CN114675113A - Test system and test method based on battery management system - Google Patents
Test system and test method based on battery management system Download PDFInfo
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- CN114675113A CN114675113A CN202210373349.4A CN202210373349A CN114675113A CN 114675113 A CN114675113 A CN 114675113A CN 202210373349 A CN202210373349 A CN 202210373349A CN 114675113 A CN114675113 A CN 114675113A
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Abstract
The invention discloses a testing system and a testing method based on a battery management system, which relate to the technical field of battery testing and comprise a control computer, a PLC (programmable logic controller), a communication module, a power supply module, a detection module, a BMS (battery management system) and a jig, wherein the BMS is respectively connected with the power supply module and the detection module through the jig; the power supply module is used for providing adjustable voltage and current for the BMS, and the detection module is used for detecting electric data of the BMS in different working states; various working conditions possibly encountered by the BMS in the use process are simulated by controlling the output of the voltage source and the current source through the control computer, so that whether each circuit module of the BMS is normal or not and the protection function of the BMS under various limit working conditions are tested.
Description
Technical Field
The invention relates to the technical field of battery testing, in particular to a testing system and a testing method based on a battery management system.
Background
A Battery Management System (BMS) is a set of control System for protecting the use safety of a Battery pack, and provides guarantee for the use safety of the Battery pack. Due to the importance of battery management systems, it is necessary to test battery management system development to ensure that the battery management system meets the relevant functional requirements.
In the actual use process of the electric automobile, due to the reason that the battery pack is improperly used and the like, the BMS reports the current fault state according to a fault handling mechanism and timely makes a fault response so as to protect the battery pack from being abused. Meanwhile, when the BMS is in the sleep state, although the power consumption of the BMS itself is small, an error may be generated in the calculation of the remaining power of the battery pack if the battery pack is left for an excessively long time. BMS development and test engineers are expected to reproduce failures while analyzing failure data and finding the cause of the failure. However, the detection device for manual detection is relatively simple, the whole detection process is manually completed, and the detection efficiency and quality are relatively low.
Disclosure of Invention
The invention provides a testing system and a testing method based on a battery management system aiming at the problems and technical requirements, the testing system is used for simulating limit working conditions possibly met by various BMSs in the using process to finish accurate testing of the BMSs, and the technical problems of low troubleshooting efficiency and the like caused by the fact that multiple repeated measurements are needed aiming at the same kind of testing items are solved.
The technical scheme of the invention is as follows:
a testing system based on a battery management system comprises a control computer, a PLC, a communication module, a power supply module, a detection module, a BMS and a jig, wherein the BMS is installed on the jig, the BMS is respectively connected with the power supply module and the detection module through the jig, the control computer controls the power supply module through the PLC, the control computer is connected with the detection module, and the control computer is connected with the BMS through the communication module;
the power supply module is used for providing adjustable voltage and current for the BMS, and the detection module is used for detecting electric data of the BMS in different working states; the control computer is used for determining whether the BMS meets the testing preset conditions or not according to the electric data fed back by the detection module and/or the electric data fed back by the BMS, and the electric data comprises voltage data and current data; the control computer is also used for determining whether the BMS is abnormal or not according to the information fed back by the BMS, wherein the information comprises the working state of the control computer, correction data and real-time.
The power supply module comprises a voltage source, a current source and an electronic load; the voltage source is used for supplying power to the BMS and providing adjustable voltage; the current source is used for providing adjustable current for the BMS, and the adjustable current comprises adjustable charging and discharging current; the electronic load is used to provide a load for the BMS main loop.
The detection module comprises a Hall sensor, a voltage collector, a current probe and a temperature sensor; the Hall sensor is connected to a charge-discharge loop of the BMS and used for detecting charge-discharge current data of the charge-discharge loop; the voltage collector is used for detecting voltage data of the BMS; the current probe is connected to a power supply voltage source loop of the BMS and used for detecting balance current data and power consumption current data of the power supply voltage source loop; the temperature sensor is used for detecting the ambient temperature where the BMS is located.
