A battery simulator developed by using a battery

Abstract

The utility model provides a kind of battery simulator developed with battery, it is related to new energy battery testing equipment technical field, the battery simulator includes three-level power supply architecture, multichannel voltage regulating circuit, protection circuit and insulation shell, three-level power supply architecture is connected by voltage reduction module, isolation module and voltage regulating module and is composed;Multichannel voltage regulating circuit includes several independent adjustable potentiometer, protection circuit includes the self-restoring fuse and LDO chip built-in overcurrent or overheat protection unit corresponding number with adjustable potentiometer;Three-level power supply architecture, multichannel voltage regulating circuit, protection circuit are arranged in insulation shell.The utility model solves the problem of low efficiency, high risk, single function, poor safety and poor adaptability in traditional BMS test method.The battery simulator adopts multichannel independent voltage output, short-circuit protection, overload and overheat protection and other functions, can flexibly simulate the working state of battery pack and guarantee the safety of test process.

Description

Technical Field

[0001] This utility model relates to the field of new energy battery testing equipment technology, specifically to a battery simulator for the development and debugging of a battery management system (BMS). Background Technology

[0002] With the continuous development of the new energy industry, Battery Management Systems (BMS), as a crucial component for battery pack performance monitoring, protection, and management, play a vital role in new energy vehicles, energy storage systems, and other fields. Traditional testing methods face many challenges in the development and testing of BMS, particularly in terms of testing efficiency, safety, functional diversity, and versatility. Current BMS testing largely relies on the series configuration of real battery packs. This approach is not only complex but also poses safety hazards during charging and discharging, especially when encountering abnormal states such as battery overvoltage or undervoltage, making it difficult to fully verify the functionality and safety of the BMS system.

[0003] To address these issues, the market urgently needs a new type of battery simulation device that can provide accurate voltage simulation and safety protection functions without relying on real battery packs, helping developers to test and debug BMS more efficiently and safely. Utility Model Content

[0004] In view of this, the purpose of this utility model is to propose a battery simulator developed using batteries, which solves the problems of low efficiency, high risk, limited functionality, poor safety, and poor adaptability in traditional BMS testing methods. This battery simulator adopts functions such as multi-channel independent voltage output, short-circuit protection, overload and overheat protection, and can flexibly simulate the working state of battery packs while ensuring the safety of the testing process.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] Based on the above objectives, in the first aspect, this utility model provides a battery simulator for battery development, including a three-level power supply architecture, a multi-channel voltage regulation circuit, a protection circuit, and an insulating shell.

[0007] The three-level power supply architecture consists of a step-down module, an isolation module, and a voltage regulation module connected in series.

[0008] The multi-channel voltage regulation circuit includes several independent adjustable potentiometers, and the protection circuit includes a number of self-resetting fuses corresponding to the adjustable potentiometers and an LDO chip built-in overcurrent or overheat protection unit.

[0009] The three-level power supply architecture, multi-channel voltage regulation circuit, and protection circuit are housed within an insulating casing.

[0010] As a further embodiment of this utility model, the step-down module uses a JW5361 step-down chip U1 to convert a 6-18V input voltage into a stable 5V±0.1V voltage.

[0011] The isolation module contains 24 B0505S isolation power supply units, which output 24 mutually isolated 5V power supplies.

[0012] The voltage regulation module contains 24 SGM2036-ADJ adjustable LDO chips, and the output voltage can be adjusted from 1.5 to 4.5V through the adjustable potentiometer R15.

[0013] As a further embodiment of this utility model, the step-down module includes an EN start / stop control circuit, which is controlled by a voltage divider between resistors R1 and R4, wherein the threshold value of the EN pin is >1.1V.

[0014] As a further embodiment of this utility model, the input interface of the step-down module is a 5521 DC socket, which supports a wide voltage input of 6-18V; the output interface is a 2EDGKDM-5.08 pitch terminal block, which is directly connected to the BMS voltage acquisition port.

[0015] As a further embodiment of this invention, the voltage regulation module achieves voltage regulation through adjustable resistor voltage division, and the output voltage satisfies the formula:

[0016] Vout = (R11 / R15 + 1) × 0.8V;

[0017] R11 is a 10kΩ fixed resistor, and R15 is an adjustable potentiometer.

[0018] As a further embodiment of this utility model, the multi-channel voltage regulation circuit includes 24 independently adjustable potentiometers R15, which can adjust the output voltage range to 1.5V-4.5V with an accuracy of ±10mV.

