Mobile test specimen carrier, test device and test procedure for battery pack test specimens in battery test stands with predetermined setup

Abstract

Mobile battery test carrier (10) for at least one battery pack test specimen (30) in a battery test stand (35) with a predetermined design, wherein the battery pack (30) is designed for an electric or hybrid vehicle and the battery test carrier (10) has several interfaces for the battery pack test specimen (30) and for the battery test stand (35), characterized in that all interfaces are combined in a common uniform connection field (50).

Description

The present invention relates to a mobile test specimen carrier for battery packs in battery test stands of predetermined construction. The invention further relates to a testing device for automatically testing the wiring of a battery pack test object to a test object carrier, and to an associated test method.Prior ArtBattery packs, in particular Li-ion battery packs, are subjected to a plurality of functional and performance tests in the test stand which are carried out by the pack manufacturer before delivery to the customer. In this case, a distinction is made between extended validation and verification tests on prototypes and battery packs of a pre-series production on the one hand, and very short removal tests (three to four hours) on packs from the series production on the other hand.The installation of the Li-ion battery pack test piece has hitherto been carried out in the climate chamber in the test stand itself. The coupling of the battery packs to the test devices is very cumbersome due to the restricted space conditions in the climate chamber and the battery pack connections that are therefore difficult to access.In the battery pack patterns, prototypes and pre-series models used, the interfaces are not always clearly defined, in particular with regard to their alignment, occupancy and plug. This can also be the case in battery packs of the same project for prototypes of different development statuses. Such deviations entail complex modification work either on the test stand or on the test object.Up to now, no competitors have been found on the market that both manufacture and test electric vehicle battery packs in series. For the series packs tested in the hybrid electric vehicle sector, the same test systems are used as are also used in the test of prototype packs. This is due to the fact that the series tests are also subject in principle to the same requirements, for example with regard to the measurement accuracy, as tests of packs of the prototype phases and therefore have to be tested with test stands (testers) of the same specification. For this reason, the installation of the battery pack in the test bench (tester) represents a substantial proportion of the total test time of the removal tests carried out. With a total test time of three to four hours, the installation time (setup time) according to the prior art can be approximately one third of the total test time (gross test time).From document DE 196 44 048 A1 a container for a traction battery of an electric vehicle for test stand purposes is known, wherein the container comprises a plurality of swivel rollers, which make the container travelable. Furthermore, the container comprises a plurality of interfaces in order to come from the outside to the connections of the traction battery. A disadvantage of this is that the use of such a space-intensive container causes difficulties in introducing the container into spaces with restricted space conditions, such as the climate chamber of test stands. Moreover, the interfaces encompassed by the container are arranged spaced apart from one another on different sides of the container for different purposes. Due to the spatial distribution of the interfaces, the interfaces of the container are not always clearly defined, in particular with regard to their assignment or their occupancy. As a result, the installation of the traction battery in the test stand is complicated and time-consuming.Disclosure of the InventionAccording to the invention, a drivable test specimen carrier for at least one battery pack test specimen is provided in a battery test stand having a predetermined structure, wherein the battery pack is designed for an electric or hybrid vehicle and the test specimen carrier has a plurality of interfaces for the battery pack test specimen and the battery test stand. All interfaces of the test specimen carrier present are combined in a uniform common connection field. In particular, Li-ion battery packs are used.By using a common, uniform connection field for the interfaces of the test specimen carrier according to the invention, a massive shortening of the installation times (setup times) is achieved, since the interfaces are situated spatially adjacent to one another and are thus arranged in a clear manner. As a result, the assignment of the interfaces of the test specimen carrier to the connections of the test stand by means of the connection field is clearly defined and can be carried out easily. The significant shortening of the setup times made possible thereby is relevant in particular for the total time to be used for the home (small) series tests and for the customer return.Furthermore, the use of the test specimen carrier according to the invention allows a simplified structure and connection of the battery pack in the test specimen carrier compared to the known installation in a test stand, because shorter cable lengths are made possible in the invention and assigned interfaces are clearly present in advance.The invention furthermore makes it possible to avoid faults in principle during the installation of the battery pack in the test stand and during the design of the cable connections from the battery pack test object to the test stand.Furthermore, by means of the test specimen carrier according to the invention having a common uniform connection field, responsibilities for the correct execution of the cabling and the structure of the test specimen can be clearly defined, thus avoiding misunderstandings.Furthermore, the test specimen carrier according to the invention enables a conceptually improved connection of the fluid temperature control system of the test specimen carrier (with test specimen) in the test stand, since the assignment of the connections of the fluid temperature control system is clearer by the use of a common uniform connection. This prevents a liquid leakage in the climate chamber, in particular as a result of the incorrect assignment of the connections of the fluid temperature control system to the associated connections of the connection field and an associated incorrect triggering of the safety mechanisms of the test system.The connection field, which comprises all connections of the test object and further components of the test structure, can be mounted particularly advantageously on the end face of the test object carrier. The test object is connected to the test stand via this connection field. The set of cables and hoses required for this purpose always remains in the test stand. This is thus always ready for use with the same hardware stand and can be equipped with any available test object. The connection field is preferably mounted inclined at the working height, so that the mounting of the cables and hoses is facilitated.According to a preferred embodiment of the invention, it is provided that the test specimen carrier is constructed from flexible mounting system profiles, preferably as a lead frame, and in particular is firmly connected to a rolling table.The test piece is mounted on this unit consisting of the test piece carrier and the rolling table, and the connections to the connection pad are produced. At this time, it is now possible to check the correct execution of the connections, such as the assignment of the data logger channels, the signal cables, the power supplies for the pump and battery management system, or the fluid temperature control, and to remedy any faults before the test object is installed in a test stand.By configuring the test specimen carrier as a lead frame from flexible mounting system profiles, it can be quickly and easily adapted to different mechanical fastening possibilities of the respective test specimen. In particular, when prototypes and pre-series patterns are tested, the mechanical fastening possibilities are often different depending on the prototype or pre-series pattern.The unit consisting of the rolling table and the specimen carrier also serves to simplify the transport of specimens within the usual working premises.According to a preferred embodiment of the invention, a battery testing device is used which automatically carries out a testing of the cabling (in particular of the low-voltage and signal cabling) of the test object on the test object carrier and outputs a evaluation of the cabling state (pass / fail evaluation) in particular by LED display. In this case, the test device according to the invention simulates the connection of the test specimen carrier to a test stand before the test specimen carrier is installed in a test stand. This facilitates a possible fault finding considerably.Furthermore, a test method according to the invention very advantageously enables testing of a test object by means of a battery test device according to the invention, wherein the battery test device is connected to the connection field, the connection of the test object carrier to a test stand is simulated by means of the battery test device, the state of the cabling of the test object is understood, the state of the cabling of the test object is evaluated, and the state of the cabling of the test object is displayed.The test method according to the invention evaluates the state of the cabling of the test object before installation in the test stand. Thus, an unnecessary test shutdown of the test stands can be avoided.The changes described can already be seen optically on the test stand or on the test object.Advantageous refinements of the invention are specified in the dependent claims and described in the description.DRAWINGSA particularly advantageous exemplary embodiment of the invention is explained in more detail on the basis of the drawings and the following description. The following are shown: FIG. 1 shows a schematic side view of a test specimen carrier with test specimen in the test stand according to a first embodiment of the invention, FIG. 2 shows a schematic plan view of a connection field according to the invention according to the first embodiment of the invention, and FIG. 3 shows a schematic side view of a test specimen carrier with a test specimen connected to a test apparatus according to a second embodiment of the invention.Embodiments of the InventionFIG. 1 shows a test specimen carrier 10 according to the invention, which is fixedly connected to a rolling table 20 according to a first embodiment of the invention. A test object 30 is placed on the test specimen carrier 10, which is connected via a plurality of connections 40 to a common uniform connection field 50. The connection field 50 forms a common uniform interface 50 of the test object to the test stand 35. The connection field 50 is attached to the end face of the test object 30 inclined at the working height, so that the attachment of the cables and hoses is facilitated.FIG. 2 shows a schematic plan view of a connection field 50 according to the invention according to the first embodiment of the invention from FIG. 1. The connection interfaces of the cabling of the test object 30 to the fluid cooling 60, 61, the flow monitor 62, the temperature sensors 63, 64, 65 of the data logger cabling 70, 71, 72, the Can bus connection 80, the signal cabling 90, 91, 92, the battery management system 100 and the pump supply 110 are shown. Also shown are spare port interfaces 120, 121.FIG. 3 shows a test specimen carrier 10 according to the invention, which is fixedly connected to a rolling table 20 according to the first embodiment of the invention. Here, the terminal pad 50 is connected to a battery tester 36 via a plurality of connections 46. In this case, the battery test device 36 according to the invention simulates the connection of the test specimen carrier 30 to a test stand before the test specimen carrier 30 is installed in a test stand 35. This facilitates a possible fault finding considerably.