A test method based on a battery management system comprises a no-load detection method, an accuracy detection method, a protection function detection method and a power consumption detection method of a BMS, wherein:
the no-load detection method comprises the following steps:
the control computer controls the power supply module to output power supply voltage to enable the BMS to enter a working state, the BMS replies the working state to the control computer, the control computer compares the working state with preset BMS no-load state data, if the error is within a threshold range, other test items are entered, and otherwise, the BMS is abnormal;
the precision detection method comprises the following steps:
the control computer changes the output voltage of the power supply module, the output voltage is connected with a voltage acquisition circuit of the BMS, the BMS replies first voltage data acquired by the BMS to the control computer, the control computer receives second voltage data acquired by the detection module, and determines whether the voltage acquisition precision of the BMS is within a voltage threshold range by comparing the first voltage data with the second voltage data, if so, other test items are entered when the test is not finished, otherwise, the voltage acquisition circuit and the voltage precision of the BMS have faults;
the protection function detection method comprises the following steps:
the control computer changes the output voltage and current of the power supply module to enable the output voltage and current to exceed the protection threshold of the BMS; the BMS replies first current data acquired by the BMS to the control computer, the control computer receives actual current data of a loop acquired by the detection module, and whether the overcurrent protection function and the undervoltage/overvoltage protection function of the BMS have faults or not is determined by comparing whether the two current data meet a test preset condition or not, if the two current data meet the test preset condition, the protection function of the BMS is normal, when the test is not finished, other test items are entered, otherwise, the protection function of the BMS is abnormal;
the power consumption detection method comprises the following steps:
the control computer changes the output voltage and current of the power supply module to enable the BMS to be in different working states including a normal working state, a dormant state and an under-voltage dormant state; the control computer receives power consumption current data acquired by the detection module under different working states, and determines whether the power consumption of the BMS has a fault or not by comparing whether the power consumption current data are within the corresponding power consumption threshold range or not, if the power consumption current data are within the corresponding power consumption threshold range, the power consumption of the BMS is normal, when the test is not completed, other test items are entered, otherwise, the power consumption of the BMS is abnormal.
The further technical scheme is that the precision detection method further comprises the following steps:
the control computer controls the power supply module to output power supply voltage, receives the environmental temperature acquired by the detection module and outputs a corresponding voltage value according to a corresponding relation table of the voltage and the temperature; changing the output voltage of the power supply module to be a voltage value, and connecting the output voltage with a temperature acquisition circuit of the BMS; and the control computer receives third voltage data replied by the BMS, outputs a corresponding temperature value according to the corresponding relation table of the voltage and the temperature, enters other test items when the test is not finished if the deviation between the temperature value and the ambient temperature does not exceed the temperature threshold range, or fails in a temperature acquisition circuit and temperature precision of the BMS.
The further technical scheme is that the method for detecting the protection function further comprises the following steps:
the control computer changes the output voltage of the power supply module, so that the BMS has an excessive voltage difference alarm, the control power supply module outputs a first current, the first current only passes through a pre-charging loop of the BMS, the control power supply module outputs a second current, the second current ensures that the pre-charging loop is disconnected due to overcurrent protection, the control power supply module controls the electronic load in the power supply module to be disconnected and outputs the first current, the control computer receives actual current data of each change process acquired by the detection module and judges whether the change of the actual current data of the loop recovers to a preset current value from the preset current value to zero, and therefore whether faults exist in the pre-charging loop protection and recovery functions of the BMS is determined, if the protection function of the BMS is normal, other test items are entered when the test is not completed.
The further technical scheme is that the test method also comprises a BMS correction detection method, which comprises the following steps:
the control computer controls the power supply module to output power supply voltage and sends a parameter correction signal corresponding to the power supply voltage to the BMS, and the parameter correction signal is used for correcting the controller parameter of the BMS to a preset value; if the deviation between the correction data received by the control computer and the preset value replied by the BMS does not exceed the correction threshold, entering other test items when the test is not completed, otherwise, the BMS is abnormal.
The further technical scheme is that the test method also comprises a real-time read-write function detection method of the BMS, which comprises the following steps:
the control computer reads the time data of the computer, converts the time data into a communication message and sends the communication message to the BMS, and the BMS writes the first real-time; the control computer controls the power supply module to cut off the power supply voltage, so that the BMS enters a power-off state, and after standing for a preset time, the BMS is supplied with power again, so that the BMS is charged and activated; if the difference between the second real-time and the first real-time when the control computer receives the BMS reply meets the preset time range value, entering other test items when the test is not finished, otherwise, the real-time read-write function of the BMS is abnormal.
