Power supply control module for high current density battery performance testing

Abstract

The utility model discloses a kind of power control module of high current density battery performance test, comprising: shell, inside is formed with cavity;Power unit, it is arranged in cavity, including one or more power board sequentially arranged along first direction, power interface is arranged on power board;Control unit, it is arranged in cavity and located the second direction side of power unit, including one or more control board sequentially arranged along first direction, one or more control interface is arranged on control board.This application will control unit and power unit unbind, according to test current demand can select the power interface of different power board and the control interface of control board to connect, meet different current output demand, every control board can simultaneously connect with multiple power interface, single control board can control multiple different power board, can realize large current output fast response, avoid the problem that large current response is slow by traditional large number of small current power unit parallel connection.

Description

Technical Field

[0001] This utility model belongs to the technical field of battery testing equipment, specifically relating to a power control module for high current density battery performance testing. Background Technology

[0002] With the rapid development of the energy storage industry, the ampere-hour rating of energy storage batteries is increasing rapidly, leading to a corresponding surge in the current required for battery performance testing. Currently, performance testing of high-current-density batteries typically employs a traditional approach: small aluminum profile heat sinks paired with power devices to form low-current power units, which are then connected in parallel to provide a large current. This testing architecture suffers from numerous control chips, poor synchronization, and high costs, and can no longer meet market demands. Utility Model Content

[0003] The purpose of this invention is to provide a power control module for high current density battery performance testing, so as to solve the problems of existing technologies that use parallel small current power units for high current density battery performance testing, resulting in multiple control chips, poor synchronization effect, and high cost.

[0004] To achieve the above objectives, the first aspect of this utility model provides a power control module for high current density battery performance testing, comprising:

[0005] The shell has an internal cavity;

[0006] A power unit is arranged in the cavity, the power unit comprising one or more power boards arranged sequentially along a first direction, and each power board having a power interface.

[0007] A control unit is arranged inside the cavity and located on one side of the power unit in a second direction. The control unit includes one or more control boards arranged sequentially along the first direction. Each control board is provided with one or more control interfaces, which are used to connect to the power interface via a connecting cable.

[0008] The first direction and the second direction are perpendicular to each other.

[0009] In one or more embodiments, the housing includes a bottom plate, a front panel, and a rear panel, wherein the second direction is the direction from the rear panel to the front panel;

[0010] The cavity contains an air duct extending along the second direction. The air duct is located between the front panel and the rear panel, and between the power unit, the control unit and the base plate. The front panel and the rear panel are provided with heat dissipation holes corresponding to the position of the air duct.

[0011] The power control module also includes a fan and a heat dissipation unit arranged in the air duct.

[0012] In one or more embodiments, the heat dissipation unit is arranged on the side of the power unit facing the base plate.

[0013] In one or more embodiments, it further includes:

[0014] The first air duct plate is connected to the front panel at one end and extends toward the rear panel at the other end;

[0015] The second air duct plate is connected to the rear panel at one end and extends along the second direction at the other end.

[0016] The heat dissipation unit is connected at one end to the first air duct plate and at the other end to the second air duct plate. The first air duct plate, the second air duct plate, the heat dissipation unit, and the base plate form the air duct. The control unit is arranged on the first air duct plate, and the power unit is arranged on the heat dissipation unit.

[0017] In one or more embodiments, the housing further includes side plates located on both sides, and the heat dissipation unit is fixedly disposed with the side plates.

[0018] In one or more embodiments, the power board includes a metal substrate, an insulating layer, and a power circuit layer stacked sequentially, wherein the metal substrate is tightly fitted to the heat dissipation unit.

[0019] In one or more embodiments, the fan is arranged in the duct near one end of the front panel, forming a front passage between the fan and the front panel.

[0020] In one or more embodiments, the power unit includes a plurality of power boards, each power board having a plurality of input ports and a plurality of output ports arranged thereon, and the power unit further includes:

[0021] A plurality of busbars are provided, each corresponding to one of the input ports, and the busbars extend along the first direction to connect to the corresponding input ports on the power boards.

[0022] A plurality of busbars are provided, each corresponding to a plurality of the aforementioned busbars. The busbars extend along the second direction, with one end connected to the corresponding busbar and the other end extending out of the rear panel.

[0023] A plurality of cable trays are provided, each corresponding to a plurality of output ports. Each cable tray includes a connecting section and an extension section. The connecting section extends along the first direction and connects to the corresponding output ports on the power boards. The cable tray extends along the second direction, with one end connected to the connecting section and the other end extending out of the rear panel.

