CN213183232U - Intelligent power battery module training platform for small vehicle - Google Patents

Detailed Description

Spatially relative terms such as "above … …", "above … …", "above … …", "above", and the like, may be used herein for ease of description to describe the spatial relationship of one feature or characteristic to another feature or characteristic as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Fig. 2 shows the design of the control panel. The control panel comprises a connection relation and a circuit schematic diagram among hardware structures such as an equipment control switch, a power battery pack and a battery management system thereof. The circuit connection schematic diagram is drawn according to the functional layout, all the components and the connection relation of the circuit are shown in detail, the high-voltage circuit, the low-voltage circuit and the CAN communication circuit are visually shown, some electrical appliances in the diagram are represented by outline or characteristics, and the wires on the same path in the wiring harness are drawn together as much as possible. The charging switch, the speed regulation knob, the forward and reverse rotation switch and the like respectively control the running state of the components on the test platform, and the simulation of various working schemes can be conveniently realized. The circuit layout is scientific and reasonable, the assembly, maintenance, operation convenience and aesthetic property of the pipeline are considered, and the direct exposed part conforms to the principle of horizontal and vertical as much as possible;

firstly, an interference source and an interference source wire harness are far away from a sensitive device, the sensitive device wire harness is arranged independently, and the interference source wire harness are arranged in a vertical crossing manner (in a geometric shape) when the sensitive device wire harness needs to be close to the sensitive device;

secondly, when the wire harness is arranged, the wire harness is arranged in a manner of being attached to a metal car body as closely as possible, suspension arrangement is avoided, and interference and external radiation are reduced;

and circuit loop area and harness length of the interference source and the sensitive device are reduced as much as possible, radiation is reduced, and anti-interference capability and external radiation capability are enhanced.

The lithium battery pack comprises a Battery Management System (BMS) which is used as a main device for providing test data of the practical training platform. A lithium battery pack which is commonly used by a small vehicle of the type 60V80AH is selected, and necessary devices for improving the service performance of the battery pack and protecting the safety performance of the battery pack, such as BMS, a relay, a fuse, insulation detection and the like, are included in the lithium battery pack.

The charging system is characterized in that: the power battery pack on the practical training platform can be charged by the aid of the plug-in terminal and the charging socket. The direct charging can be realized by using external civil electricity, and the charging is more convenient and faster. The charger adopts an intelligent control system, can communicate with a battery BMS management system in real time, controls charging current and prolongs the service life of the battery.

The discharge system: the power battery pack of the practical training platform controls a discharge system to discharge through an ignition switch.

The vehicle control unit: the vehicle control unit commonly used by the small-sized automobile is selected, comprises matched upper computer software, and provides data acquisition and reading service for the tested battery pack. The parameters of the whole vehicle controller are selected as follows:

performance parameters: the model is as follows: temperature detection range (DEG C) of ZDC-VCU024C 01: -25 to +85, operating voltage (vdc): 9-36, temperature detection precision (DEG C): 1, input current (mA): 50-1500, and the working temperature (DEG C): -25 to +70, communication mode: CAN J1939, size (mm): L202W 169.5H 40.5, protection rating: IP 54.

High-voltage junction box: a common high-voltage junction box of a new energy electric vehicle is selected. The wiring harness connecting device is additionally provided with a necessary protection circuit when the whole vehicle and the power battery pack normally work, so that the normal work of the system is ensured; the problem that the whole system cannot normally operate when one device is damaged is avoided.

A touch screen: and selecting a high-configuration 15-inch touch type all-in-one machine, connecting the all-in-one machine with the vehicle controller, and displaying BMS information read by the vehicle controller, so that testers can know basic parameters, control strategies, operation information and the like of the current test battery.

A lead-acid battery: a 12V lead-acid battery commonly used on a small vehicle is selected to provide a power supply for a low-voltage system of the whole vehicle on the whole vehicle and provide a starting signal for a power battery; after the power battery is started, the power battery charges the power battery. The function on the training platform is completely consistent with that of the whole vehicle.

A relay: the model of the ohm dragon relay G2R-1-12VDC is selected.

A gun inserting seat: a new national standard vehicle end power supply end 7-hole alternating current charging socket with an electric automobile charging pile socket charging interface is selected.

A fuse: the model number of the product is RT 18-32X. The main characteristics are as follows: rated voltage is 380V-500V; rated current 32A; high-temperature resin for product material.

An emergency stop switch: in order to avoid the occurrence of dangerous accidents caused by misoperation, a set of safety device, namely an emergency stop switch, is added on the test platform. A safety state diagnosis method and an information transmission path are established, and judgment and protection can be carried out on the power battery system side. In emergency, only the emergency stop switch is pressed down to ensure safety.

The scram switch is made of Schneider and is ZB4BS 844. The main working characteristics are as follows: an emergency operation mode, a composite button contact structure and a mushroom head rotation reset protection mode; the main parameters are as follows: working voltage AC220 (V), working current 1.5(a), rated heating current 5(a), contact resistance 25(Ω), insulation resistance 25(M Ω), head protection level IP 65.

Working principle of system

Real standard platform of kart intelligent power battery module is equipped with detection experiment platform device based on safety control technique, and the device uses with electric power battery is supporting, only needs to be connected high-pressure pencil and control pencil to electric power battery and device, installs the test port on the experiment platform, can test inside monomer voltage of battery, current, temperature, status information such as heating signal. The PC terminal can also be directly opened, the test software is installed, the internal information of the battery can be read, and related alarm parameters can also be set.