The further technical scheme is that the test method also comprises a balancing function detection method of the BMS, which comprises the following steps:
the control computer changes the output current of the power supply module, so that the BMS enters a charging state, changes the output voltage of the power supply module to meet the balancing condition of the BMS, and the detection module collects first balancing current data in a balancing mode; changing the output voltage of the power supply module again to enable the BMS to exit the equalization mode, and acquiring second equalization current data by the detection module when the BMS exits the equalization mode; and if the control computer determines that the first and second balance current data both meet the balance preset condition, entering other test items when the test is not completed, otherwise, the balance function of the BMS is abnormal.
The further technical scheme is that the test method further comprises the following steps:
the control computer controls the power supply module to output power supply voltage to enable the BMS to enter a working state and controls the charging or discharging MOS tube of the BMS to be opened; if the actual current data of the loop collected by the detection module and the second current data replied by the BMS are both zero, the BMS enters other test items when the test is not completed, otherwise, the BMS cannot enter a dormant state.
The beneficial technical effects of the invention are as follows:
the control computer detects various functions of the BMS, detects voltage and current detection parameters of the BMS when the BMS normally operates, adjusts the parameters which do not meet the requirements, and writes real-time into the control computer, so that the faults of various battery management systems can be recorded in real time, and fault reasons can be conveniently searched;
in addition, various working conditions which the BMS may encounter in the use process are simulated through the voltage source and the current source, so that whether each circuit module of the BMS is normal or not and the protection function of the BMS under various limit working conditions are tested, and the problems of low BMS detection efficiency and low accuracy are solved; the situations of fault expansion, combustion, explosion and the like caused by over power when the electric vehicle controller has the problems of short circuit, open circuit, abnormal insulation and the like are avoided, the safety of the debugging and testing process of the electric vehicle controller is improved, the parameters of the automatic detection BMS and the quick adjustment of the electric vehicle controller are achieved, and the detection precision and efficiency are improved.
Drawings
Fig. 1 is a schematic diagram of a test system based on a battery management system according to an embodiment.
Fig. 2 is a flowchart of a testing method based on a battery management system according to another embodiment.
Detailed Description
The following further describes the embodiments of the present invention with reference to the drawings.
As shown in fig. 1, the present embodiment provides a testing system based on a battery management system, which comprises a control computer, a PLC, a communication module, a power supply module, a detection module, a BMS and a fixture, wherein the BMS is installed on the fixture, the BMS is respectively connected to the power supply module and the detection module through the fixture, the control computer controls the power supply module through the PLC, the control computer is connected to the detection module, and the control computer is connected to the BMS through the communication module. Wherein:
the power supply module is used for providing adjustable voltage and current for the BMS. Specifically, the power supply module comprises a voltage source, a current source and an electronic load. The voltage source is used for supplying power to the BMS and providing adjustable voltage; the current source is used for providing adjustable current for the BMS, and the adjustable current comprises adjustable charging and discharging current; the electronic load is used to provide a load for the BMS main circuit.
The detection module is used for detecting electrical data when the BMS is in different working states, and the electrical data comprises voltage data and current data. Specifically, the detection module comprises a Hall sensor, a voltage collector, a current probe and a temperature sensor. The Hall sensor is connected to a charge-discharge loop of the BMS and used for detecting charge-discharge current data of the charge-discharge loop and detecting protection delay time; the voltage collector is used for detecting voltage data of the BMS; the current probe is connected to a power supply voltage source loop of the BMS and used for detecting balance current data and power consumption current data of the power supply voltage source loop; the temperature sensor is used for detecting the ambient temperature where the BMS is located.
The control computer is used for determining whether the BMS meets the testing preset conditions according to the electric data fed back by the detection module and/or the electric data fed back by the BMS; the control computer is also used for determining whether the BMS is abnormal or not according to the information fed back by the BMS, wherein the information comprises the working state of the control computer, correction data and real-time.
Optionally, the jig of the embodiment is a needle bed jig; the communication module is a CAN module or a 485 module; the temperature sensor is an NTC temperature sensor.
