Battery Module Harness Test Circuit for Sequential Cell Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery module wire harness on-off test methods are inefficient due to the need for frequent wiring and manual labor, leading to low testing speed and precision, and potential errors in detecting connection quality issues.
Innovation Solution
A test system comprising a test circuit board with multiple main lines connected to battery cells, a test device, and a computer system that controls the connection of these lines to detect parameter information without repeated plugging and unplugging, using a multimeter for voltage and resistance measurements, and a reading mechanism for bar code information to invoke targeted test schemes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual wiring and frequent plugging/unplugging is used for testing, then the test device can be simple, but the testing efficiency is low and time-consuming
Solution Approach 1:
The test circuit board is segmented into multiple main lines, each corresponding to a specific battery cell. Each main line is further divided into first and second branches with independent control switches, allowing selective testing of individual cells without affecting others. This segmentation enables efficient sequential testing while maintaining circuit organization and reducing the need for repeated plugging/unplugging.
Solution Approach 2:
The test circuit incorporates dynamic switching capability through control switches on each branch. The lower computer dynamically controls these switches to connect or disconnect specific battery cells from the test device based on testing requirements. This dynamic reconfiguration allows the system to adapt to different testing scenarios without manual intervention, significantly improving testing efficiency.
2Measurement precision
If frequent wiring changes are performed manually, then the test device structure can be simple, but the testing precision decreases due to potential errors
Solution Approach 1:
The test system implements self-service through automated control. The lower computer automatically controls the control switches to connect the appropriate battery cells to the test device based on pre-programmed testing sequences. This eliminates manual wiring changes and the associated human errors, ensuring consistent and precise connection quality detection throughout the testing process.
Solution Approach 2:
The system replaces manual mechanical wiring operations with automated electronic switching. Instead of physically plugging and unplugging connectors, the lower computer electronically switches connections through control switches on the circuit board. This substitution eliminates the variability and potential errors of manual operations while maintaining simple physical device structure.
3Productivity
If sequential detection of multiple battery cells is implemented, then testing efficiency improves, but the risk of wire harness damage increases
Solution Approach 1:
The test circuit board is pre-configured with all necessary connection paths and control switches before testing begins. The lower computer pre-programmes the sequential testing sequence for all battery cells. This preliminary preparation allows the system to perform efficient sequential detection while eliminating the need for repeated physical connection changes that could damage the wire harness during the actual testing process.
Data Source
AI summary
A test system comprises a test circuit board, a test device, a lower computer, and an upper computer. The test circuit board includes a test circuit, the test circuit comprising multiple main lines arranged side by side, one end of each of the main lines being used to connect with a positive electrode or a negative electrode of each battery cell of the battery module, and the other end of each of the main lines being connected with a first branch and a second branch. The lower computer controls a first branch connected to one of the main lines to be electrically conductive to a positive electrode of the test device and a second branch connected to another one of the main lines to be electrically conductive to a negative electrode of the test device. The upper computer controls the lower computer and reads parameter information for the test device.