CN108819732B - BMS hardware function test system - Google Patents
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- CN108819732B CN108819732B CN201810399240.1A CN201810399240A CN108819732B CN 108819732 B CN108819732 B CN 108819732B CN 201810399240 A CN201810399240 A CN 201810399240A CN 108819732 B CN108819732 B CN 108819732B
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- 238000012360 testing method Methods 0.000 title claims abstract description 45
- 241000234295 Musa Species 0.000 claims description 16
- 235000018290 Musa x paradisiaca Nutrition 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
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- 238000010586 diagram Methods 0.000 description 12
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- 238000000034 method Methods 0.000 description 3
- 238000012795 verification Methods 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000009191 jumping Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
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- RVCKCEDKBVEEHL-UHFFFAOYSA-N 2,3,4,5,6-pentachlorobenzyl alcohol Chemical compound OCC1=C(Cl)C(Cl)=C(Cl)C(Cl)=C1Cl RVCKCEDKBVEEHL-UHFFFAOYSA-N 0.000 description 1
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- 239000003990 capacitor Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R35/00—Testing or calibrating of apparatus covered by the other groups of this subclass
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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Abstract
The invention discloses a BMS hardware function test system, which comprises a BMU load box, a CSC load box, a shell and a wire harness, wherein the BMU load box is connected with the CSC load box; the BMU load box is provided with a power interface, a CAN interface, an external load interface and a signal input interface; the CSC load box is connected with 2 CSCs, two 12s battery modules and the NTC interface through a wire harness; indicating that the silk screen of the test is positioned on the upper surface of the shell; the BMU load box is connected with the BMU through a wire harness; the power interface is connected with a direct current power supply; the CAN interface comprises 1 male connector and 1 female connector, and is respectively connected to 60 omega and 120 omega resistors and unmatched resistors through a three-terminal mechanical switch with an impedance matching function; the external load interface is connected with an external load. The invention can realize the connection with other BMS controllers with consistent architecture and different interfaces by changing one end of the wiring harness, thereby realizing the change of the wiring harness without changing the load box.
Description
Technical Field
The invention belongs to the field of new energy automobiles, and particularly relates to a BMS hardware function testing system.
Background
For a long time, the specifications and sizes of power batteries, especially single battery cores, are not uniform, which is always one of the main contradictions between the cooperation of a host factory and a power battery enterprise, and is also a significant obstacle for preventing the further development of the power battery industry in China, thus bringing great pressure to both the host factory and the battery factory. With the host factory OEM's purchase of battery modules from different channels of the BMS, coupled with the severe constraints of the overall vehicle time node, these are translated into stress for the BMS provider.
The battery Management system bms (battery Management system) is a system for managing batteries, and is mainly used for intelligently managing and maintaining each battery unit, preventing overcharge and overdischarge of the batteries, prolonging the service life of the batteries, and monitoring the states of the batteries. The battery management system is tightly combined with a power battery of an electric automobile, the voltage, the current and the temperature of the battery are detected in real time through a sensor, meanwhile, leakage detection, thermal management, battery balance management and alarm reminding are carried out, the residual capacity (SOC) and the discharge power are calculated, the battery degradation degree (SOH) and the state of the residual capacity (SOC) are reported, the maximum output power is controlled through an algorithm according to the voltage, the current and the temperature of the battery to obtain the maximum driving mileage, the charger is controlled through the algorithm to charge the optimal current, and real-time communication is carried out through a CAN bus interface, a vehicle-mounted main controller, a motor controller, an energy control system, a vehicle-mounted display system and the like.
At present, more and more battery enterprises in China adopt the German automobile industry Association (VDA) standard to produce a new generation of battery cell products, and the battery cell products are mainly matched with the field of new energy passenger vehicles. CSC single battery management unit: the module side/internal installation realizes the functions of single voltage acquisition and voltage backup and temperature acquisition. The main chips are LT6804 and 6811, which are transmitted out through CAN bus or isoSPI and other communication modes. BMU battery pack management unit: the BMU realizes the functions of insulation impedance measurement and HVIL (high voltage interlock connector) detection, and supervises a plurality of CSC single battery management units.
Considering the VDA standard module popular in the market at present, it is most reasonable that the BMS architecture adopts "one master multiple slave (1 BMU + multiple CSCs)", and in addition, under the condition that the development and test of the BMU and the CSCs are not completely synchronous, the test system adopts 1 BMU load box and 1 CSC test load box (24 strings of batteries, which can be connected with 2 CSCs) to be most suitable.