In this embodiment, utilize above-mentioned test system to simulate the limit condition that various BMS probably met in the use, accomplish the accurate test to BMS, solved to the test project of the same kind but need many times to measure repeatedly and the fault finding inefficiency scheduling technical problem that exists.
Further, another embodiment further provides a testing method based on a battery management system, where the testing method includes a no-load detection method, a correction detection method, a precision detection method, a protection function detection method, a real-time read-write function detection method, an equalization function detection method, and a power consumption detection method of a BMS, except for the no-load detection method, a detection order of the other detection items may be changed at will, and each function may be detected separately and repeatedly in a testing process, in this embodiment, a complete testing method in a detection order is provided, as shown in fig. 2, which specifically includes the following steps:
s1) the control computer outputs the power supply voltage through the voltage source in the PLC control power supply module, and the voltage is supplied to the BMS through the jig to enable the BMS to enter the working state; the control computer sends data to the BMS through the communication module, the BMS replies the working state of the control computer, if the BMS fails and the control computer does not receive the replied data, the BMS supplies power or the communication module fails and stops testing, and the testing is continued after the fault removal is recovered; and the control computer compares the self working state with the preset BMS no-load state data, if the self working state and the preset BMS no-load state data are the same (namely, the error of the self working state and the preset BMS no-load state data is within the threshold range), the next test item is entered, otherwise, the BMS is abnormal.
S2) the control computer outputs the power supply voltage through the voltage source in the PLC control power supply module, and sends a parameter correction signal corresponding to the power supply voltage to the BMS, wherein the parameter correction signal is used for correcting the controller parameter of the BMS to a preset value; and if the correction data received by the BMS and replied by the control computer is the same as the preset value (namely the deviation between the correction data and the preset value does not exceed the correction threshold value), entering the next test item, otherwise, the BMS is abnormal.
S3) the control computer changes the output voltage of the voltage source in the power supply module through the PLC, the output voltage is connected with the voltage acquisition circuit of the BMS, the control computer sends data to the BMS through the communication module, the BMS replies the first voltage data acquired by the BMS to the control computer, the control computer receives the second voltage data acquired by the voltage acquisition device in the detection module, and determines whether the voltage acquisition precision of the BMS is within the voltage threshold range or not by comparing the first voltage data with the second voltage data, if so, the voltage acquisition circuit of the BMS is normal and enters the next test item, otherwise, the voltage acquisition circuit and the voltage precision of the BMS have faults.
S4) the control computer outputs power supply voltage through a voltage source in the PLC control power supply module, receives the environmental temperature collected by a temperature sensor in the detection module, and outputs a corresponding voltage value according to a corresponding relation table of the voltage and the temperature; the output voltage of the power supply module is changed into a voltage value, the output voltage is connected with a temperature acquisition circuit of the BMS, and the temperature acquisition circuit outputs a voltage signal; and the control computer receives third voltage data replied by the BMS and outputs a corresponding temperature value according to the corresponding relation table of the voltage and the temperature, if the deviation between the temperature value and the ambient temperature does not exceed the temperature threshold range, the temperature acquisition circuit of the BMS is normal and enters a next test item, otherwise, the temperature acquisition circuit and the temperature precision of the BMS have faults.
S5) the control computer outputs power supply voltage through a voltage source in the PLC control power supply module to enable the BMS to enter a working state, and sends a message through the communication module to control the charging or discharging MOS tube of the BMS to be opened; and if the actual current data of the loop acquired by the Hall sensor in the detection module received by the control computer and the second current data (namely, the charging or discharging current data) replied by the BMS are zero, entering a next test item, otherwise, the BMS cannot enter a dormant state.
S6) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the charging loop of the BMS outputs the set charging current, the control computer sends data to the BMS through the communication module, if the actual loop current data collected by the Hall sensor in the detection module and the charging current data replied by the BMS are the same as the preset charging current, the BMS is in a normal working state and enters the next test item, otherwise, the charging loop and the charging precision of the BMS have faults.
S7) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the discharge loop of the BMS outputs the set discharge current, the control computer sends data to the BMS through the communication module, if the actual loop current data collected by the Hall sensor in the detection module and the discharge current data replied by the BMS are the same as the preset discharge current, the BMS is in a normal working state and enters the next test item, otherwise, the discharge loop and the discharge precision of the BMS have faults.