[0024] In one or more embodiments, a plurality of the input ports are arranged sequentially along the second direction at one end of the power board near the front panel, and a busbar seat is also arranged at one end of the power board near the rear panel. A section of the busbar located inside the housing is mounted between the input ports and the busbar seat, and the middle part protrudes in a direction away from the power board.

[0025] Among them, several of the busbars are located at different positions in the first direction.

[0026] In one or more embodiments, a plurality of the output ports are arranged sequentially along the first direction at one end of the power board near the rear panel, and a cable outlet bracket is also arranged at one end of the power board near the rear panel.

[0027] The cable outlet also includes multiple branch segments corresponding to the multiple power boards. Each branch segment extends from the connecting segment along the second direction and connects to the output interface of the corresponding power board. The extension segment is connected to the cable outlet base.

[0028] The heights of the connecting sections of some of the outgoing cable rows are different.

[0029] The advantages of this application, which differ from existing technologies, are:

[0030] This application decouples the control unit from the power unit. According to different test current requirements, different power board power interfaces can be selected and connected to the control board control interface to meet different current output requirements. In addition, each control board can be connected to multiple power interfaces at the same time, so that a single control board can control multiple different power boards, which can achieve fast response to high current output and avoid the problem of slow response to high current caused by a large number of small current power units in parallel in the traditional way.

[0031] This application uses a single control core on a single control board. Compared with the traditional method of directly connecting multiple low-current channels in parallel, it reduces the frequency of sending and receiving information when the upper-level controller controls the power module, and improves the response speed and data transmission speed.

[0032] The modular and independent design of the heat dissipation unit, power unit, and control unit in this application allows for direct airflow without direct contact with the control and power systems, thus avoiding corrosion problems and extending the equipment lifespan. It also ensures heat dissipation and heat distribution performance, significantly improving the current carrying capacity per unit area of ​​the conductive carrier in the power circuit and enhancing high current output efficiency.

[0033] This application realizes the input and output of the power board based on the irregular structure of the busbar and the output busbar. The busbar and the output busbar can be rapidly produced by laser cutting and simple bending, avoiding cumbersome cable connection operations, significantly improving production efficiency and ensuring the stability of current transmission. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 This is a top view of one embodiment of the power control module for high current density battery performance testing in this application after removing the cover plate.

[0036] Figure 2 yes Figure 1 Schematic diagram of the cross-sectional structure of the middle AA surface;

[0037] Figure 3 This is a three-dimensional structural diagram of one embodiment of the power control module for high current density battery performance testing in this application after removing the cover plate.

[0038] Figure 4 yes Figure 3 A magnified view of part B in the diagram.

[0039] Explanation of key figure labels:

[0040] Housing 100; cavity 101; front panel 102; rear panel 103; bottom plate 104; side plate 105; air duct 106; front channel 1061; heat dissipation hole 107;

[0041] Power unit 200; power board 201; input port 2011; output port 2012; power interface 202; busbar 203; busbar 204; outgoing line 205; connection section 2051; outgoing line section 2052; branch section 2053; busbar socket 206; outgoing line socket 207;

[0042] Control unit 300; Control board 301; Control interface 302;

[0043] Fan 400;

[0044] Heat dissipation unit 500;

[0045] First air duct plate 600;

[0046] Second air duct plate 700. Detailed Implementation

[0047] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0048] To address the problems existing in the current technology of using parallel small-current power units for high current density battery performance testing, the applicant has developed a novel power control module for high current density battery performance testing. This module features modular designs for the control system, power system, and heat dissipation system, allowing for switching between the control system and power system according to testing requirements. It can achieve rapid response to high current output while also taking advantage of multiple current ranges.

[0049] Specifically, please refer to Figure 1 , Figure 1 This is a top view of one embodiment of the power control module for high current density battery performance testing in this application, after removing the cover plate.

[0050] like Figure 1 As shown, the power control module includes a housing 100, a cavity 101 is formed inside the housing 100, and a power unit 200 and a control unit 300 are arranged inside the cavity 101.

[0051] Specifically, the power unit 200 includes a plurality of power boards 201 arranged sequentially along the first direction x, and each power board 201 is provided with a power interface 202.

[0052] The control unit 300 is arranged on the second direction y side of the power unit 200, and the control unit 300 includes two control boards 301 arranged sequentially along the first direction x. Each control board 301 is provided with multiple control interfaces 302, which are used to connect to the power interface 202 via connecting lines.

