DP9830 Battery Pack EOL Integrated Test System
dp9830-battery-pack-eol-integrated-test-system
Overview
DP9830 Battery Pack EOL Integrated Test System is a test system designed for lithium-ion battery assembly, it tests and verifies the potential failures and safety issues during the battery pack assembly process to ensure the safety and reliability of the products shipped. The system caters to the testing requirements of various batteries and features an one-stop operation, it enables both automatic and manual testing, saves test data in real time, and immediately halts testing after a single test failure to protect the battery pack. The test content includes module OCV, cell voltage, cell voltage difference, AC resistance, AC and DC withstand voltage, insulation impedance, equipotential test, cell temperature, cell temperature difference, etc. Unlike the traditional integration methods, our company’s equipment adopts a modular design, allowing for the selection of corresponding test modules based on specific testing requirements.
Feature
- High test efficiency
Implement intelligent automation for software operations, detailing the parameters to reduce the need for operators and improve testing efficiency
- Scalable functionality
Strong compatibility of equipment, can meet the power / energy storage modules, packages and other different test requirements; add the corresponding functions according to the test requirements
- High precision
Integration of high-precision instrumentation for accurate and reliable test results; suitable for production workshops and R & D testing
- Support BMS communication
The software supports the analysis of various BMS communication protocols, and can be customized and developed to test functions and projects.
1.Stand-alone EOL static test
- Accurate test of total voltage and resistance
- Voltage withstand and insulation test
- BMS system test
- CAN communication test
- Program burning
- Relay test
2.Seamless MES
The DP9830 battery pack EOL integrated test system has powerful test data management functions. It can be seamlessly connected with MES system to upload test data and test reports, retrieve and query test data, and monitor the operation status of the test line in real time. This helps to enhance the level of production line automation and improve efficiency.
Application
- Energy storageenterprises
- Automated productionlines
- Energystorage power supply
- Newenergy vehicle enterprises
- Powerbattery, Pack manufacturers
Specification
| Specification parameters | |||
| Indicator name | Parametric indicators | Notes | |
| Number of equipment channels | 1 channel | ||
| Operation mode | Single channel | ||
| Power Supply | 220V AC | ||
| Operating environment | Temperature :10~40℃;
Humidity :20%~75% |
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| Insulation withstand voltage test point | 2 points | 2-channel high voltage test (positive and negative) to case | |
| Number of insulation test connections | 2-channel | 2-channel insulation test (positive and negative) to case | |
| Number of withstanding voltage test connections | 2-channel | ||
| Max output voltage for AC withstand voltage | AC 5KV | ||
| Max output voltage for DC withstand voltage | DC 6KV | ||
|
Insulation test |
Voltage | 0. 500KV-3.000KV | ±(3%set points + 5V) |
| Measurement range | 100K ~99GΩ | ||
|
Mode display |
100 KΩ ~ 999KΩ; 1.00MΩ ~ 9.99MΩ;
10.0MΩ ~ 99.9MΩ; 100MΩ ~ 999MΩ; 1.00GΩ ~ 9.99GΩ; 10GΩ ~ 99GΩ |
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| Accuracy | 2%（100KΩ≤R≤9.99GΩ）
20%（10GΩ≤R≤99GΩ） (when no swing in the test line) |
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| Voltage measurement range | 10uV-1000V | Voltage Resistance Tester | |
| Voltage measurement accuracy | 0.01% rdg+0.001% F. S | Voltage Resistance Tester | |
| Resistance measurement range | 0. 1 uΩ-3KΩ | Voltage Resistance Tester | |
| Ground conductivity meter parameters | Test current: 10-60A Resistance range 0-600mΩ | ||
| EOL System Specification | ||||||||
| Test Item | Functional Description | Notes | Software & Hardware | |||||
| Pack Total Voltage Measurement | The CAN system reads the voltage of each individual cell in the Battery Management System (BMS) and sums these values to calculate the total voltage (V1). It also reads the total voltage of the battery pack as measured by the BMS (V2), then compares V1 and V2 with the actual measured total voltage of the battery pack. This process determines whether the voltage values and the accuracy of the measurements fall within the normal range. | Voltage Resistance Tester, CAN, Software | ||||||
| CAN Communication Test | Read the initialization information of the battery pack through CAN communication. | CAN, Software | ||||||
| Terminal Resistance Test | Use a voltmeter to measure the resistance and detect the presence of 120Ω and 60Ω resistors in each CAN circuit. This should be done through direct measurement, without any parallel connections involved. | Main CAN | Voltmeter, Software | |||||
| Ambient Temperature Comparison | Compare the temperature detected by BMS with the ambient temperature, or other functions for ambient temperature reference. | Accuracy ±1℃ | Temperature and Humidity Meter, Software | |||||
| BMS Power Supply | Provide BMS power supply | |||||||
| ACR Test | Test the AC internal resistance of the battery pack | Voltage Resistance Tester | ||||||
| Ground Conductivity Test | Test the conductive state of Pack ground wire | |||||||
| Equipotential Test | Test the resistance between the equipotential points of the packs | Equipotential Tester | ||||||
| Insulation Impedance Test | Turn off the insulation monitoring function, and use the insulation meter to test the insulation impedance between the total positive and negative terminals of the battery system, as well as between the positive and negative terminals of the charger and the case (ground) | Insulation Tester | ||||||
| Withstanding Voltage Test (Positive) | Turn off the insulation monitoring function and test the leakage current of the battery system.
1. Voltage withstand machine positive to pack positive, voltage withstand machine negative to shell leakage current I1; 2. Voltage withstand machine positive to pack negative, voltage withstand machine negative to shell leakage current I2; |
Withstanding Voltage Tester |
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Withstanding Voltage Test (Reverse) |
Turn off the insulation monitoring function, test the leakage current of the battery system
1. Voltage withstand machine negative to pack positive, voltage withstand machine positive to shell leakage current I1; 2. Voltage withstand machine negative to pack negative, voltage withstand machine positive to shell leakage current I2; |
The following conditions must be met before reversed voltage withstanding:
1.the BMS insulation test of the battery pack is not directly or indirectly connected to the shell; 2.if the BMS insulation test is indirectly connected to the shell, the voltage withstand level can only meet the DC <1500V, AC <1000V |
Withstanding Voltage Tester | |||||
| Cell voltage differential detection | Detect the maximum value and minimum value of the battery string voltage by BMS. Calculate the difference between the maximum and minimum values. | CAN, Software | ||||||
| Cell temperature differential detection | Detect the maximum and minimum temperature values from the battery pack temperature sensor through the BMS. Then, calculate the difference between these maximum and minimum values. | CAN, Software | ||||||
Dimension
