II. Features

Part 1: Power Battery PACK Installation and Commissioning Training Bench

1. The training bench consists of multiple battery pack modules. The battery is composed of lithium iron phosphate power cells. A total of 36 power cells are connected in series and divided into two modules. The single cell capacity is 20AH, and it is equipped with a 24-inched touch device in which supporting teaching resources is embedded.

2. Equipped with a vehicle-grade distributed battery management system, which includes one main control module and two slave acquisition modules. After the battery is assembled, data can be exchanged through the intelligent interaction display system and distributed battery management system of the equipment, so as to complete related data monitoring of the power battery pack.

3. Equipped with a national standard AC charging port and a on-board charger. After the data calibration is completed, the charge testing can be performed to the battery pack and the charging circuit principle and practicing teaching can be completed.

4. The training bench is equipped with a 220V AC charging gun, which is convenient for students to test the charging circuit. The bench supports the charging of the national standard 7-core AC charging pile (including CC and CP signals).

5. The bench is equipped with a simulated load system. The load is divided into two modes: high and low, which can complete the commissioning of the discharging principle circuit of the power battery pack.

6. The bench is equipped with a high-voltage power distribution box module, which can complete the commissioning and teaching of the principle of high-voltage power-on / power-off control circuits, including discharging relays, charging relays, pre-charging relays, pre-charging resistors, and hall current sensors.

7. The charging module of the training bench, the high-voltage power distribution box module and the distributed battery management system module are protected by transparent materials, and there are signal detection ports on the top. The diameter of the detection port is 8mm, which ensures the safety of the measurement process, and can visually display the configuration of each module and the line connection status between the modules.

8. The bench is made of strong cold-rolled steel plate. After strict degreasing, pickling, rust-proof phosphating, electrostatic spraying and other technological processes, it is featured with the characteristics of natural color, high stability, impact resistance, water resistance, and aging resistance. The platform is covered with pure wood, which is not easy to be scratched, and at the same time ensures the insulation performance. The platform contains two super large storage drawers, which are smooth to draw, with strong balance, not easy to rust and fade.

9. The base of the equipment is equipped with a dual brake universal caster lock-up mechanism, and the surface is processed with high-quality galvanized technology, which ensures the strength and hardness of the caster mechanism. The interior adopts precision steel balls, which can realize all-round rotation, environmental protection, quietness, and higher safety. The braking system adopts large ox tendon wear-resistant brake pads, which makes the braking more stable and firm.

10. The power battery pack is equipped with an emergency power-off switch. The emergency power-off switch is installed in the easy-to-operate part of the front of the power battery pack. Press the red emergency power-off switch button in emergency, and the entire high-voltage power system will be powered off to ensure the safety of the teaching process.

11. In addition to 36 single cells in the power battery pack, 10 extra single cells are equipped for series parallel assembly practice which will help the students to judge which cell is broken and which cell is good.

12. The cells adopt the M6 stud positive and negative pile head type, and the connection between the cells is connected by a flexible conductive sheet to meet the technical requirements of repeated connection.

Part 2: New Energy Vehicle Power Battery System Teaching Resource Pack Software V1.0

1. The intelligent teaching system can calibrate and dynamically detect the assembled battery pack, and can graphically control the power battery PACK training bench through the human-computer interface, which is convenient for data analysis and calibration of the battery pack. 

2. The system can detect the connection status of communication equipment such as CAN devices in real time, and can judge the detection result, the system will report the corresponding error prompt when abnormal result comes up.

3. In training mode, the total voltage of power battery pack will be graphically and dynamically displayed, including 8 battery temperatures, 36 cell voltages, the highest voltage of cells, the lowest voltage of cells, the highest temperature of the battery, the lowest temperature of the battery, the bus current, SOC and other data information.

4. During discharging, the equipment can dynamically display the discharge current, remaining discharge time, etc.. During charging, the equipment dynamically displays the connection status of the charging gun, CC, CP, charging current, remaining charging time and other information.

5. The matched host computer software has the function of contactor detection, which can detect the total positive relay, total negative relay, pre-charging relay, charging relay, etc. in real time. When the contactor is working, the corresponding button on the software interface can be highlighted. In the commissioning state, students can also control the pulling-in and turning-off of the contactor through the mouse, so as to verify the working status of the equipment.

6. The upper computer software has the function of displaying data flow, which can dynamically display the relevant data flow of the power battery management system, including: total voltage of battery, bus current, system SOC, system operating status, charging gun connection status, charging status, charging gun charging mode and status, insulation positive resistance value, insulation negative resistance value, CC resistance value, CC2 resistance value, battery temperature difference, CP duty cycle, high voltage interlock status, communication status with the vehicle, charger communication status, AC charging gun holder temperature, etc. The software has the function of restoring default settings, which can restore the calibrated data with one click.

7. The system has built-in battery virtual structure display platform which is completely consistent with the equipment, and completely displays the control principle of the power battery pack. The display of the power battery pack is made of 3D animation, and the assembly process and precautions of the power battery pack are described in detail according to the factory process.

III. Technical Parameter: 

1. Power battery pack: Power battery type: environmentally friendly lithium iron phosphate power battery (square aluminum shell, cell of 3.2V20AH), power battery pack capacity: 115.2V20AH, full charge and discharge times: 2000 times, operating temperature: -20 ℃～60℃, BMS battery management system: 1 master control module, 2 slave control modules with additional 10 cells

2. Battery capacity distribution instrument: constant current charging, constant voltage charging, constant current and constant voltage charging, constant power charging, constant current discharging, constant load discharging, constant power discharging, channel parallel supported. A total of 8 channels. 

3. On-board charger: Type: forced air-cooled on-board smart charger, input voltage: 100～240VAC, input power: 1.2KW, protection level: no lower than IP67, anti-vibration level: SAEJ1378, communication method with power battery pack: through CAN network communication

4. DC-DC Converter: Type: Natural Air Cooling DC-DC Converter, Input Voltage: 115VDC, Output Voltage: 13.5VDC, Output Power: 500W

5. External working power supply of the device: 220V AC, power 1.2KW

6. Equipment working temperature: -20℃～+40℃

7. Dimensions of worktable body (mm): 1450*800*835 (length*width*height) 

IV. Basic Configuration 

1 lithium iron phosphate power battery pack (including 36 + 10 cells, discharging relay, charging relay, precharging relay, precharging resistance, hall sensor, maintenance switch, charging discharging socket, distributed battery management system, etc.), 1 power battery pack display screen, 1 on-board charger, 1 charging socket, 1 emergency power-off switch, 1 DC-DC converter, 1 auxiliary battery, 2 discharging control relays, 2 aluminum case resistors, 1 worktable (with suction bucket), 2 digital clamp multimeter, 1 insulation tester, 1 rubber hammer, 4 pairs of insulating gloves (withstand voltage 1500V), 1 set of 24 inch touch device, 1 high precision voltage internal resistance meter.