[0053] Understandably, in this embodiment, the control unit 300 and the power unit 200 are decoupled. According to different test current requirements, the power interface 202 of different power boards 201 can be selected to connect with the control interface 302 of the control board 301 to meet different current output requirements. In addition, each control board 301 can be connected to multiple power interfaces 202 at the same time, so that a single control board 301 can control multiple different power boards 201, which can achieve fast response to high current output and avoid the problem of slow response to high current caused by a large number of small current power units 200 connected in parallel in the traditional way.

[0054] Meanwhile, the single control board 301 uses a single control core, which, compared to the traditional method of directly connecting multiple low-current channels in parallel, reduces the frequency of sending and receiving information when the upper-level controller controls the power module, and improves the response speed and data transmission speed.

[0055] In addition, the power interfaces 202 of different power boards 201 are unified, and the control board 301 can control all types of power boards 201. Only the power board 201 needs to be replaced to complete the design and production of various power modules with different currents and voltages, which provides strong support for large-scale stock preparation.

[0056] It should be noted that in this embodiment, the power unit 200 includes multiple power boards 201 and the control unit 300 includes two control boards 301. In other embodiments, the number of power boards 201 and control boards 301 can be adjusted according to actual needs. For example, only one power board 201 or only one control board 301 can be arranged.

[0057] For further details, please refer to Figure 1 and Figure 2 , Figure 2 yes Figure 1 A schematic diagram of the cross-sectional structure of the middle AA surface.

[0058] like Figure 1 and Figure 2 As shown, in this embodiment, the housing 100 includes a front panel 102, a rear panel 103, a bottom plate 104, and a side plate 105. A duct 106 extending in the second direction y is formed in the cavity 101. The duct 106 is located between the front panel 102 and the rear panel, and between the power unit 200, the control unit 300, and the bottom plate 104. Heat dissipation holes 107 corresponding to the positions of the duct 106 are arranged on the front panel 102 and the rear panel 103.

[0059] The power control module also includes a fan 400 and a heat dissipation unit 500 arranged in the air duct 106, thereby realizing the modular independent design of the heat dissipation unit 500, the power unit 200, and the control unit 300. The air duct 106 achieves straight inlet and straight out, and does not directly contact the control system and the power system, avoiding the corrosion problems of the latter two and extending the equipment life.

[0060] The following details how, for example Figure 2 As shown, in this embodiment, the heat dissipation unit 500 is arranged on the side of the power unit 200 facing the base plate 104, thereby achieving efficient heat dissipation of the power device. Specifically, in this embodiment, the substrate of the power board 201 can be made of metal, which may include a metal substrate, an insulating layer, and a power circuit layer stacked sequentially. An exemplary power board 201 can be an aluminum substrate power board 201. The metal substrate can be tightly attached to the heat dissipation unit 500, thereby significantly reducing thermal resistance and effectively conducting the heat of the power circuit to the heat dissipation unit 500. On this basis, the current carrying capacity per unit area of ​​the conductive carrier of the power circuit can be significantly improved, thereby increasing the high current output efficiency.

[0061] In one embodiment, the heat dissipation unit 500 may be a finned heat sink, the back of which may be tightly attached to the power board 201. For example, the heat dissipation unit 500 may be a low thermal resistance, high-density toothed finned heat sink, the back of which may be provided with screw holes for fixing to the power board 201. The two are tightly attached by bolt structure, thereby improving heat dissipation performance and temperature uniformity.

[0062] Furthermore, in this embodiment, a first air duct plate 600 and a second air duct plate 700 are also arranged inside the housing 100. The first air duct plate 600 is connected to the front panel 102 at one end and extends toward the rear panel 103 at the other end. The second air duct plate 700 is connected to the rear panel 103 at one end and extends along the second direction y at the other end.

[0063] One end of the heat dissipation unit 500 is fixed to the first air duct plate 600, and the other end is fixed to the second air duct plate 700, thus realizing the installation of the heat dissipation unit 500. The first air duct plate 600, the second air duct plate 700, the heat dissipation unit 500, and the base plate 104 form an air duct 106. The control unit 300 is arranged on the first air duct plate 600, and the power unit 200 is arranged on the heat dissipation unit 500, thereby optimizing the internal structural design. The independent air duct 106 design avoids heat circulation inside the housing 100, maximizing the heat dissipation performance of the heat dissipation unit 500.

[0064] To ensure the stability of the heat dissipation unit 500, in this embodiment, the heat dissipation unit 500 is also fixedly connected to the side plate 105 of the housing 100.