S8) controlling the computer to change the output voltage and current of the power supply module to exceed the protection threshold of the BMS; BMS replies the first current data of self collection to the control computer, and the control computer receives the actual current data of return circuit that detection module gathered to whether satisfy the test through comparing two kinds of current data and predetermine the condition, thereby confirm whether overcurrent protection function, the undervoltage/overvoltage protection function of BMS have the trouble, if satisfy the test and predetermine the condition, then the protect function of BMS is normal, gets into next test item, otherwise the protect function of BMS is unusual. The method specifically comprises the following steps:
s81) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the discharge loop of the BMS outputs large discharge current, the control computer sends data to the BMS through the communication module, if the actual loop current data collected by the Hall sensor in the detection module and the discharge current data (namely, the first current data) returned by the BMS become zero from the preset discharge current, the situation that the discharge loop of the BMS is disconnected due to discharge overcurrent protection and enters the next test item is indicated, and otherwise, the overcurrent protection function of the BMS discharge loop has a fault.
S82) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the charging loop of the BMS outputs large charging current, the control computer sends data to the BMS through the communication module, if the actual loop current data collected by the Hall sensor in the detection module and the charging current data (namely, the first current data) returned by the BMS become zero from the preset charging current, the fact that the charging loop of the BMS is disconnected and enters the next test item due to charging overcurrent protection is indicated, and otherwise, the overcurrent protection function of the BMS charging loop has a fault.
S83) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the discharge loop of the BMS outputs small discharge current and enters a discharge state, and the control computer changes the output voltage of the voltage source in the power supply module through the PLC, so that the BMS is in an undervoltage state; the control computer sends data to the BMS through the communication module, if the actual current data of a loop collected by the Hall sensor in the detection module and the discharge current data (namely the first current data) returned by the BMS are all changed from the preset discharge current to zero, the fact that the discharge loop of the BMS is disconnected due to undervoltage protection and enters a next test item is indicated, and otherwise, the undervoltage protection function of the BMS discharge loop has a fault.
S84) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the charging loop of the BMS outputs small charging current and enters a charging state, and the control computer changes the output voltage of the voltage source in the power supply module through the PLC, so that the BMS is in an overvoltage state; the control computer sends data to the BMS through the communication module, if the actual current data of a loop collected by the Hall sensor in the detection module and the charging current data (namely the first current data) returned by the BMS are all changed from the preset charging current to zero, the situation that the charging loop of the BMS is disconnected and enters a next test item due to overvoltage protection is indicated, and otherwise, the overvoltage protection function of the BMS charging loop has a fault.
S9) controlling the computer to read the Time data of the computer, converting the Time data into a communication message and sending the message to the BMS through the communication module, so that the BMS writes a first Real Time Clock (RTC); the control computer controls a voltage source in the power supply module to cut off power supply voltage through the PLC, so that the BMS enters a power-off state, and power is supplied to the BMS again after the power supply module is kept still for a preset time, so that the BMS is charged and activated, wherein the preset time in the embodiment is set to 10s optionally; if the difference between the second RTC and the first RTC received by the control computer and replied by the BMS meets the preset time range value, namely 10s +/-2 s, the RTC read-write function of the BMS is normal and enters the next test item, otherwise, the RTC read-write function of the BMS is abnormal.
S10) the control computer changes the current source and the electronic load in the power supply module through the PLC, so that the charging loop of the BMS outputs small charging current and enters a charging state, and the control computer changes the output voltage of the voltage source in the power supply module through the PLC, so that the output voltage meets the balancing condition of the BMS; a current probe in a detection module acquires first balanced current data in a balanced mode; changing the output voltage again to enable the BMS to exit the equalization mode, and collecting second equalization current data in the equalization exit mode by a current probe in the detection module; if the control computer determines that the first equalizing current data and the second equalizing current data both meet the preset equalizing condition, it indicates that the equalizing function of the BMS is normal and other test items are entered, otherwise, the equalizing function of the BMS is abnormal.
