600V300A Battery Test System for Charge and Discharge Testing
System Introduction
Battery Testing System
Product introduction :
Power battery simulation test, rate test;
Cycle life testing;
Power, capacity, energy detection;
Virtual matching of power battery packs: charge-discharge curve
fitting, battery consistency detection and evaluation;
High rate charging and discharging capability detection;
Power battery, energy storage battery series module detection:
monomer voltage, monomer temperature monitoring (high voltage
equipment).
Features (some functions need to be customized):
A high-performance charge-discharge detection platform specially
developed for high-power-density battery modules (packages).
Power frequency isolation design, combined with low temperature
drift, high performance multi-channel 24-bit
ADC analog-to-digital conversion chip, the steady-state accuracy is
higher than traditional equipment.
The system has high power density, multi-channel integration and
energy recovery functions.
HMI operation, one-key intelligent automatic calibration.
A variety of BMS adaptability, support charging and discharging the
same/different port, support relay/MOSBMS scheme; support
independent CAN and RS485 communication expansion; support DBC
configuration function.
The remote control of the host computer is realized through
Ethernet, which can realize the parallel connection of channels,
support pulse and working condition simulation.
Human-computer interaction interface design, the system functions
are simple and easy to operate; support a number of custom
settings; equipped with regular calibration automatic reminder
service.
①System description
Module &PACK detection system is a high-precision charging and
discharging device specially developed for high-power battery pack
testing. It has the characteristics of high dynamic response speed,
high stable accuracy, flexible configuration of multiple channels,
etc. It supports pulse testing, cycle life testing, industrial
Situation simulation test. The system has multi-channel input and
energy recovery functions, which can save a lot of power
consumption during the charging and discharging process; it adopts
bidirectional high-frequency DC conversion topology, combined with
high-performance multi-channel 24-bit AD conversion chip, the
sampling resolution is higher than the traditional single-range
equipment.
②Practice with numbers
③System Architecture
The whole system adopts a three-layer architecture design (power
system layer, centralized monitoring layer, remote interaction
layer), and each layer is independent of each other and performs
its own duties to ensure the reliable operation of the system.
④System design
1. Strict simulation verification
Build and improve the MTALAB simulation model;
Guarantee the optimal design of each parameter index.
2. Original adaptive damping control algorithm
Effectively suppress the resonance peak generated by the LCL filter
to ensure the stability of the closed-loop system .
⑤System structure
1. Three-phase AC-DC module
Three-phase zero-line design: Adopting advanced three-phase zero-line design, through mature and
reliable three-phase bridge PFC circuit, the bus voltage is stable,
meeting the needs of fast response;
High power and low harmonics: bidirectional power factor > 0.99, low current harmonic <
5%, suitable for various harsh power grids, and the inverter is
connected to the grid reliably;
frequency isolation design: through the power frequency isolation transformer, two-way
isolation, two-way energy flow, stable and reliable;
Strong compatibility: excellent electromagnetic compatibility, the module is more
reliable and efficient.
2. Bidirectional DC-DC module
Adopt BUCK-BOOST circuit: adopt efficient and reliable BUCK-BOOST circuit to realize fast
response of charging and discharging;
High-performance LCL filter design: combined with high-performance LCL filter circuit, low ripple,
high precision, independent control of each channel, support for
channel/module parallel connection;
Meet different test requirements: The topology supports flexible transformation, and can be expanded
to be compatible with different charging and discharging ports,
zero negative pressure discharge, and meet various battery testing
needs.
Equipment Parts List
| Equipment accessories list |
| serial number | name | Remark |
| 1 | Main channel current output line | 3m long |
| 2 | Main channel voltage sampling line | 3 m long |
| 3 | The current wire is connected to the battery terminal | Line nose |
| 4 | Auxiliary channel temperature sampling line | 3 m |
| 5 | AC power cord | Cable, 3 meters long |
| 6 | network communication line | Field configuration |
Data Management and Analysis
| Data segment recording function |
| Each step has independent recording conditions, which can be set in
3 stages according to the voltage |
| database |
| Centrally manage test data with MySQL database |
| Data output method |
| EXCEL, TXT, Charts |
| Curve type |
| customizable drawing |
| Host computer communication method |
| Based on TCP/IP protocol |
| network extension |
| Based on LAN, independent network segment, IP pool is set according
to the number of devices |
| calibration | Including current and voltage calibration software |
PC System Configuration Requirements
| server |
| i5 and above processor, frequency above 2.4G, memory above 8G Windows 10 Pro System hard disk 500G or more A UPS power supply (recommended) switch |
| NEWARE software system |
| BTS 8.0.X client test control software software BTSDA8.X data analysis software |
| interface |
| network port |
System Network Deployment Diagram
The BTS battery detection chemical composition system is based on
the original office network and the working platform of the
computer equipment. It is very easy to implement, the operation is
simple, and the user can log in the system remotely through the
Internet to realize various operations on the equipment; using
network connection and SQL database, Centralized control of
multiple connected equipment cabinets, and centralized management,
analysis and statistics of all data. Figure 4is a network
deployment diagram of a BTS battery detection device.