[0065] Furthermore, in this embodiment, the fan 400 is arranged near one end of the front panel 102, forming a front channel 1061 between the fan 400 and the front panel 102. This design ensures that, on the one hand, the control unit 300 is positioned above the air inlet, maintaining its temperature near room temperature and maximizing the stability, reliability, and accuracy of the sampling and analysis circuit; on the other hand, the narrow front channel 1061 formed between the fan 400 and the front panel 102 significantly improves the ventilation effect of the fan 400.

[0066] It should be noted that in other embodiments, the fan 400 can also be arranged in other positions of the air duct 106, such as the middle of the air duct 106, or near one end of the rear panel 103, etc., which can also achieve effective heat dissipation.

[0067] Further, please refer to Figure 1 , Figure 3 and Figure 4 , Figure 3 This is a three-dimensional structural diagram of one embodiment of the power control module for high current density battery performance testing according to this application, after removing the cover plate. Figure 4 yes Figure 3 A magnified view of part B in the diagram.

[0068] like Figure 1 , Figure 3 and Figure 4 As shown, in this embodiment, the power board 201 is provided with two input ports 2011 and two output ports 2012. In order to achieve unified wiring of the power board 201 and avoid cumbersome cable connection operations during production, the power unit 200 in this embodiment also includes two busbars 203, two busbars 204 and two outgoing line bars 205.

[0069] Specifically, the two busbars 203 correspond one-to-one with the two input ports 2011 of the power board 201. Each busbar 203 extends along the first direction x and is connected to the corresponding input ports 2011 on the multiple power boards 201.

[0070] Two busbars 204 correspond one-to-one with two busbars 203. One end of each busbar 204 is connected to the corresponding busbar 203, and the other end extends out of the rear panel 103, thereby realizing the unified input wiring of multiple power boards 201.

[0071] Two cable trays 205 correspond one-to-one with the two output ports 2012 of the power board 201. Each cable tray 205 includes a connecting section 2051 and a cable outlet section 2052. The connecting section 2051 extends along the first direction x and connects to the corresponding output ports 2012 on multiple power boards 201. The cable outlet section 2052 extends along the second direction y, with one end connected to the connecting section 2051 and the other end extending out of the rear panel 103, thereby realizing unified output wiring for multiple power boards 201.

[0072] Furthermore, in order to optimize the structural design, in this embodiment, the two input ports 2011 of the power board 201 are arranged sequentially along the second direction y at the end of the power board 201 near the front panel 102, and a busbar seat 206 is also arranged at the end of the power board 201 near the rear panel 103. A section of the busbar 204 located inside the housing 100 is erected between the input port 2011 and the busbar seat 206, and the middle part protrudes in the direction away from the power board 201, thereby avoiding accidental contact between the busbar 204 and the power line layer.

[0073] The two busbars 204 are located at different positions in the first direction x to avoid short-circuiting the two input ports 2011 of the power board 201.

[0074] In this embodiment, the two output ports 2012 of the power board 201 are arranged sequentially along the first direction x at the end of the power board 201 near the rear panel 103, and the end of the power board 201 near the rear panel 103 is also provided with a cable tray 207.

[0075] The cable outlet 205 also includes multiple branch segments 2053 corresponding to multiple power boards 201. Each branch segment 2053 extends from the connecting segment 2051 along the second direction y and connects to the output interface of the corresponding power board 201. The extension segment is connected to the cable outlet base 207.

[0076] Furthermore, the connection segments 2051 of the two output busbars 205 overlap in projection and are located at different heights, thereby preventing the two output ports 2012 of the power board 201 from being short-circuited.

[0077] Based on the irregular structure design of the busbar 204 and the outgoing line 205, rapid production can be achieved by laser cutting and simple bending, avoiding cumbersome cable connection operations, significantly improving production efficiency, and ensuring the stability of current transmission.

[0078] It should be noted that in this embodiment, the power board 201 is provided with two input ports 2011 and two output ports 2012. In other embodiments, the power board 201 may also be provided with other numbers of input ports 2011 and output ports 2012. These can be adjusted according to actual needs, and the number of busbars 204, busbars 203 and outgoing lines 205 can be adjusted accordingly to achieve the effect of this embodiment.

[0079] In addition, in this embodiment, multiple input ports 2011 are arranged sequentially along the second direction y at the end of the power board 201 near the front panel 102, and multiple output ports 2012 are arranged sequentially along the first direction x at the end of the power board 201 near the rear panel 103. In other embodiments, the input ports 2011 and output ports 2012 can also be arranged at other positions on the power board 201, and the structure of the busbar 204, busbar 203 and output busbar 205 can be adjusted accordingly to achieve the same effect as this embodiment.