S11) the control computer changes the output voltage of the voltage source in the power supply module through the PLC, so that the BMS has an alarm of overlarge voltage difference, and at the moment, the MOS of the main loop of the BMS is disconnected; the method comprises the steps of controlling a current source and an electronic load in a power supply module to output a first current, wherein the first current only passes through a pre-charging loop of the BMS, controlling the power supply module to output a second current, the second current enables the pre-charging loop to be disconnected due to overcurrent protection, controlling the electronic load in the power supply module to be disconnected and outputting the first current, receiving actual loop current data of each change process collected by a Hall sensor in a detection module by a control computer, judging whether the actual loop current data change is recovered to a small current value from the small current value to zero, determining whether faults exist in the pre-charging loop protection and recovery functions of the BMS, and entering a next test item if the protection function of the BMS is normal. The first current is a small current data, and the second current is a large current data.
S12) the control computer changes the output voltage of the voltage source in the power supply module through the PLC, so that the BMS is in a normal working state, and the current probe in the detection module collects the working power consumption current data of the BMS in the state; the control computer cuts off the output voltage of a voltage source in the power supply module through the PLC, the BMS is placed still to be in a natural dormancy state, and a current probe in the detection module collects dormancy power consumption current data of the BMS in the state; the control computer changes the output voltage of a voltage source in the power supply module through the PLC, so that the BMS is in an under-voltage sleep state, and a current probe in the detection module acquires the sleep power consumption current data of the BMS in the state; the control computer receives power consumption current data acquired by the detection module under different working states, and determines whether the power consumption of the BMS has a fault or not by comparing whether the power consumption current data are within the corresponding power consumption threshold range, if the power consumption data are within the corresponding power consumption threshold range, the power consumption of the BMS is normal, a next test item is entered, and otherwise, the power consumption of the BMS is abnormal.
S13) the control computer controls the output of the voltage source, the current source and the electronic load in the power supply module through the PLC, so that the BMS is in a sleep state; the control computer controls the current source and the electronic load to output charging current through the PLC, receives BMS power consumption current data collected by the current probe in the detection module and judges whether the BMS is activated by the charging current and is in a working state at the moment; the control computer controls the electronic load to be disconnected through the PLC, so that the BMS enters the dormant state again, the control computer sends data to the BMS through the communication module, and the control computer receives BMS power consumption current data collected by the current probe in the detection module and judges whether the BMS is activated to be in the working state by communication or not. And finishing each protection function test of the BMS.
During the test, the voltage source outputs voltage to be connected with the voltage acquisition circuit of the BMS, and simultaneously, the output voltage simulates temperature to be connected with the temperature acquisition circuit of the BMS, and the two settings are default settings in steps S1-S13.
In the charging and discharging current function and accuracy detection processes of steps S6-7 and S81-S82, after the charging and discharging current is output, once the hall sensor and BMS of the detection module detect the current, the control computer controls the PLC to turn off the current source and the electronic load to switch the charging and discharging state.
In the step S83 and S84 process of detecting the overvoltage and undervoltage protection function, once the hall sensor and BMS of the detection module detect that the current is zero, the control computer will control to turn off the current source and the electronic load, and then set the voltage to the original default state to switch the voltage state.
In the real-time read-write function detection process of step S9, the time of the control computer itself must be guaranteed to be accurate, so as to ensure the detection precision.
In the step S10 balance function detection process, since the BMS balance function is turned on, it is usually necessary that the voltage difference is within a preset range in the charging state, and the balance current flows from one section of the high voltage electric core to the adjacent low voltage electric core of the electric core, so that the electric cores need to be tested at intervals in the test process, and the odd number of the electric cores can be tested first and then the even number of the electric cores, or the even number of the electric cores can be tested first and then the odd number of the electric cores can be tested.
In the step S11, during the detection of the pre-charge circuit, the pre-charge circuit does not have over-current protection, and also has over-temperature protection, so the magnitude of the first current and the duration of the current need to be set according to the over-temperature resistor, thereby avoiding the interference of the over-temperature protection circuit.
All the steps S1-S13 can be freely added, and after the test is finished or the test is stopped due to faults, the control computer can automatically disconnect elements such as a voltage source, a current source and an electronic load, and the safety of the test system is ensured.