[0019] As a further embodiment of this invention, the protection circuit includes 24 self-resetting fuses (F1-F24, rated current 1A), and each channel of the multi-channel voltage regulating circuit is connected in series with a 1A self-resetting fuse.

[0020] As a further embodiment of this utility model, the insulating shell is made of ABS and PC composite materials with an insulation strength ≥3000V.

[0021] As a further embodiment of this invention, each channel is equipped with an LED status indicator D3, which is turned off when the LDO chip triggers overcurrent or overheat protection.

[0022] As a further embodiment of this invention, the self-resetting fuse and the LDO chip provide coordinated protection and response, with a short-circuit fault cut-off time of ≤0.5ms.

[0023] As a further embodiment of this utility model, the isolation module achieves electrical isolation between channels, supports a wide input voltage range of 9-15V, and has a crosstalk voltage of <5mV between adjacent output channels.

[0024] As a further embodiment of this invention, the battery simulator supports 24 independent voltage settings to simulate the series connection of lithium battery packs and the fault status of a single battery cell.

[0025] As a further embodiment of this utility model, the three-level power supply architecture adopts a modular parallel design, supporting the expansion of the number of channels to 48; each channel can independently adjust the voltage to simulate the overvoltage (4.5V) and undervoltage (1.5V) fault states of a single battery cell.

[0026] As a further embodiment of this utility model, the voltage regulation module has an output accuracy of ±10mV and a maximum load current of 200mA; the output terminal of the step-down module is equipped with a C1-C7 filter capacitor group, and the ripple voltage is <10mV.

[0027] As a further embodiment of this utility model, the insulating shell has a wall thickness of 2.5mm and an impact resistance of >50J; the output terminal spacing error is controlled within ±0.1mm.

[0028] Compared with existing technologies, the battery simulator developed using batteries proposed in this utility model has the following advantages:

[0029] 1. This utility model eliminates the series connection and charging waiting process of real battery packs, reducing the preparation time for a single test from more than 30 minutes to less than 1 minute; the multi-channel voltage synchronization setting function (such as 24-channel parallel output of 3.7V) reduces the time required for BMS sampling consistency testing; the standard 5521 input interface (compatible with 9-15V power adapters) and 5.08mm pitch output terminals enable plug-and-play functionality, eliminating the need for professional wiring tools; the mechanical potentiometer (R15) knob for voltage adjustment shortens the single-channel voltage adjustment time, making operation more convenient and improving testing efficiency.

[0030] 2. The 1A self-resetting fuse per channel of this utility model can accurately cut off the faulty channel and achieve channel-level short circuit protection; it can effectively prevent thermal runaway through built-in overheat protection; and it adopts a composite material shell for high-voltage insulation protection, which is a leapfrog upgrade in safety performance.

[0031] 3. The voltage of this utility model is continuously adjustable, covering the full voltage range of lithium iron phosphate and ternary lithium batteries. It supports boundary fault injection, 24 isolated power supplies to eliminate common-mode interference, inter-channel crosstalk <5mV, SGM2036-ADJ linear voltage regulation, and voltage drift <0.1% when the load current is 200mA. The architecture of three-level power supply, dual protection and mechanical voltage regulation shortens the single test time, reduces the equipment failure rate and the test life cycle cost of a single BMS.

[0032] In summary, the battery simulator provided by this utility model, through its unique design and innovative technical solution, successfully solves the problems of efficiency, safety, and versatility in traditional BMS testing methods. It has significant application value and is particularly suitable for BMS development and testing in fields such as new energy vehicles and energy storage systems.

[0033] These or other aspects of this application will become more apparent from the following description of embodiments. It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the application. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of this utility model or related technologies, the accompanying drawings used in the description of the exemplary embodiments or related technologies will be briefly introduced below. The drawings are used to provide a further understanding of this utility model and constitute a part of the specification. They are used together with the embodiments of this utility model to explain this utility model and do not constitute a limitation on this utility model. In the drawings:

[0035] Figure 1 This is a hardware architecture diagram of a battery simulator developed using batteries, according to an embodiment of this utility model.

[0036] Figure 2 This is a circuit diagram of the input interface of the step-down module in a battery simulator developed using batteries, according to an embodiment of this utility model.

[0037] Figure 3 This is a circuit diagram of a step-down module in a battery simulator developed using a battery, according to an embodiment of this utility model.

[0038] Figure 4 This is a circuit diagram of the voltage regulation module of the U4 chip in a battery simulator developed using a battery, according to an embodiment of this utility model.