Equipment Operating Environment Requirements
| temperature |
| range of working temperature | 25℃±10℃ (accuracy guaranteed) |
| Storage temperature range | -20℃~50℃ |
| humidity |
| Relative humidity range of working environment | ≦70% RH (no condensation) |
| Storage environment relative humidity | ≦80% RH (no condensation) |
| Protection class |
| IP20 |
Technical Specifications
| Technical Specifications |
| 1. Equipment model |
| 1. Material code | 6002n-600V300A |
| 2. Channel information |
| 1. Number of channels | Channels per rack | 2 |
| 2. Main channel | Channel Features | CC-CV constant current source and constant voltage source adopt double closed-loop structure |
| Channel control mode | Independent control |
| Channels in parallel | Support up to 4 channels in parallel, pulse and analog tests are
not supported after parallel connection |
| 3. Input indicators |
| 1. Input power | | AC380V±10% 50/60±5Hz |
| 2. Power factor | | ≥99% (full load) |
| 3. THDi _ | | ≤5% (full load) |
| 4. Input impedance | | ≥1MΩ |
| 5. Input power | | 400KW |
| 6. Input current | | 607.8 A/phase |
| 7. Overall efficiency (Max) | | 94% |
| 8. Noise | | ≤75dB |
| 9. Voltage and current detection and sampling | | Four-wire connection (same port for charging and discharging) |
| 10. Type of power control module | | IGBT |
| 11. Input power wiring | | Three-phase four-wire |
| 12. Protection | | Anti-surge, anti-islanding, over and under frequency, over and
under voltage, phase loss protection, etc. |
| 4. Function and performance indicators |
| 1. Voltage | Measurement range per channel | Charging: 0V～600V |
| Discharge: 10V～600V |
| Minimum discharge voltage | 10V |
| precision | ± 0.02 % of FS |
| Resolution | 24bit |
| 2. Current | Measurement range per channel | 1.5A～300A |
| Accuracy (Independent Range) | ± 0.05 % of FS |
| Constant voltage cut-off current | 300mA |
| Resolution | 24bit |
| 3. Power | single channel output power | 180KW |
The output power of the whole machine | 360KW |
| 4. Time | Current response time | ≤5ms |
| Current transition time | ≤10ms |
| Minimum step time | 0.1s _ _ |
| 5. Charge and discharge mode | Charge and discharge mode | Constant current charging, constant voltage charging, constant
current and constant voltage charging (smooth transition from constant
current to constant voltage, preventing current spikes and large current from
impacting the battery, protecting the battery), constant power charging |
Constant current discharge, constant voltage discharge, constant power discharge, constant resistance discharge |
| Deadline | Voltage, current, relative time, capacity, -ΔV |
| 6. Working condition simulation steps | charging mode | current, power |
| discharge mode | current, power |
| toggle | Support charging and discharging continuous switching |
| Deadline | time, line number |
| Download data volume | Maximum support for 1 million line downloads |
| 7. Pulse step | charging mode | current, power |
| discharge mode | current, power |
| Minimum pulse width | 100ms |
| number of pulses | A single pulse step can support 32 different pulses |
Continuous switching of charge and discharge | One pulse step can realize continuous switching from charge to
discharge |
| As of the conditions | Voltage, relative time |
| 8. DCIR DC internal resistance test | | Supports custom points for DCIR calculation |
| 9. Security protection | software protection | Power-down data protection |
| With offline test function |
The safety protection conditions can be set, and the settable parameters include: voltage lower limit, voltage upper limit,
current lower limit, current upper limit, delay time |
| hardware protection | Anti-reverse connection protection, over voltage protection, over current protection, over temperature protection, etc. |
| 5. Data management and analysis |
| 1. Step setting method | | Form editing |
| 2. Data record | record condition | Minimum time interval: 10ms (100ms for access to auxiliary channel) |
| Minimum voltage interval: 1.2V |
| Minimum current interval: 0.6A |
| record frequency | 100Hz (10Hz when connected to auxiliary channel) |
| 3. Database | | with MySQL database |
| 4. Data output method | | Excel , Txt |
| 5. Curve type | | Customizable plot , 4 Y axes |
| 6. Barcode scanning | | Support barcode scanning function, which can be realized by battery
barcode |
| Management and traceability of historical data |
| 6. Communication method |
| 1. Communication mode of the host computer | | Based on TCP/IP protocol |
| 2. Communication interface | | Ethernet |
3. The communication baud rate of the lower computer | | 1M bandwidth |
| 4. Host computer communication baud rate | | 10M ~ 100M adaptive |
| 5. Networking method | | Set up a local area network through switches and routers |
| 6. Communication expansion ( optional ) | | Support CAN, RS485 communication and BMS communication, with DBC configuration function |
| 7. Environmental requirements and size and weight |
| 1. Working temperature | | -10℃ ～ 40℃ (within the range of 25±10℃ , the measurement accuracy is guaranteed: the accuracy drift is 0.005% of FS/℃ ) |
| 2. Storage temperature | | -20℃~50℃ |
| 3. Relative humidity of working environment | | ≤70% RH (without condensation) |
| 4. Relative humidity of storage environment | | ≤80% RH (without condensation) |
| 5. Equipment size W*D*H | | / |
| 6. Weight | | / |
| 7. AUX auxiliary test system ( optional ) |
| 1. Temperature auxiliary channel | temperature range | Thermistor : -30 ℃ ～ 120 ℃ |
| Thermocouple : -200 ℃ ～ 260 ℃ |
| temperature accuracy | ±1℃ (within 2m of wire length) |
| temperature resolution | 0.1℃ |
| 2. Voltage auxiliary channel | voltage range | 0V ~ 5V |
| Voltage accuracy | ±0.1 % of FS |
| Voltage resolution | 0.1mV |
| 3. Introduction to AUX | It is mainly used for monitoring the temperature of the surface and
the tabs during the battery test process. The test accuracy is high, and the test data can be bound with the
main voltage and current data. At the same time, the measured temperature can be used as the
control and protection conditions of the process steps. |