At present, the traditional mode of the function test platform of a plurality of BMS companies is still reserved:
1. during testing, bare copper wires at one end of a disordered wire harness touch each other, so that the test result is abnormal, even the controllers are burnt out due to mutual short circuit;
2. an engineer needs to search for the controller interface definition to search for corresponding wire harnesses one by one;
3. the external load cannot be firmly and neatly placed and cannot be simply plugged and pulled out;
4. a layman cannot preliminarily judge whether the hardware function of the controller operates normally;
5. when bad parts of a client are repaired, a test platform needs to be built again.
In view of the above, the present invention provides a simple, fast and reliable method for testing hardware functions of BMS.
Disclosure of Invention
1. The invention aims to provide a novel method.
In order to solve the problems, the invention provides a BMS hardware function testing system.
2. The technical scheme adopted by the invention is disclosed.
The invention provides a BMS hardware function test system which comprises a BMU load box, a CSC load box, a shell and a wiring harness, wherein the BMU load box is connected with the CSC load box;
the BMU load box is provided with a power interface, a CAN interface, an external load interface and a signal input interface;
the CSC load box is connected with 2 CSCs, two 12s battery modules and the NTC interface through a wire harness;
indicating that the silk screen of the test is positioned on the upper surface of the shell;
the BMU load box is connected with the BMU through a wire harness;
the power interface is connected with a national standard power supply;
the CAN interface comprises 1 male connector and 1 female connector DB9 interface, and is respectively connected with 60 omega and 120 omega resistors and unmatched resistors through a three-terminal mechanical switch with an impedance matching function;
the external load interface is connected with an external load;
the signal input interface is respectively connected with an external high-side driving circuit and a temperature signal input circuit;
a plurality of equivalent circuits equivalent to the external loads are arranged in the BMU load box, and a switch for selecting the size of the loads, a banana interface and a status indicator lamp are further arranged.
Furthermore, the BMU load box is connected with a wiring harness at one end through Molex500762-0481 and Molex 500762-0483, and is connected with a banana interface at the other end.
Furthermore, the 1A-1H pin interface of Molex500762-0481 is respectively connected with the high-side driving circuit branch, the high-side driving circuit branch is externally connected with 1 two-end mechanical switch in series connection with 1 10K resistor and 1 red LED to be connected with the high-side driving chip, and the high-side driving connected mechanical switch closed state indicator lamp is turned on.
Furthermore, pins 1J, 1K and 2A-2K of the Molex500762-0481 are respectively connected with a temperature signal input interface, and externally connected with 1 mechanical switch at two ends and 1 resistor 10K which are connected in series, so as to measure the NTC thermistor connected to the BMU load box.
Furthermore, pins 2L, 2M, 3L, 3M, 4L and 4M of the Molex 500762-; the positive pole of the parallel branch is connected with a parallel branch circuit and then grounded, the parallel branch circuit is formed by connecting a two-end mechanical switch and a 100k series branch circuit in series, and connecting a two-end mechanical switch and a 10M resistor in series and then connecting the two-end mechanical switch and the 10M resistor in parallel, wherein the parallel branch circuit is connected and insulated by connecting a switch in parallel.
Furthermore, the 1G-1H interface of the Molex 500762-.
Furthermore, the shell is a metal plate/plastic/aluminum shell, and an interface indicating label is arranged on the shell.
3. The technical effect produced by the invention.
The system provided by the invention can realize connection with other BMS controllers with consistent architectures and different interfaces by changing one end of the wiring harness, so that the load box is not changed, the wiring harness is changed, the cost is reduced on the one hand, and the system is universal on the other hand.
Drawings
FIG. 1 is a logical block diagram of the present invention, wherein a thick line represents a wiring harness; thin wires, representing connection to banana sockets on the housing (pluggable).
Fig. 2 is a schematic diagram of the CSC load box of the present invention.
Fig. 3 is a schematic diagram of a BMU load box of the present invention.
FIG. 4 is a signal diagram of Molex500762-0481 pin according to the present invention.
FIG. 5 is a schematic diagram of a high-side driver circuit of the Molex500762-0481 pin of the present invention.
FIG. 6 is a schematic diagram of temperature signals of Molex500762-0481 pin of the present invention.
FIG. 7 is a signal diagram of the Molex 500762-0483 pin of the present invention.
Fig. 8 is a schematic view showing the connection of the wire harness of the present invention.
FIG. 9 is a schematic diagram of the CAN interface connection of the present invention.
Fig. 10 is a schematic diagram of the connection of the CSC load box of the present invention.