[0039] Figure 5 This is a circuit diagram of the voltage regulation module in a battery simulator developed using a battery, according to an embodiment of this utility model. Detailed Implementation

[0040] The present application will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0041] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model are further described in detail below with reference to specific examples and the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit this application.

[0042] It should be noted that all uses of the terms "first" and "second" in the embodiments of this utility model are for the purpose of distinguishing two different entities or different parameters with the same name. Therefore, "first" and "second" are merely for convenience of expression and should not be construed as limiting the embodiments of this utility model. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, such as other steps or units inherent in a process, method, system, product, or device that includes a series of steps or units.

[0043] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0044] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0045] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0046] Traditional BMS testing methods suffer from low testing efficiency, reliance on real battery packs in series, cumbersome configuration, and charging / discharging safety risks; a single voltage source cannot simulate abnormal battery states such as overvoltage and undervoltage, resulting in incomplete verification; lack of channel-level output protection, making the equipment susceptible to damage due to BMS board failure; and fixed power supply interfaces and voltage ranges, making it difficult to adapt to different BMS specifications. This invention proposes a battery simulator developed using batteries, employing a 24-channel battery simulator. Through adjustable voltage output, short-circuit protection, and standardized power supply design, these problems are addressed.

[0047] See Figures 1 to 5 As shown, an embodiment of this utility model provides a battery simulator for battery development, including a three-level power supply architecture, a multi-channel voltage regulation circuit, a protection circuit, and an insulating shell. The three-level power supply architecture consists of a step-down module, an isolation module, and a voltage regulation module connected in series. The multi-channel voltage regulation circuit includes several independently adjustable potentiometers. The protection circuit includes a number of resettable fuses corresponding to the adjustable potentiometers and an LDO chip with built-in overcurrent or overheat protection units. The three-level power supply architecture, the multi-channel voltage regulation circuit, and the protection circuit are housed within the insulating shell.

[0048] In this embodiment, the step-down module uses a JW5361 step-down chip U1 to convert a 6-18V input voltage into a stable 5V±0.1V voltage; the isolation module includes 24 B0505S isolation power supply units, outputting 24 mutually isolated 5V power supplies; the voltage regulation module includes 24 SGM2036-ADJ adjustable LDO chips, achieving 1.5-4.5V output voltage adjustment via adjustable potentiometer R15. Specifically, the voltage regulation module uses adjustable LDO chips, with an input of 5V, and an adjustable output of 1.5V-4.5V with an accuracy of ±10mV and a current of 200mA.

[0049] The step-down module includes an EN start / stop control circuit, controlled by a voltage divider between resistors R1 and R4, where the EN pin threshold is >1.1V. The input interface of the step-down module is a 5521 DC socket, supporting a wide voltage input range of 6-18V; the output interface is a 2EDGKDM-5.08 pitch terminal block, directly connected to the BMS voltage acquisition port.

[0050] In this embodiment, the voltage regulation module achieves voltage regulation through adjustable resistor voltage division, and the output voltage satisfies the formula:

[0051] Vout = (R11 / R15 + 1) × 0.8V;

[0052] R11 is a 10kΩ fixed resistor, and R15 is an adjustable potentiometer.

[0053] In this embodiment, the isolation module achieves electrical isolation between channels, supports a wide input voltage range of 9-15V, and has a crosstalk voltage of <5mV between adjacent output channels. The voltage regulation module has an output accuracy of ±10mV and a maximum load current of 200mA; the buck module output is equipped with a C1-C7 filter capacitor bank, resulting in a ripple voltage of <10mV.

[0054] In this embodiment, the multi-channel voltage regulation circuit includes 24 independently adjustable potentiometers R15, adjusting the output voltage range to 1.5V-4.5V with an accuracy of ±10mV. Each channel is equipped with an LED status indicator D3, which turns off when the LDO chip triggers overcurrent or overheat protection.

[0055] In this embodiment, the protection circuit includes 24 resettable fuses (F1-F24, rated current 1A), with each channel of the multi-channel voltage regulator circuit connected in series with a 1A resettable fuse. The resettable fuses and the LDO chip provide coordinated protection, with a short-circuit fault cut-off time ≤0.5ms.

[0056] In this embodiment, the insulating shell is made of ABS and PC composite material with an insulation strength ≥3000V. The insulating shell has a wall thickness of 2.5mm and an impact resistance >50J; the output terminal spacing error is controlled within ±0.1mm.

