Switch Matrix Battery Testing for Repeatable Field Diagnostics
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Solution Overview
Problem
Conventional battery system testing methods are time-consuming, prone to human error, and inconsistent due to reliance on manual data collection and expert analysis, and existing automatic solutions are large and impractical for field deployment.
Innovation Solution
An automatic battery test system utilizing a switch matrix to couple with the battery system, peripheral instruments, and a computing system for automated testing, allowing non-expert operators to perform uniform and repeatable tests across various settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual data collection and expert analysis methods are used, then testing can be performed with simple equipment, but the testing process becomes time-consuming and prone to human error
Solution Approach 1:
The system enables automated self-testing of battery systems through embedded sensors and control circuits that automatically collect data, analyze results, and generate reports without requiring manual expert intervention. The BMS autonomously performs diagnostic functions and communicates test results directly to the reporting module.
Solution Approach 2:
Manual mechanical data collection processes are replaced with electronic automated systems including voltage sensors, current sensors, temperature sensors, and communication interfaces that automatically measure and transmit battery parameters to the computing system for analysis.
2Productivity
If automated testing systems are implemented, then testing efficiency and consistency improve, but the system size and weight increase making field deployment impractical
Solution Approach 1:
The testing system is designed as a universal multi-functional platform that can test various battery types and configurations using the same core hardware. The switch matrix and sensor array can be reconfigured through software to accommodate different battery chemistries, voltages, and form factors, eliminating the need for multiple specialized testing systems.
Solution Approach 2:
The testing system is divided into modular functional segments including power management modules, sensing modules, communication modules, and processing modules that can be independently configured and deployed. This segmentation allows the system to be scaled down for field deployment while maintaining core testing capabilities.
3Adaptability or versatility
If expert operators perform manual analysis, then complex battery system functionalities can be evaluated, but operator variability leads to inconsistent results
Solution Approach 1:
The system incorporates automated feedback loops where test results are immediately analyzed by the computing system and used to adjust testing parameters in real-time. The BMS receives feedback from sensors and automatically modifies charging/discharging profiles based on detected anomalies, ensuring consistent evaluation criteria are applied across all tests.
Solution Approach 2:
The system automatically adjusts testing parameters such as current rates, voltage thresholds, and temperature limits based on the specific battery configuration being tested. The computing system modifies test protocols dynamically according to battery chemistry, capacity, and state of charge, ensuring optimal and consistent testing conditions for each battery type.
Data Source
AI summary
Systems and methods are provided for an automatic battery test system for a battery system. The automatic battery test system includes a switch matrix coupled to the battery system, a peripheral instrument coupled to the battery system via the switch matrix, a communication interface coupled to the switch matrix, and a computing system coupled to the switch matrix via the communication interface.