Battery Pack Test Power Routing for Peak Demand Utilization
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Solution Overview
Problem
High-power test laboratories face inefficiencies due to underutilization of power equipment during endurance tests of electric vehicle battery packs, as peak power demands are infrequent, leading to high operational costs and the need for dedicated, non-scalable test bench systems.
Innovation Solution
A power allocation manager system that clusters power units and uses a programmable logic controller to dynamically route power to test channels based on test plans, allowing for intelligent and flexible allocation of power across multiple devices under test, enabling efficient use of power resources and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate test bench systems are dedicated to each device under test to handle peak power demands, then reliability of power supply is improved, but device complexity and hardware costs increase
Solution Approach 1:
Multiple power units that were previously dedicated to individual test benches are merged into a shared power pool. The power router dynamically allocates and routes power from this shared pool to multiple test channels simultaneously, eliminating the need for separate dedicated power systems for each device under test while maintaining reliable power supply.
Solution Approach 2:
The power router creates a universal power distribution system that can serve multiple test benches and device types. Instead of each test bench having specialized dedicated power equipment, a single multi-functional power router can dynamically configure power distribution to any test channel based on real-time requirements, handling various power profiles and device configurations.
2Power
If power equipment is sized for peak power levels to ensure adequate capacity, then power capacity is improved, but productivity and utilization efficiency deteriorate
Solution Approach 1:
The power allocation system transitions from static dedicated power assignments to dynamic real-time power routing. The power router continuously monitors power demands of multiple test channels and dynamically adjusts power distribution in real-time, allowing the same power equipment to adapt its capacity allocation based on instantaneous needs rather than being locked into fixed peak-capacity assignments.
Solution Approach 2:
Instead of allocating full peak power capacity to each test bench continuously, the system applies partial power allocation based on actual instantaneous demands. The power router distributes power dynamically, providing only the necessary power level to each test channel at any given moment, thereby avoiding the waste associated with continuously supplying excessive peak power to all channels simultaneously.
3Adaptability or versatility
If multiple test channels are implemented to meet diverse testing demands, then adaptability is improved, but loss of energy and operational costs increase
Solution Approach 1:
The power router ensures continuous and optimized power distribution across multiple test channels. By dynamically routing power in real-time based on actual test requirements, the system maintains continuous useful power delivery to active test channels while automatically idle or reducing power to channels not currently in use, eliminating periods of wasted power consumption.
Solution Approach 2:
The power allocation system incorporates real-time feedback mechanisms that monitor the power consumption and test status of multiple channels. Based on this feedback, the power router continuously optimizes power distribution, routing power only to channels that currently require it and adjusting allocation levels according to actual test demands, thereby reducing energy waste while maintaining testing versatility.
Data Source
AI summary
A battery pack test system includes a power cluster, a power router, a power allocation manager, and a plurality of test bench control units. The power cluster includes a plurality of power units. The power allocation manager is configured to dynamically switch allocations of power from individual power units of the plurality of power units to a plurality of test channels each connected to a different device under test. The plurality of test bench control units are each configured to interface with the power router and a different corresponding device under test. Each of the test bench control units includes a plurality of measurement sensors for measuring characteristics of the corresponding device under test.