[0057] The working principle of this utility model is as follows:

[0058] 1. Voltage simulation, overvoltage / undervoltage simulation: Adjust the potentiometer to adjust the voltage of each channel between 1.5-4.5V.

[0059] 2. Output protection: Each channel has a current limiting function, providing overload and overheat protection to prevent thermal runaway caused by short circuits in the downstream stage; each channel is equipped with a 1A fuse, which will automatically cut off the power supply if the current exceeds the limit, protecting the power supply from damage.

[0060] 3. Power supply management: The external 12V power supply is converted to 5V through the step-down module to power each channel, supporting wide voltage input (9V-15V).

[0061] 4. Input / output interfaces: The input adopts a 5521 power interface, and the output adopts a 2EDGKDM 5.08 pitch interface, which is compatible with BMS test equipment and facilitates wiring between different devices.

[0062] 5. Power indicator: There are LED indicators at the input and output terminals. The lights will turn off when there is a power supply failure.

[0063] In this invention, the J1 terminal of the input interface uses a 5521 DC socket, supporting 6-18V DC power input. The step-down module of the power supply section uses a JW5361 step-down chip, supporting an input voltage range of 6V-18V, a fixed output voltage of 5V, and a maximum output current of 3A. Taking the power module of the U1 chip as an example: C1-C3 and C5-C7 are filter capacitors, making the power supply more stable. R1 and R4 divide the voltage and send it to the EN pin. When the EN pin level is greater than 1.1V, the chip starts to work. Vout=(56k / 10k+1)×0.765=5.049V. D2 is a 5V power indicator light; if the voltage is abnormal, the light will turn off. The voltage regulation module is first isolated by the B0505S isolation power module, and then regulated by the SGM2036-ADJ chip, with an adjustable output voltage range of 1.2V-5.5V and a maximum output current of 3A. Taking the U4 chip voltage regulator module as an example: C17-C19 are filter capacitors to make the power supply more stable. Vout = (R11 / R15+1)x0.8V, where R11 is a 10k resistor and R15 is an adjustable resistor; adjusting R15 changes the output voltage. D3 is the indicator light for this voltage regulator module; if the voltage is abnormal, the light will turn off. The output interface consists of 24 voltage regulator modules connected in series, then output through the 2EDGKDM 5.08 terminal.

[0064] This utility model features a 1A self-resetting fuse per channel, which can accurately cut off faulty channels and achieve channel-level short-circuit protection; it effectively prevents thermal runaway through built-in overheat protection; and it adopts a composite material shell for high-voltage insulation protection, resulting in a leapfrog upgrade in safety performance.

[0065] For example, the battery simulator of this utility model can be applied to the following scenarios:

[0066] Scenario 1: Simulate a 24-cell lithium battery pack equalization test, dynamically adjust the voltage of the 12th channel to 4.5V, and verify the BMS overvoltage shutdown function.

[0067] Scenario 2: Multi-channel parallel output of 3.7V±0.1V, detecting the consistency of BMS voltage sampling.

[0068] Scenario 3: A human short circuit occurs on the 5th output. The simulator automatically cuts off the output and illuminates the alarm LED. The BMS log records the anomaly.

[0069] This invention is applicable to hardware-in-the-loop (HIL) testing of BMS in fields such as new energy vehicles and energy storage systems, production line functional verification and maintenance diagnosis. It can replace real battery packs to complete key function verification such as overvoltage protection, undervoltage alarm, and equalization logic.

[0070] This utility model's battery simulator supports 24 independent voltage settings to simulate the series operation of lithium battery packs and single-cell battery fault states. The three-level power supply architecture adopts a modular parallel design, supporting an expansion of the number of channels to 48; each channel can independently adjust its voltage to simulate single-cell overvoltage (4.5V) and undervoltage (1.5V) fault states.

[0071] This invention eliminates the series connection and charging waiting time of real battery packs, reducing the preparation time for a single test from more than 30 minutes to less than 1 minute; the multi-channel voltage synchronization setting function (such as 24-channel parallel output of 3.7V) reduces the time required for BMS sampling consistency testing; the standard 5521 input interface (compatible with 9-15V power adapters) and 5.08mm pitch output terminals enable plug-and-play functionality, eliminating the need for professional wiring tools; the mechanical potentiometer (R15) knob for voltage adjustment shortens the single-channel voltage adjustment time, making operation more convenient and improving testing efficiency.