Fig. 11 is a schematic diagram of the CSC harness connection NCT and the battery pack connection according to the present invention.
FIG. 12 is a flow chart of the testing process of the present invention.
Detailed Description
Example 1
As shown in fig. 1, the BMS hardware function testing system according to the present invention comprises a BMU load box, a CSC load box, a housing, and a wire harness;
a national standard power supply interface, a CAN interface, an external load interface and a signal input interface are arranged on the BMU load box; the CSC load box is connected with 2 CSCs, two 12s battery modules and the NTC interface through a wire harness; indicating that the silk screen of the test is positioned on the upper surface of the shell; the BMU load box is connected with the BMU through a wire harness; the power interface is connected with a national standard power supply; the CAN interface comprises 1 male connector and 1 female connector DB9 interface, and is respectively connected with 60 omega and 120 omega resistors and unmatched resistors through a three-terminal mechanical switch with an impedance matching function; the external load interface is connected with an external load; the signal input interface is provided with a banana interface and is respectively connected with an external high-side driving circuit and a temperature signal input circuit; the BMU load box is internally provided with a plurality of equivalent circuits equivalent to the external load, a switch for selecting the size of the load to enable the load to be equivalent to the external load, and a status indicator lamp.
As shown in fig. 2-7, the BMU load box is connected with the wiring harness through Molex500762-0481 and Molex 500762-0483, one end of the BMU load box is connected with the wiring harness, the pins at the other end of the BMU load box are respectively connected with the banana interface, the 1A-1H pin interface of the Molex500762-0481 is respectively connected with the high-side driving circuit branch, the high-side driving circuit branch is externally connected with 1 two-end mechanical switch connected in series with 1 10K resistor and 1 red LED to be connected with the high-side driving chip, and the high-side driving connected mechanical switch closed state indicator light is turned on. Pins 1J, 1K and 2A-2K of the Molex500762-0481 are respectively connected with a temperature signal input banana interface, and externally connected with 1 mechanical switch at two ends and 1 10K resistor in series to measure an NTC thermistor connected to a BMU load box; pins 2L, 2M, 3L, 3M, 4L and 4M of the Molex 500762-; the positive pole of the parallel branch is connected with a parallel branch and then grounded, the parallel branch is a branch which is connected in parallel after a two-end mechanical switch and a 100k series branch are connected in series, and a two-end mechanical switch and a 10M resistor are connected in series, wherein the parallel branch is connected and insulated by connecting a switch in parallel; the 3A-3D pin of the Molex500762-0481 is connected with a signal input interface; the 3G-3K pin of the Molex500762-0481 is connected with a signal output interface; the 3E-3F pin of the Molex500762-0481 is connected with the PWM signal input interface. The 4A-4K pin of the Molex500762-0481 is connected with a relay power switch. The 4J-4K pin of the Molex500762-0481 is connected with a jumper wire. The shell is a metal plate/plastic shell, and an interface label is arranged on the shell.
As shown in FIG. 7, the 1A-1D of Molex 500762-0483 is connected with E-Lock; 1E is connected with KL15, a pin 1F is connected with a variable capacitor CP, a pin 1J-1K is connected with pins HVIL _ H and HVIL _ L of a high-voltage interlocking connector, 1L is connected with a relay power switch, and 1M, 2L and 2M are respectively connected with the ground; IM is connected to the pin 3A, IP is connected to the pin 3B, iso _ SPI communication interface is connected to the pin 3C, and CAN male head and CAN female head are connected to the pins 4C-4F respectively. The 1G-1H interface of the Molex 500762-0483 is connected with a charging gun and a charging socket connector on a vehicle through one end of a national standard charging interface, and the other end of the charging socket connector is integrated to a BMU load box through a plurality of resistors and two-end mechanical switches.
