The original power battery module (including the battery management system) of the Toyota Corolla dual-engine 1.8L new energy hybrid vehicle is selected to be produced, and the battery is cooled by forced air cooling technology. The power battery adopts nickel-metal hydride battery technology. The battery module assembly includes a battery management system, a current sensor, main positive, main and auxiliary relays, and a pre-charge relay, with leakage detection functions, pre-charge functions, current detection functions, and SOC value calculation functions. A high-voltage maintenance switch is installed on the battery module, which can train students on safety precautions for high-voltage system maintenance.
Through the OBD diagnostic interface of the drive system training bench, a dedicated diagnostic instrument can be used to read the fault code, data stream reading, fault code clearing, etc, of the battery management system. Through reasonable modification, the connection control relationship, installation position and operating parameters between the core components of the original high-voltage battery module package are fully reflected on the training bench. The battery module is connected with the drive system through the high-voltage harness and the low-voltage harness to realize the overall operation effect of the hybrid system and train the students' ability to analyze and handle the faults of Toyota hybrid battery pack.
The training bench is equipped with a wireless intelligent fault setting module, which can be used to set the line cutoff, line-to-ground short circuit, poor line contact, and occasional line failure settings for each electronic control system line, actuator line, and sensor line through a mobile phone or tablet computer.
The training panel is made of 4mm thick advanced aluminum-plastic plate with corrosion resistance, impact resistance, pollution resistance, fire resistance and moisture resistance. The surface is treated with a special process of spraying primer, and the panel adopts UV spray painting process to spray the circuit diagram of the hybrid system. The controller, sensor, and actuator circuit are all equipped with detection terminals, which are convenient for students to measure voltage, current, waveform, resistance, etc. It can analyze and troubleshoot the corresponding faults according to the schematic diagram, and improve and cultivate the students' ability to analyze and deal with the faults of the high-voltage battery and management system of the new energy hybrid vehicle. It is suitable for the teaching needs of in secondary and senior vocational skill schools, normal education and training institutions for the integration of vehicle theory and practice.
ii. Features
1. The main components are installed on the bench, and the electrical connection method is the same as that of the real vehicle. It can be easily disassembled after power failure, so that students can master the disassembly and assembly points and safety protection of high-voltage system components during the disassembling and connecting process (according to the overall wiring requirements, some fuses and relays were moved to the corresponding racks).
2. The main low-voltage control lines of the battery management system are led out on the panel, which is convenient for detection and data collection.
3. The battery management system has leakage detection function, precharge function, current detection function, and SOC value calculation function.
4. This training bench provides power source for driving and transmission system and other training benches, with extended connecting cable. The high-voltage power line and the low-voltage control line are all parts of the original vehicle and are connected in the same way as the original vehicle.
5.The power battery module shell is designed with translucent. The internal battery arrangement, the total positive relay, the total negative relay, the precharge relay, the current sensor, the battery temperature sensor, the battery voltage collection and other components are clear, which is convenient for the trainees to observe the internal structure of the battery pack.
6. With the help of the original factory data, fully describe the functions and pin definitions of the main components on the device.
7. The panel fully displays the working principle diagram of the power battery module, and installs the detection terminals. The light-emitting diodes display the real-time working conditions of the precharge relay and the main positive and main negative relays in real time. With the help of a multimeter and an oscilloscope, real-time detection of various conditions parameter changes.
8.The training bench is equipped with a power battery pack assembly to show the connection structure of the battery pack assembly and the structure of the single battery, which is convenient for the detection and assembly training of the single battery.
9. The training bench is composed of a platform and a panel. The platform is placed horizontally and the main components are installed, 4 casters are installed at the bottom of the training bench, which can move flexibly. At the same time, the casters are equipped with self-locking devices, which can fix the position.
10. Equipped with a wireless intelligent fault setting module, the teacher sets the fault, and the students analyze and find the fault point. The main components are led out of the detection port, and they can be directly detected at the fault location to master the fault handling ability.
iii. Basic Parameter
1. Dimensions (mm): not less than 1200*1000*1800 (length*width*height)
2. Working power supply: DC12V
3. Power battery type: NiMH power battery
4. Power battery voltage: 201.6V
5. Working temperature: -20℃～60℃
iv. Basic Configuration
1 set of original power battery assembly, 1 power battery pack assembly (displayed on the stand), 1 battery management control unit, 1 set of high voltage connection cable, 1 cooling blower, 1 wireless fault setting system motherboard, etc.