Through studying new forms of energy power battery control principle, control strategy, carry out deep research to hardware and software, data acquisition unit and the control unit of BMS, develop small-size car BMS management platform, monitor the voltage, current, the temperature isoparametric value of battery, through the charge-discharge of communication information control power battery system, under safe and reliable's prerequisite, promote the performance of battery, increase of service life.

Through the research to power battery BMS, box, module, high-voltage apparatus, and connecting harness etc. develop new small-size low-speed car battery, can carry out the power matching with other multiple vehicles. A power battery performance test platform is developed, and the platform is mainly used for small intelligent power battery control principle research, battery performance index test and performance optimization.

Design of MS hardware control board and logic circuit

The BMS hardware comprises a current sensor, a temperature sensor, a controller, various control driving switches and an information communication storage module. BMS has integral type, master-slave mode, total linear formula, and the BMS design of integral type is chooseed for use according to the characteristics that the relative passenger car of small-size car battery control requirement is low to this patent.

The BMS mainly comprises a pre-charging design, a high-voltage detection design and an insulation design.

Design of precharge circuit

The working principle of the electric automobile pre-charging circuit is as follows: and when the pre-charging process is finished, the BMS opens the pre-charging relay, closes the main contactor and starts the DC/DC converter. The schematic diagram is shown in fig. 3.

High voltage detection and insulation detection module design

The high voltage insulation resistance monitoring circuit is shown in fig. 4 below. The measurement module is used for measuring the insulation resistance of the electric chassis by the positive pole and the negative pole of the high-voltage system of the electric automobile respectively; the MCU control module is used for processing the information of the insulation resistance measuring module and sending corresponding control information according to the measuring result; c, an insulation fault alarm module for warning a driver that the system detects that the electric vehicle has an insulation fault and corresponding protective measures should be taken when the system has the insulation fault; and the CAN communication module is used for outputting the insulation fault information monitored by the system to the vehicle controller so as to optimize the vehicle control strategy.

The main function of the battery management system is to detect data such as current, voltage, overcurrent, leakage current, temperature, etc. of the battery pack, and simultaneously estimate the remaining capacity of the battery and make various alarms during operation. A main program flow chart of the battery management system is designed according to the power battery safety control technology and the power battery information dynamic detection technology, as shown in fig. 5.

Each submodule measures the voltage and temperature of the single battery pack, data are reported to the master controller through the CAN bus, the master module finishes the measurement of the voltage, current, overcurrent, leakage current and other data, meanwhile, the start and stop of the heat management fan are controlled, and important data information is reported to the whole vehicle controller through the CAN bus.

The work of the training platform is mainly divided into two parts: (1) the practical training platform monitors the charging of the lithium battery pack; (2) and (5) monitoring the discharge of the power battery pack (lithium battery pack) by the training platform.

And (3) charging process: the charger provides the power for the BMS in the lithium battery pack, the BMS controls the actuation time of the charging relay in the lithium battery pack, meanwhile, the BMS transmits the working information and the control strategy of the battery pack to the vehicle control unit, and then the vehicle control unit transmits all the acquired information to the touch screen to realize man-machine conversation.

And (3) discharging: the ignition switch controls the lead-acid battery to supply power to the BMS in the lithium battery pack, the BMS controls the actuation time of a discharge relay in the lithium battery pack, meanwhile, the BMS transmits the working information and the control strategy of the lithium battery pack to the vehicle control unit, and then the vehicle control unit transmits all collected information to the touch screen to realize man-machine conversation.

The lithium battery pack is self-checked after being electrified, and the self-checking content comprises network communication state, correctness of battery pack data acquisition, insulation resistance and other conventional battery pack safety performance detection. After the self-check is passed, the BMS determines whether the charging is activated. If yes, the battery charger is firstly communicated, and after the communication is completed and no fault exists, the main relay is attracted and charged according to the national standard mode. And when a fault occurs, corresponding actions are carried out according to the battery system protection strategy. During discharging, the BMS needs to communicate with the controller, the controller sends an instruction, and the BMS receives the instruction and then controls output. In any state, the BMS can immediately disconnect the main relay as long as the BMS detects abnormal signals, electric leakage and unsafe signals, so that the safety is ensured.

Introduction to working procedure

1. The training platform is powered on, and a power supply is mainly provided for a touch screen (an all-in-one touch computer).

2. When the power battery pack is subjected to a discharge test, an ignition switch on the rack is turned on, and an ignition signal is provided for a BMS of the power battery pack through a lead-acid battery.

3. And BMS self-checking, wherein after the BMS self-checking passes and no fault is determined, the discharging relay is actuated to allow the power battery pack to discharge outwards.

4. The discharge power resistor starts operating.

5. The vehicle control unit collects BMS operation information through a communication line and transmits the data to upper computer software of the touch screen, and testers can master the discharge process, the battery pack discharge curve, alarm information and various control strategies of the power battery pack at any time through the all-in-one touch computer.

6. When the power battery pack needs to be charged, the ignition switch does not need to be turned on, because the BMS power supply signal at the moment is sent by the charger.

7. When the charger self-check is passed, a 12V power signal is output to supply power to the BMS, the BMS is firstly subjected to self-check after being electrified, an internal relay is attracted after the self-check is passed, a request is sent to the charger through a communication line, the charger can judge after receiving the signal, and after the judgment is qualified, a large current is output to charge the power battery pack.

8. The vehicle control unit collects BMS operation information through a communication line, monitors the whole charging process, and transmits data to upper computer software of the touch screen, so that testers can know the charging process and working state of the system, the charging curve of the power battery pack, the overcharge protection information of the battery, control strategies and the like.

The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, a plurality of modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.