1. Functionality:
- Cycle life testing
- Capacity testing
- Charging and discharging characteristics testing
- Charging and discharging efficiency testing
- Over charging and over discharging endurance testing
- DC Internal resistance testing
- Slope discharging and impulse discharging testing
2. Main Features:
- Independent channels with configurable parameter and condition setting for each individual channel.
- Reliable and ultra-high precision testing with 0.05% accuracy.
- Precise control without overshot during CC-CV and CV-CC transition.
- Remote control of start, stop and monitoring for the equipment on any on-line computer via WLAN.
- Modular design, convenient for maintenance.
- Software system is strong enough to show friendly human-machine interface for operation.
- Four-wire output.
3. General Introduction
HYNN high accuracy battery pack test equipment PT60V100A is mainly designed for power battery pack. Designed with high accuracy, high flexibility and high performance, PT60V100A can meet all test requirements for battery pack with the range of 0-60V (Voltage), 0-100A (Current). The hardware consists of power module, main board, power module, radiator fan and etc. The main board receives control instructions from the upper computer and dispatches various control signals, such as power module for charging and discharging battery, current and voltage data acquisition module for data acquisition and automatically real time dealing, capacity calculating, data storage, real time data uploading and historical data uploading.
4. Detailed Specification:
Function Introduction: This equipment is to test battery charge, discharge and related characteristics. Each channel is completely independent. Through software programming, the operator can charge and discharge the battery with any current or voltage within testing range. Data is traceable by barcode. Data change can be monitored in real time during battery charging and discharging.
Safety protection: The equipment has functions of polarity reverse protection, abnormal voltage sampling line testing, abnormal detection and protection of current test line. When battery polarity reverse, the input and output circuit will be locked and stopped, output port warning with red light. When the voltage sampling line is powered off or the current line is in poor contact, the device will detect the abnormality and stop the test channel. With power off protection, over current protection, over voltage protection, over temperature protection, it can ensure the safety in testing.
Step processes: Support 255 steps of programming, can be customized variables in programming to achieve a variety of combinatorial testing schemes, support multi-loop nesting.
Single channel independence: Each channel has an independent programmable constant current source and constant voltage source; test step can be set independently. Reconnection after interrupt: Channel stops such as sudden power outages, communication interruptions, or other abnormalities, the system has the function of automatic connection and compulsory continuation operation.
Offline protection: When the communication between the master computer and slave computer is interrupted or abnormal, the equipment will stop the test work in time. After the problem fixed, the former test can be continued.
Capture for abnormality: Can accurately capture the detailed changes of voltage and current. For example, when the current and voltage changes are beyond testing range, equipment will automatically alarm and stop testing.
Log tracking: Log tracking function, including the testing of the entire process of operation records, abnormal records, can be used for traceability and queries.
Equipment and computer interface: The Ethernet interface between the computer and equipment can ensure the stability and real-time of remote data acquisition, and the operation of the equipment can be activated by the office network and remote monitoring workshop in real time.
Data storage and processing: The main channel can select any auxiliary temperature or voltage channel to monitor the battery temperature or voltage in real time, and synchronously display the total voltage, total current, total capacity, auxiliary channel temperature, voltage-capacity curves and data.
voltage-time curve, Curve analysis and processing: Curve analysis function. Can flexibly select the cycle that needs to be displayed, a variety of curve combinations (such as voltage, current, capacity-time; capacity-voltage cycle times- charge-discharge end voltage and etc.); Graphics can be arbitrarily moved,
horizontal/longitudinal magnified or reduced to check the voltage, current, capacity, cell voltage and other data details. Can compare one data file for different cycle data or compare several data file curves at one time.
5. Main Part Functions:
- Modular design for hardware Each channel with more than one module.
- Current sampling device uses imported alloy material, which ensures large current testing stabily.
- The current output uses the soft start mode, which avoids heat impact to the battery and the connector caused by the instantaneous output high current ripple.
- Equipment hardware control loop uses current and voltage double loop No ripple for constant current and constant voltage switching.
- The device can measure DC internal resistance and can be used to detect batteries with potential safety hazard or battery with defective connection impedance.