[0072] This invention features continuously adjustable voltage, covering the full voltage range of lithium iron phosphate and ternary lithium batteries, supports boundary fault injection, eliminates common-mode interference with 24 isolated power supplies, has inter-channel crosstalk <5mV, uses SGM2036-ADJ linear voltage regulator, and has a voltage drift of <0.1% at a load current of 200mA. Utilizing a three-level power supply, dual protection, and mechanical voltage regulation architecture, it shortens the single test time, reduces equipment failure rate, and lowers the lifecycle cost of a single BMS test.

[0073] In summary, the battery simulator provided by this utility model, through its unique design and innovative technical solution, successfully solves the problems of efficiency, safety, and versatility in traditional BMS testing methods. It has significant application value and is particularly suitable for BMS development and testing in fields such as new energy vehicles and energy storage systems.

[0074] The above are exemplary embodiments disclosed in this utility model. However, it should be noted that various changes and modifications can be made without departing from the scope of the embodiments of this utility model as defined by the claims. The functions, steps, and / or actions of the methods according to the disclosed embodiments described herein do not need to be performed in any particular order. Furthermore, although the elements disclosed in the embodiments of this utility model may be described or claimed individually, they may be understood as multiple unless explicitly limited to a singular number.

[0075] It should be understood that, as used herein, the singular form "a" is intended to include the plural form as well, unless the context clearly supports an exception. It should also be understood that, as used herein, "and / or" refers to any and all possible combinations of one or more of the associatedly listed items. The embodiment numbers disclosed above are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0076] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the present invention (including the claims) is limited to these examples. Within the framework of the present invention, technical features of the above embodiments or different embodiments can also be combined, and many other variations of different aspects of the present invention exist, which are not provided in the details for the sake of brevity. Therefore, any omissions, 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 battery simulator developed using battery technology, characterized in that, Includes a three-level power supply architecture, multi-channel voltage regulation circuit, protection circuit, and insulating casing; The three-level power supply architecture consists of a step-down module, an isolation module, and a voltage regulation module connected in series. The multi-channel voltage regulation circuit includes several independent adjustable potentiometers, and the protection circuit includes a number of self-resetting fuses corresponding to the adjustable potentiometers and an LDO chip built-in overcurrent or overheat protection unit. The three-level power supply architecture, multi-channel voltage regulation circuit, and protection circuit are housed within an insulating casing.

2. The battery simulator for battery development as described in claim 1, characterized in that, The step-down module uses the JW5361 step-down chip U1 to convert the 6-18V input voltage into a stable 5V±0.1V voltage. The isolation module contains 24 B0505S isolation power supply units, which output 24 mutually isolated 5V power supplies. The voltage regulation module contains 24 SGM2036-ADJ adjustable LDO chips, and the output voltage can be adjusted from 1.5 to 4.5V through the adjustable potentiometer R15.

3. The battery simulator for battery development as described in claim 2, characterized in that, The step-down module includes an EN start / stop control circuit, which is controlled by a voltage divider between resistors R1 and R4, wherein the EN pin threshold is >1.1V.

4. The battery simulator for battery development as described in claim 3, characterized in that, The input interface of the step-down module is a 5521 DC socket, which supports a wide voltage input of 6-18V; the output interface is a 2EDGKDM-5.08 pitch terminal block, which can be directly connected to the BMS voltage acquisition port.

5. The battery simulator for battery development as described in claim 4, characterized in that, The voltage regulation module achieves voltage regulation through adjustable resistor voltage division, and the output voltage satisfies the formula: Vout = (R11 / R15 + 1) × 0.8V; R11 is a 10kΩ fixed resistor, and R15 is an adjustable potentiometer.

6. The battery simulator for battery development as described in claim 2, characterized in that, The multi-channel voltage regulation circuit includes 24 independently adjustable potentiometers R15, which can adjust the output voltage range from 1.5V to 4.5V with an accuracy of ±10mV.

7. The battery simulator for battery development as described in claim 6, characterized in that, The protection circuit includes 24 resettable fuses, with each channel of the multi-channel voltage regulating circuit connected in series with a 1A resettable fuse.

8. The battery simulator for battery development as described in claim 7, characterized in that, The insulating shell is made of ABS and PC composite materials, with an insulation strength ≥3000V.

9. The battery simulator for battery development as described in claim 8, characterized in that, Each channel is equipped with an LED status indicator, which turns off when the LDO chip triggers overcurrent or overheat protection.

10. The battery simulator for battery development as described in claim 9, characterized in that, The self-resetting fuse and LDO chip protection work together to respond, and the short-circuit fault cut-off time is ≤0.5ms.

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