It can realize high-voltage structure recognition of electric vehicle power battery, high-voltage interlock function training, high-voltage power-on and power-off operation training, bus current detection during charging and discharging process, setting and troubleshooting of common faults of power battery pack, power battery liquid cooling system work principle cognition, working principle cognition of power battery PTC heating system.
ii. Features
1. Select BYD Qin PLUS-EV pure electric vehicle original vehicle power battery pack (vehicle date in October 2021 or later) 3+3 platform lithium iron phosphate blade power battery. The total capacity of the power battery pack is not less than 352V135AH (about 47.5 kWh). A distributed battery management system is adopted, which consists of a battery management controller (BMC), multiple battery information collectors (BIC) and a set of power battery sampling lines. The power battery adopts battery liquid cooling and PTC heating system to adjust the temperature. Transparent modification without changing the layout of the original vehicle is conducive to understanding the battery structure, and at the same time, contact is strictly prohibited to ensure safe learning. The low-voltage control line and the high-voltage power line are all original vehicle parts, the length is increased, the high-voltage power line is orange, plus a protective bellows, and a warning mark is added at the connection. It is strictly forbidden to plug and unplug any high-voltage power line when the power is on. Make students understand the composition and connection relationship of power battery components as soon as possible.
2. The distributed battery management system consists of a battery management controller (BMC), multiple battery information collectors (BIC) and a set of power battery sampling lines. The main functions of the battery management controller are charge and discharge management, contactor control, power control, battery abnormal state alarm and protection, SOC/SOH calculation, self-test and communication functions. The main functions of the battery information collector include battery voltage sampling, temperature sampling, battery equalization, and abnormal detection of sampling lines. The main function of the power battery sampling line is to connect the battery management controller and the battery information collector to realize communication and information exchange between the two.
3. The training board is equipped with a teaching board, which fully displays the power battery pack, the working principle diagram of charging and discharging, and the detection terminals for the installation of the low-voltage control circuit. With the help of tools such as multimeters, the parameter changes in various states can be detected in real time. The length of the teaching board is not less than 1600mm, which can satisfy 2 students at the same time for testing and learning in different parts.
4. The training bench consists of a platform and a teaching board. The platform is placed horizontally and the main components are installed. Four casters, two swivel casters and two directional wheels are installed at the bottom of the platform, which can move flexibly. At the same time, the swivel casters have a self-locking device, which can fix the position. The casters have low rolling resistance, quietness and wear resistance, and the outer diameter is not less than 5 inches. The teaching board is installed on an alloy steel base, and four casters are also installed, which can be moved independently.
5. It can realize high-voltage structure cognition and test training of electric vehicle power battery system.
6. It can realize the training and troubleshooting of the high-voltage interlocking function of the electric vehicle power battery system.
7. Equipped with a special clamp meter for new energy vehicles and a high-voltage test pen, which are used to control line voltage, current and other parameters measurement and orange high-voltage loop high-current non-contact measurement.
8. The bottom frame of the training platform is welded with alloy steel profiles, which are strong and reliable, and the size of the main material is not less than 40*40mm. The upper front and rear are protected by stainless steel armrests.
9. Supporting new energy vehicle power battery system teaching resource package software V1.0. Use 3D animation to explain the structural composition and control principle of the original power battery pack of mainstream new energy vehicles, including the following knowledge points:
9.1 Introduction: installation location, function, battery parameters
9.2 Composition structure: battery pack structure, distribution box structure
9.3 Lithium iron phosphate blade power battery: battery structure and working principle
9.4 Battery Pack Circuit: Precharge Process
9.5 Internal Sensors: Hall Sensors, Contactors
9.6 High Voltage Maintenance Switch: Location, Structure
9.7 Connector pins: low-voltage signal connector, high-voltage connector
iii. Basic Parameter
1. Power battery pack:
Domestic mainstream lithium iron phosphate blade power battery; single battery: not less than 3.2V135AH; total voltage of power battery pack: 3.2*110=352V; power battery pack capacity: 352V135AH (about 47.5 kWh);
2. The external working power supply of the equipment: 220V AC, the power is not more than 500W
3. Equipment working temperature: -20°～+40°
4. Dimensions of the platform main frame (mm): not less than 1900*1350*900 (length*width*height)
5. Dimensions of the test stand (mm): not less than 1600*600*1810 (length*width*height)
iv. Basic Configuration
Lithium iron phosphate power battery pack, Multiple collectors for distributed battery management system, Orange high-voltage power line, Low-voltage control line, Automobile special clamp meter, High-voltage test pen, Movable platform and teaching board.
V. Training project
Training task 1: The latest blade power battery system high-voltage structure cognition and test experiment.
Training task 2: The power battery system high voltage interlock function and troubleshooting experiment of fault setting.
Training task 3: Insulation test experiment of high-voltage bus line of power battery system.
Training task 4: Experiment of power battery bus current induction measurement.
Training task 5: The fault setting and troubleshooting experiment that the power supply line of the power battery system disconnection cause the HV system unable to power on.
Training task 6: The fault setting and troubleshooting experiment that the data communication signal line of the power battery system disconnection cause the HV system unable to power on.
Training task 7: The fault setting and troubleshooting experiment that the contactor of the power battery system is faulty cause the HV system unable to power on.
Training task 8: The fault setting and troubleshooting experiment that the signal line of the DC charging contactor of the power battery system disconnection cause the HV system unable to power on.
Training task 9: The fault setting and troubleshooting experiment that the pre-charging resistance of the power battery system is faulty cause the HV system unable to power on.