6. Hardware Functions:
| No. | Function | Function Introduction |
|
1 |
Charging |
Constant-current charging (CC)
The channel is output by constant current with soft start, and no current impact occurs. Constant-voltage charging (CV) The channel is output by constant voltage without limiting the output current (the output current is restrained by the maximum current value of the device’s model). CCCV charging Restrain the output of voltage and current at the same time, and current hardware with soft start. No impact voltage and current during CC-CV transition. |
|
2 |
Discharging |
Constant-current discharging (CD)
The channel is output by constant current with soft start, and no current impact occurs. Constant-power discharging (CP) The channel is in constant power discharge mode, and the channel adjusts the current in real time according to the voltage of the battery port. |
| 3 | Standing (Rest) | Current circuit is cut off, without impact on data acquisition. |
| 4 | DC Internal
Resistance |
The testing process for DC internal resistance can be set as per
different requirements. |
| 5 | Cycle | Cycle test is supported. |
| 6 | Stop | Channel stopped completely
The circuit of the battery and the machine are completely cut off. |
7.Software Functions:
| No. | Function | Function Introduction |
|
1 |
Judgment |
Voltage Current
Time: 1～9999min/STEP Capacity DCIR DCIR |
| Support steps: STOP, NEXT STEP，GOTO, LOOP. | ||
|
2 |
Constraint conditions for skip |
Time restriction
Initial voltage cut, overcharge voltage restriction, over-discharge voltage restriction Current and current stage restriction Capacity restriction Test cycle times restriction DCIR restriction |
| 3 | Barcode scanning | Support barcode start and bind with test data |
| 4 | Data statistics | Support charge-discharge data to selection for statistical tabulation |
8. Strengths:
- High output accuracy: Current sampling device uses imported alloy material, which ensures large current testing stably. Use 16 bit ADC/DAC unit, accuracy is higher than 05%.
- Safety protection function: equipment channel has multi-channel signal acquisition module, real-time monitoring the voltage sampling line and the current Stop testing and alarming at abnormalities, to ensure testing safely.
- Battery polarity reverse protection: When battery polarity reverse, the input and output circuit will be locked and stopped, output port warning with red
- CCCV charging: CCCV transit with no voltage and current impact during charging. It can effectively prevent the PCB protection action and secondary protection action caused by the peak current heat concentration and the islanding effect or overshoot caused by polar dust or micro-short circuit.
- Current start: the charging and discharging step starts with soft start, with no current
- DC internal resistance testing: with high testing precision, the test provides strong evidence for battery pack assembly.
8. Product Specifications:
| No. | Item Name | PT60V100A | |
| 1 | Channel numbers | 2CH (2 Channels/Cabinet) | |
| 2 | Channel action
mode |
Independent | |
|
3 |
Working mode |
Charging: constant-current (CC), constant-voltage (CV), CC-CV; Discharging: CC, constant-power (CP)
Standing: rest |
|
| Termination
condition |
Time, voltage, current, capacity, cell voltage, temperature, protection
and etc. |
||
|
4 |
Channel voltage |
Charging voltage
range |
0V to 60V |
| Discharging voltage range | 5V to 60V | ||
| Accuracy | ±(0.05%FS+0.05%RD) | ||
| Resolution | 0.1mV | ||
|
Channel current |
Testing range | ±100A | |
| Minimum output
current |
20mA | ||
| Accuracy | ±(0.05%FS+0.05%RD) | ||
| Resolution | 0.1mA | ||
|
Time |
Resolution | 1S (Singe channel time resolution is
up to 20mS) |
|
| Data storage | Standard set up for 1S, minimum to
100mS |
||
|
Power |
Output power | Consistent working power at 12KW
for single channel |
|
| Accuracy | ±0.1%FS | ||
| Supplementary
testing channel cut-off conditions |
When the supplementary testing channel reaches to cut-off conditions, the main testing channel will be stopped or skipped. | ||
|
5 |
Control program |
Support for data protection when power off: When power failure or cut,
the data still can continue to test and editable for working step parameter. |
|
| Safety protection conditions include voltage range limits, current range
limits and current/ voltage trend. |
|||
| Supplementary protection conditions include parameter for voltage superior limit, voltage inferior limit, temperature superior limit,
temperature inferior limit. |
|||
| Cycle times | Maximum of 9999 times | ||
| Programmable
steps |
Maximum of 255 steps | ||
| Embedded
loop |
Maximum of 10 layers | ||
| Step time range | Support for h, min, S format | ||
| Data storage | Time≥1S (Singe channel time
resolution is up to 20mS) |
||
| Program
feature |
Each step has more than one export
port |
||
|
6 |
Data presented mode |
Cycle list |
Including cycle serial number, charging and discharging capacity, charging and discharging efficiency, charging and discharging power, charging and discharging average
voltage and etc. |
|
Process List |
Including process serial number, working mode, progress time, capacity, power, mid-value voltage,
final voltage, final current and etc. |
||
|
Details list |
Including recording serial number, system time, cumulative time,
voltage, current, energy, power and etc. |
||
|
7 |
Data exported mode | Data exported as EXCEL, TXT, IMAGE files, can be shown as data analysis
wave for charging and discharging efficiency, charging and discharging wave, voltage, capacity, current & time feature. |
|
| 8 | Data saved mode | Data saving as file | |
|
9 |
Curve Type |
X coordinate; total time, charging and discharging capacity, cycle time | |
| Y coordinate; total voltage, current, capacity, monomer temperature,
capacity and voltage after charging and discharging |
|||
|
10 |
Software protection |
Power failure protection, reconnection when power on, overvoltage and over- discharging protection, over current or undercurrent protection, capacity protection, over temperature protection, abnormal voltage trend protection, abnormal current trend protection, abnormal voltage wave protection, abnormal current wave protection, abnormal rising speed for charging voltage protection, abnormal falling speed for
discharging current protection. |
| Hardware protection | Power off protection, open circuit protection, short circuit protection, reverse connection protection, misconnection protection, over current
protection, overvoltage protection and high temperature protection |
|
|
Alarming function |
The hardware is capable with cutting off power when in emergency automated shoot off when power off, automated load to connection and
disconnection. |
|
|
11 |
Voltage and current sampling
method |
Four-wire system connection, fixture as wire beezer or others. |
|
12 |
Energy
consumption mode |
Consumption |
| 13 | Cooling method | Forced air cooling. |
|
14 |
Safety class | As per EN60950, GB4943 requirement. |
|
Noise |
According to IEC62040-3 noise testing method, the noise is lower than70dBA. The sound level meter as per IEC804 I type requirement,
accuracy higher than±0.5dB. |
|
| Protection Class | IP22 | |
| Lightning
protection |
As per GB17626 Class 2 lightning protection requirements. | |
| 15 | Software | Provide software upgrading during the whole life cycle. |
| 16 | Communication | Equipment uses RJ-45 interface which can ensure the stability and real-
time for the remote data collection. |
| 17 | Cooling method | Forced air cooling, minimum 20cm should be left from air outlet to air
intake |
| 18 | Equipment
maintenance |
Calibrate once per year and non-professionals should not open the crate.