The control computer detects various functions of the BMS, detects voltage and current detection parameters of the BMS when the BMS normally operates, adjusts the parameters which do not meet the requirements, and writes real-time into the control computer, so that the faults of various battery management systems can be recorded in real time, and fault reasons can be conveniently searched;
in addition, various working conditions possibly encountered by the BMS in the use process are simulated through the voltage source and the current source, so that whether each circuit module of the BMS is normal or not and the protection function of the BMS under various limit working conditions are tested, and the problems of low BMS detection efficiency and low accuracy are solved; the situations of fault expansion, combustion, explosion and the like caused by over power when the electric vehicle controller has the problems of short circuit, open circuit, abnormal insulation and the like are avoided, the safety of the debugging and testing process of the electric vehicle controller is improved, the parameters of the automatic detection BMS and the quick adjustment of the electric vehicle controller are achieved, and the detection precision and efficiency are improved.
What has been described above is only a preferred embodiment of the present application, and the present invention is not limited to the above embodiment. It is to be understood that other modifications and variations directly derivable or suggested by those skilled in the art without departing from the spirit and concept of the present invention are to be considered as included within the scope of the present invention.
Claims (10)
1. A testing system based on a battery management system is characterized by comprising a control computer, a PLC, a communication module, a power supply module, a detection module, a BMS and a jig, wherein the BMS is installed on the jig and is respectively connected with the power supply module and the detection module through the jig;
the power supply module is used for providing adjustable voltage and current for the BMS, and the detection module is used for detecting electric data of the BMS in different working states; the control computer is used for determining whether the BMS meets a preset test condition according to the electric data fed back by the detection module and/or the electric data fed back by the BMS, and the electric data comprises voltage data and current data; and the control computer is also used for determining whether the BMS is abnormal or not according to information fed back by the BMS, wherein the information comprises the working state of the control computer, correction data and real-time.
2. The battery management system based test system of claim 1, wherein the power module comprises a voltage source, a current source, and an electronic load; the voltage source is used for supplying power to the BMS and providing adjustable voltage; the current source is used for providing adjustable current for the BMS, and the adjustable current comprises adjustable charging and discharging current; the electronic load is used for providing a load for the BMS main loop.
3. The battery management system based test system of claim 1, wherein the detection module comprises a hall sensor, a voltage collector, a current probe and a temperature sensor; the Hall sensor is connected to a charge-discharge loop of the BMS and used for detecting charge-discharge current data of the charge-discharge loop; the voltage collector is used for detecting voltage data of the BMS; the current probe is connected to a power supply voltage source loop of the BMS and used for detecting balance current data and power consumption current data of the power supply voltage source loop; the temperature sensor is used for detecting the ambient temperature of the BMS.
4. A test method based on a battery management system is characterized in that the test method comprises a no-load detection method, an accuracy detection method, a protection function detection method and a power consumption detection method of a BMS, wherein:
the no-load detection method comprises the following steps:
the control computer controls a power supply module to output power supply voltage to enable the BMS to enter a working state, the BMS replies the working state of the control computer to the control computer, the control computer compares the working state of the control computer with preset BMS no-load state data, if the error is within a threshold range, other test items are entered, and if the error is not within the threshold range, the BMS is abnormal;
the precision detection method comprises the following steps:
the BMS replies first voltage data acquired by the BMS to the control computer, the control computer receives second voltage data acquired by the detection module and determines whether the voltage acquisition precision of the BMS is within a voltage threshold range by comparing the first voltage data with the second voltage data, if so, other test items are entered when the test is not finished, otherwise, the voltage acquisition circuit and the voltage precision of the BMS have faults;
the protection function detection method comprises the following steps:
the control computer changes the output voltage and current of the power supply module to enable the output voltage and current to exceed the protection threshold of the BMS; the BMS replies first current data acquired by the BMS to the control computer, the control computer receives actual current data of a loop acquired by a detection module and compares whether the two current data meet a test preset condition or not so as to determine whether faults exist in an overcurrent protection function and an undervoltage/overvoltage protection function of the BMS, if the test preset condition is met, the protection function of the BMS is normal, if the test is not completed, other test items are entered, otherwise, the protection function of the BMS is abnormal;
the power consumption detection method comprises the following steps:
the control computer changes the output voltage and current of the power supply module to enable the BMS to be in different working states including a normal working state, a dormant state and an under-voltage dormant state; the control computer receives power consumption current data acquired by the detection module under different working states, and compares whether the power consumption current data are in the corresponding power consumption threshold value range, so as to determine whether the power consumption of the BMS has faults or not, if the power consumption data are in the corresponding power consumption threshold value range, the power consumption of the BMS is normal, when the test is not completed, other test items are entered, otherwise, the power consumption of the BMS is abnormal.