The test system provided by the invention consists of a BMU load box, a CSC load box and a wiring harness. 4 PCBAs are integrated in the BMU load box and the CSC load box, and elements such as banana sockets and mechanical switches are electrically connected through the PCBs, so that the device is firm and reliable;
the panel is provided with an interface indicating label and a function indicating lamp for displaying (the function can be closed through a corresponding mechanical switch, so that the measurement of the actual power consumption of the product, particularly the measurement of quiescent current, is avoided);
the high-voltage area and the low-voltage area are physically separated, and the manual switch of the high-voltage area is insulated, so that the personal safety of operators is ensured; the CAN interface is compatible with a DB9 male connector and a female connector, and is further provided with 60 omega and 120 omega impedance matching switches, so that the CAN interface CAN be plugged and used no matter how the external CAN tool interface is; the peripheral interface can be selectively connected to a real load or an equivalent load through a mechanical switch, so that the tool box can be used for internal function test and can also be used for third-party mechanism test and finished vehicle field test;
the power supply interface is protected by a fuse, so that the condition that the BMS controller is burnt down due to short circuit of the BMS is avoided; one end of the wire harness is connected with the system, the other end of the wire harness is connected with the BMS controller, the length of the wire harness is 1.7m, most of test item requirements of EMC tests are met, and the wire harness connected with the BMS can be modified to be suitable for other products with the same framework;
the load box comprises PCBA (PCB, banana socket, mechanical switch, fuse, LED, resistor and the like form electrical connection), sheet metal/plastic shell (with silk screen printing and indication function) and wiring harness.
The test system provided by the invention is a medium of a tested controller, equipment, a load and the like, and comprises an external interface (CAN, a power supply, a signal input/output, an NTC and the like).
As shown in fig. 5, the high-side driver is externally connected with 1 two-end mechanical switch, 1 10K resistor and 1 red LED in series, if the high-side driver works and the mechanical switch is closed, the lamp is turned on, thus achieving the function of primarily verifying the circuit; if the mechanical switch is disconnected, the circuit performance can be fully verified through the corresponding banana socket and the external connection of a real relay.
As shown in fig. 6, the temperature input interface is externally connected with 1 two-end mechanical switch and 1 10K resistor, and the function of preliminary verification can be realized by closing the mechanical switches and checking and acquiring corresponding temperature values through an upper computer; when the temperature acquisition precision is verified, the mechanical switch can be disconnected, and the NTC used on the external real Pack or the NTC used in the battery module can be connected through the corresponding banana socket.
According to the national standard charging interface, according to the interface schematic diagram of the GBT 18487.1-2015 electric vehicle conduction charging system-part 1-general requirements, a charging socket connecting port on a charging gun and a vehicle is integrated into the testing system through a plurality of resistors and two-end mechanical switches, so that the testing system is a good verification mode in a BMS laboratory of a company without charging pile and other conditions.
As shown in fig. 9, the CAN interface schematic diagram is provided with 1 male connector and 1 female connector for adapting to connection in different situations, and is provided with an impedance matching function (no matching resistor, 60 Ω, 120 Ω) through 1 three-terminal mechanical switch.
And simulating short power supply faults of each interface, and connecting the banana socket corresponding to the KL30 or KL31 to the banana socket corresponding to other interfaces through the short wires with the banana plugs at two ends to realize short power supply fault verification.
As shown in fig. 12, the general operational flow is as follows:
7, disconnecting the corresponding mechanical switch, and externally connecting a real or simulated external load to check the information of the upper computer;
and 8, ending the test.
Each test system consists of a load box and a wire harness.
1. Load box
a. 4 PCBAs are integrated inside, and banana sockets, mechanical switches and other elements are electrically connected through the PCBs, so that the device is firm and reliable;
b. the panel is provided with an instruction label and a function indicator lamp for display (the function can be closed through a corresponding mechanical switch, so that the measurement of the actual power consumption of the product is prevented from being influenced, particularly the measurement of static current);
c. the high-voltage area and the low-voltage area are physically separated, and the manual switch in the high-voltage area is insulated, so that the personal safety of operators is ensured;
d. the CAN interface is compatible with a male connector and a female connector, and is further provided with impedance matching switches of 60 omega and 120 omega, so that the CAN interface CAN be plugged and used no matter how the external CAN tool interface is;
e. the external interface can be selectively connected to a real load or an equivalent load through a mechanical switch, so that the tool box can be used for internal function test and can also be applied to field test of a third party mechanism and a whole vehicle;
f. the power supply interface is protected by a fuse, so that the burn-out caused by short circuit of the BMS controller is avoided;
2. wire harness
One end of the wire harness is connected with the load box, the other end of the wire harness is connected with the BMS controller, the length of the wire harness is 1.7m, most of test item requirements of EMC tests are met, and the wire harness connected with the BMS can be modified to be suitable for other products with the same framework;
the above embodiments are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.