[0080] The power control module based on the above embodiments effectively improves the power density of the power module, especially the output current of the low-voltage high-current power module, while also taking into account the advantages of multiple current ranges. A single control board 301 can control a large number of power boards 201 simultaneously, enabling fast response to high current output. This avoids the problem of slow response to high current caused by a large number of small current parallel connections in the traditional method. Furthermore, since a single control board 301 uses a single control core, compared to the traditional method of directly connecting multiple small current channels in parallel, it reduces the frequency of information transmission and reception by the upper-level controller when controlling the power module, thereby improving the response speed and data transmission speed.

[0081] It will be apparent to those skilled in the art that this disclosure is not limited to the details of the exemplary embodiments described above, and that this disclosure can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of this disclosure is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this disclosure. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0082] 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 power control module for high current density battery performance testing, characterized in that, include: The shell has an internal cavity. A power unit is arranged in the cavity, the power unit comprising one or more power boards arranged sequentially along a first direction, and each power board having a power interface. A control unit is arranged inside the cavity and located on one side of the power unit in a second direction. The control unit includes one or more control boards arranged sequentially along the first direction. Each control board is provided with one or more control interfaces, which are used to connect to the power interface via a connecting cable. The first direction and the second direction are perpendicular to each other.

2. The power control module according to claim 1, characterized in that, The housing includes a bottom plate, a front panel, and a rear panel, wherein the second direction is the direction from the rear panel to the front panel; The cavity contains an air duct extending along the second direction. The air duct is located between the front panel and the rear panel, and between the power unit, the control unit and the base plate. The front panel and the rear panel are provided with heat dissipation holes corresponding to the position of the air duct. The power control module also includes a fan and a heat dissipation unit arranged in the air duct.

3. The power control module according to claim 2, characterized in that, The heat dissipation unit is arranged on the side of the power unit facing the base plate.

4. The power control module according to claim 3, characterized in that, Also includes: The first air duct plate is connected to the front panel at one end and extends toward the rear panel at the other end; The second air duct plate is connected to the rear panel at one end and extends along the second direction at the other end. The heat dissipation unit is connected at one end to the first air duct plate and at the other end to the second air duct plate. The first air duct plate, the second air duct plate, the heat dissipation unit, and the base plate form the air duct. The control unit is arranged on the first air duct plate, and the power unit is arranged on the heat dissipation unit.

5. The power control module according to claim 4, characterized in that, The housing also includes side plates located on both sides, and the heat dissipation unit is fixedly installed on the side plates.

6. The power control module according to claim 3, characterized in that, The power board includes a metal substrate, an insulating layer, and a power circuit layer stacked sequentially, with the metal substrate being tightly fitted to the heat dissipation unit.

7. The power control module according to claim 2, characterized in that, The fan is arranged at one end of the air duct near the front panel, and forms a front channel with the front panel.

8. The power control module according to claim 2, characterized in that, The power unit includes multiple power boards, each power board having a plurality of input ports and a plurality of output ports arranged thereon; the power unit further includes: A plurality of busbars are provided, each corresponding to one of the input ports, and the busbars extend along the first direction to connect to the corresponding input ports on the power boards. A plurality of busbars are provided, each corresponding to a plurality of the aforementioned busbars. The busbars extend along the second direction, with one end connected to the corresponding busbar and the other end extending out of the rear panel. A plurality of cable trays are provided, each corresponding to a plurality of output ports. Each cable tray includes a connecting section and an extension section. The connecting section extends along the first direction and connects to the corresponding output ports on the power boards. The extension section extends along the second direction, with one end connected to the connecting section and the other end extending out of the rear panel.

9. The power control module according to claim 8, characterized in that, A plurality of the input ports are arranged sequentially along the second direction at one end of the power board near the front panel. A busbar seat is also arranged at one end of the power board near the rear panel. A section of the busbar located inside the housing is mounted between the input ports and the busbar seat, and the middle part protrudes in the direction away from the power board. Among them, several of the busbars are located at different positions in the first direction.

10. The power control module according to claim 8, characterized in that, A plurality of the output ports are arranged sequentially along the first direction at one end of the power board near the rear panel, and a cable outlet bracket is also arranged at one end of the power board near the rear panel. The cable outlet also includes multiple branch segments corresponding to the multiple power boards. Each branch segment extends from the connecting segment along the second direction and connects to the output port of the corresponding power board. The extension segment is connected to the cable outlet base. The heights of the connecting sections of some of the outgoing cable rows are different.

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