it realizes the superposition output of discrete power point and continuously adjustable power. While retaining the low cost advantage of energy-consuming loads, it realizes the function of continuously adjustable power and solves the problems of low test accuracy and poor flexibility of traditional solutions.

[0033] The above description illustrates the main features, basic principles, and advantages of this utility model. It will be apparent to those skilled in the art that this utility model is not limited to the details of the exemplary embodiments or examples described above, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the above embodiments or examples should be considered exemplary and not restrictive. The scope of this utility model is defined by the appended claims rather than the foregoing description, and therefore all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this utility model. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0034] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A battery high-voltage distribution box current accuracy detection system, characterized in that: Includes a cabinet (1), a control panel (2) and a pull-out workbench (3) located on the front panel of the cabinet (1), and a detection mechanism (4) located inside the cabinet, wherein, The control panel (2) is equipped with a touch screen (21), an operating component (22), and a protective cover (23) covering the operating area; the pull-out operating table (3) is equipped with a replaceable tooling placement area (31), and a test tool (32) for loading the power distribution box under test is detachably installed on the replaceable tooling placement area (31). The test tool (32) is equipped with conductive probes (321) for fixing the input and output copper plates of the power distribution box to make elastic contact; the testing mechanism (4) includes a programmable AC / DC power supply (41), an electronic load performance tester (42), a high-precision AC / DC ammeter (43), a high-precision power analyzer (44), and a C The CAN communication module (45) and the main control host computer (46) are all fixedly installed on the bracket inside the cabinet (1). The programmable AC / DC power supply (41), electronic load performance tester (42), high-precision AC / DC ammeter (43), high-precision power analyzer (44), CAN communication module (45) and main control host computer (46) are all fixedly installed on the bracket inside the cabinet (1). The programmable AC / DC power supply (41), electronic load performance tester (42), high-precision AC / DC ammeter (43) and high-precision power analyzer (44) are connected to the main control host computer (46) through a standardized serial port. The test fixture (32) is connected to the main control host computer (46) through the CAN communication module (45).

2. The battery high-voltage distribution box current accuracy detection system according to claim 1, characterized in that: The operating device (22) includes a power switch (221), a start test button (222), a stop test button (223), a USB interface (224), and an emergency stop switch (225). The touch screen (21) and the operating device (22) are connected to the input terminal of the host computer (46).

3. The battery high-voltage distribution box current accuracy detection system according to claim 2, characterized in that: The conductive probe (321) of the test fixture (32) adopts a spring pin structure, and the end of the test fixture (32) is provided with gold-plated contacts to form multi-point elastic contact with the copper sheet of the distribution box under test.

4. The battery high-voltage distribution box current accuracy detection system according to claim 3, characterized in that: The programmable AC / DC power supply (41) and electronic load performance tester (42) are respectively connected to the copper plates at the input and output terminals of the test fixture (32). The high-precision AC / DC ammeter (43) is connected in series in the circuit under test, and the high-precision power analyzer (44) is connected in parallel in the circuit under test. The high-precision AC / DC ammeter (43) and the high-precision power analyzer (44) are serially connected to the host computer (46) and transmit current and power parameters through serial communication.

5. The battery high-voltage distribution box current accuracy detection system according to any one of claims 1 to 4, characterized in that: The cabinet (1) is provided with sensing gratings (33) on both sides, and a proximity switch (34) is provided inside the cabinet (1). A magnetic sensor (35) is provided below the detection pull-out operating table (3) of the cabinet (1).

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