Claims (7)
1. A BMS hardware function test system which characterized in that: comprises a BMU load box, a CSC load box, a shell and a wire harness;
the BMU load box is provided with a power interface, a CAN interface, an external load interface and a signal input interface;
the CSC load box is connected with 2 CSCs, two 12s battery modules and the NTC interface through a wire harness;
indicating that the silk screen of the test is positioned on the upper surface of the shell;
the BMU load box is connected with the BMU through a wire harness;
the power interface is connected with a national standard power supply;
the CAN interface comprises 1 male connector and 1 female connector, and is respectively connected with 60 omega and 120 omega resistors and unmatched resistors through a three-terminal mechanical switch with an impedance matching function;
the external load interface is connected with an external load;
the signal input interface is respectively connected with an external high-side driving circuit and a temperature signal input circuit;
the BMU load box is internally provided with a plurality of equivalent circuits equivalent to the external load, and is also provided with a switch for selecting the size of the load to enable the load to be equivalent to the external load, a banana interface and a status indicator lamp.
2. The BMS hardware functionality testing system according to claim 1, characterized in that: the BMU load box is connected with a wiring harness through Molex500762-0481 and Molex 500762-0483 at one end, and the pins at the other end test banana interfaces respectively.
3. The BMS hardware functionality testing system according to claim 2, characterized in that: molex500762 supplyes 0481's 1A-1H pin interface connects high limit drive circuit branch respectively, and high limit drive circuit branch external 1 both ends mechanical switch, and the mechanical switch closure state pilot lamp that connects of high limit drive lights up for the instruction of functional status connects high limit drive chip with 1 red LED connection of 1K resistance in series.
4. The BMS hardware functionality testing system according to claim 2, characterized in that: the pins 1J, 1K and 2A-2K of the Molex500762-0481 are respectively connected with a temperature signal input interface, and externally connected with 1 mechanical switch at two ends and 1 10K resistor in series to measure an NTC thermistor connected to a BMU load box.
5. The BMS hardware functionality testing system according to claim 2, characterized in that: pins 2L, 2M, 3L, 3M, 4L and 4M of the Molex 500762-; the positive pole is connected with a parallel branch circuit and then grounded, the parallel branch circuit comprises a two-end mechanical switch and a 100k series branch circuit, the two-end mechanical switch and a 10M resistor are connected in series to form the parallel branch circuit, and the parallel branch circuit is connected and insulated by connecting a switch in parallel.
6. The BMS hardware functionality testing system according to claim 2, characterized in that: the 1G-1H interface of the Molex 500762-0483 is connected with a charging gun and a charging socket connector on a vehicle through one end of a national standard charging interface, and the other end of the charging socket connector is integrated to a BMU load box through a plurality of resistors and two-end mechanical switches.
7. The BMS hardware functionality testing system according to claim 1, characterized in that: the shell is a metal plate/plastic/aluminum shell, and an interface indicating label is arranged on the shell.
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| CN109581128A (en) * | 2018-12-28 | 2019-04-05 | 蜂巢能源科技有限公司 | Battery pack charge function test macro and method |
| CN110703071B (en) * | 2019-09-27 | 2021-12-14 | 福建星云电子股份有限公司 | BMS circuit testing system and testing method |
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| CN102788914B (en) * | 2011-05-20 | 2015-10-28 | 北汽福田汽车股份有限公司 | Battery analogue load circuit and BMS electronic hardware test macro |
| KR101838470B1 (en) * | 2011-10-11 | 2018-03-15 | 에스케이이노베이션 주식회사 | Battery test system |
| CN103149539A (en) * | 2013-03-06 | 2013-06-12 | 中国人民解放军国防科学技术大学 | Multifunctional power source test system |
| CN104808078A (en) * | 2014-01-29 | 2015-07-29 | 陕西汽车集团有限责任公司 | Test system for battery management system function test |
| CN205210212U (en) * | 2015-12-07 | 2016-05-04 | 武汉力神动力电池系统科技有限公司 | Battery management system's test system |
| CN106019002B (en) * | 2016-05-13 | 2019-02-05 | 合肥国轩高科动力能源有限公司 | Verification test platform for battery management system and test method thereof |
| CN106199436A (en) * | 2016-06-24 | 2016-12-07 | 安徽长城输送机械制造有限公司 | A kind of FCS functional check-out set of cell management system of electric automobile |
| CN106291427B (en) * | 2016-08-05 | 2019-10-18 | 合肥工业大学 | Battery management system BMS fault self-diagnosis function test platform and test method |
| CN106371024A (en) * | 2016-08-19 | 2017-02-01 | 重庆长安汽车股份有限公司 | Battery management system testing apparatus |
| CN207232755U (en) * | 2017-09-15 | 2018-04-13 | 北京智行鸿远汽车有限公司 | A kind of new energy vehicle BMS charging CAN communication test systems with real load |
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