Check the contact in certain time to avoid poor contact. |
| 19 | Dimension | 800(width) *950(depth) *1900(height) mm |
|
20 |
Transportation |
The package is suitable for automobile, ship, airplane, train transportation. Rain proof and civilized loading and unloading are
necessary. |
|
21 |
Test environment |
380V/220V/50Hz
Power：15KW Work mode：Continuous Work environment：-20—40 none dewfall Environment humidity：10%~90% Ground load-bearing：≤500Kg/M2 |
10. Optional accessories that will be suggested and charged additionally:
|
Supplementary temperature testing channel |
Testing range | ﹣40°C to 150°C |
| Testing
accuracy |
±1℃ | |
| Resolution | 0.1℃ | |
| Channel
quantity |
Each channel equips with one or more channels. | |
|
Supplementary voltage testing channel |
Testing range | 0V to 5V |
| Testing
accuracy |
±(0.1%FS+0.1%RD) | |
| Resolution | 1mV | |
| Channel
quantity |
Each channel equips with several channels. | |
| PC computer | Default
settings |
Lenovo, dual cores, 2.8G/2G DDRIII/500G hard disk, without CD-ROM. |
11. Safety Standards:
GB/T 50087-2013: Code for design of noise control of industrial enterprises;
JJG 700-1999: National standard for product technical performance;
GB/T 191: Packaging-pictorial markings for handling of products (ISO780-1997，EQV); GB/T 6388: Transport package shipping mark;
GB 9969.1: Instructions for use of industrial products;
12. Testing Standards:
GB/T 31484-2015: Cycle life requirements and test methods for traction battery for electric vehicle;
GB/T 31485-2015: Safety requirements and test methods for traction battery for electric vehicle;
GB/T 31486-2015: Electrical performance requirements and test methods for traction battery of electric vehicle;
GB/T 31467.2-2015: Lithium-ion traction battery pack and system of electric vehicles – Part 2: Test specification for high energy applications;
GB/T 31467.3-2015: Lithium-ion traction battery pack and system of electric vehicles – Part 3: Safety requirements and test methods.
13. Attachment: Operation screens for software:
a) Master interface of upper computer is as per below
b) Editing interface of step process is as per below
Figure2 Editing Interface of Step Process
Instruction for Figure 2:
Part 1 is the name option for testing step, e.g. power slope discharging, constant voltage charging/discharging, constant standing;
Part 2 is the operation option delete. current charging/discharging, constant power discharging and
Part 3 is the recording method option and related parameter settings for testing data,e.g. time interval, voltage interval and current interval;
Part 4 is the variance protection option and variable parameter settings, e.g. testing time, voltage value and current value;
Part 5 is the overall protection option and parameter settings, e.g. voltage inferior/ superior limit, current inferior/ superior limit, capacity superior limit and delay time;
Part 6 is the post processing method options for overall protection, e.g. end process and pause process;
Part 7 is the protection option and range limit settings for voltage, temperature and capacity of single cell.
Remarks: Please refer to the Software Instruction Manual for detailed setting process.
c) Editing interface and instructions for BMS protocol
Figure 3 is the editing interface for BMS protocol
Figure4 View Interface for testing data
Instruction for Figure 4:
Part 1 is the view mode classification (Detail View and Category View);
Part 2 is the content option of view display (Display Cycle, Display Step, Display Summary and Display Detail);
Part 3 is the data drawing list, for setting X Axis and Y Axis for curve graphics;
Part 4 is the export setting for testing data (export file and management of export); Part 5 is the display area of data curve graphics;
Part 6 is the display area of detailed data.