Claims

Drivable battery test specimen carrier (10) for at least one battery pack test specimen (30) in a battery test stand (35) of predetermined structure, wherein the battery pack (30) is designed for an electric or hybrid vehicle and the battery test specimen carrier (10) has a plurality of interfaces for the battery pack test specimen (30) and to the battery test stand (35), characterized in that all interfaces are combined in a common, uniform connection field (50).The mobile battery test specimen carrier (10) according to claim 1, wherein the battery test specimen carrier (10) is designed as a lead frame made of a plurality of flexible mounting system profiles, which is in particular fixedly connected to a rolling table (20).The wheeled battery DUT carrier (10) according to claim 1 or 2, wherein the connection pad (50) is formed on a front side of the battery DUT carrier (10).Mobile battery test specimen carrier (10) according to one of Claims 1 to 3, wherein the connection field (50) is mounted at such a working height and in particular inclined in such a way that the mounting of connections (40) is facilitated.Battery testing device (36) for automatically testing the wiring (40) of a battery pack test object (30) with a drivable battery test object carrier (10) according to one of Claims 1 to 4, wherein the testing device (36) is configured to simulate the connection of the battery test object carrier (10) to a battery test stand (35) and to test the state of the wiring (40) of the battery pack test object (30) before it is installed in a battery test stand (35).The battery test apparatus (36) according to claim 5, wherein the evaluation of the state of the wiring (40) of the battery pack test object (30) is performed by means of an LED display.A battery test stand (35) for a battery pack test object (30), comprising a drivable battery test object carrier (10) according to any one of claims 1 to 4.Test method for testing a battery pack test object (30) by means of a battery test device (36) according to one of Claims 5 or 6, characterized bythe following steps: - connecting the battery test device (36) to the connection field (50), - simulating the connection of the mobile battery test object carrier (10) to a battery test stand (35), - determining the state of the cabling (40) of the battery pack test object (30), - evaluating the state of the cabling (40) of the battery pack test object (30), and - displaying the state of the cabling (40) of the battery pack test object (30).Motor vehicle having at least one battery pack (30) which is tested in a battery test stand (30) and is mounted on a mobile battery test specimen carrier (10) according to one of Claims 1 to 4.

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