5. The battery management system-based testing method of claim 4, wherein the accuracy detection method further comprises:
the control computer controls the power supply module to output power supply voltage, receives the environmental temperature collected by the detection module and outputs a corresponding voltage value according to a corresponding relation table of the voltage and the temperature; changing the output voltage of the power supply module to the voltage value, wherein the output voltage is connected with a temperature acquisition circuit of the BMS; and the control computer receives third voltage data replied by the BMS and outputs a corresponding temperature value according to the corresponding relation table of the voltage and the temperature, if the deviation between the temperature value and the ambient temperature does not exceed the temperature threshold range, other test items are entered when the test is not finished, and otherwise, a temperature acquisition circuit and temperature precision of the BMS have faults.
6. The battery management system-based test method of claim 4, wherein the protection function detection method further comprises:
the control computer changes the output voltage of the power supply module, so that the BMS has an alarm of overlarge voltage difference and controls the power supply module to output a first current, the first current satisfies a condition that the power supply module is controlled to output a second current only through a pre-charge loop of the BMS, the second current is satisfied to ensure that the pre-charging loop is disconnected due to overcurrent protection, the electronic load in the power supply module is controlled to be disconnected, and the first current is output, the control computer receives the loop actual current data of each change process collected by the detection module, and judging whether the change of the actual current data of the loop is recovered to the preset current value from the preset current value to zero or not, therefore, whether faults exist in the protection and recovery functions of the pre-charging loop of the BMS is determined, and if the protection functions of the BMS are normal, other test items are entered when the test is not completed.
7. The battery management system-based testing method according to any one of claims 4 to 6, wherein the testing method further comprises a BMS correction detection method comprising:
the control computer controls a power supply module to output power supply voltage and sends a parameter correction signal corresponding to the power supply voltage to the BMS, wherein the parameter correction signal is used for correcting a controller parameter of the BMS to a preset value; if the deviation between the correction data received by the control computer and replied by the BMS and the preset value does not exceed the correction threshold, entering other test items when the test is not completed, otherwise, the BMS is abnormal.
8. The battery management system-based testing method according to any one of claims 4 to 6, wherein the testing method further comprises a real-time read-write function detection method of the BMS, comprising:
the control computer reads the time data of the computer, converts the time data into a communication message and sends the communication message to the BMS, and the BMS writes first real-time; the control computer controls the power supply module to cut off power supply voltage, so that the BMS enters a power-off state, and after standing for a preset time, the BMS is supplied with power again, so that the BMS is charged and activated; if the difference between the second real-time received by the control computer and the first real-time replied by the BMS meets the preset time range value, entering other test items when the test is not finished, otherwise, the real-time read-write function of the BMS is abnormal.
9. The battery management system-based testing method according to any one of claims 4 to 6, wherein the testing method further comprises a balancing function detection method of the BMS, comprising:
the method comprises the steps that a control computer changes output current of a power supply module, the BMS enters a charging state, output voltage of the power supply module is changed to meet balancing conditions of the BMS, and a detection module collects first balancing current data in a balancing mode; changing the output voltage of the power supply module again to enable the BMS to exit the equalization mode, wherein the detection module collects second equalization current data exiting the equalization mode; and if the control computer determines that the first equalizing current data and the second equalizing current data both meet the preset equalizing condition, entering other test items when the test is not completed, otherwise, the equalizing function of the BMS is abnormal.
10. The battery management system-based test method of any one of claims 4-6, further comprising:
the control computer controls the power supply module to output power supply voltage to enable the BMS to enter a working state and controls the charging or discharging MOS tube of the BMS to be opened; if the actual current data of the loop collected by the detection module and the second current data replied by the BMS are both zero, entering other test items when the test is not completed, otherwise, the BMS cannot enter a sleep state.
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