256/512 Channel 5V 3A 5A 6A Cylindrical Battery Capacity Tester Grading Machine

1. Overview

Battery Tester with recaperate energy during discharger cycle functiont is the latest generation of energy-saving battery formation detection equipment based on PWM high-frequency power feedback technology, which has been developed by our company for many years and launched in 2013. It can be widely used in the production and testing of lithium-ion battery, nickel metal hydride nickel cadmium battery. This series of equipment completely subverts the working principle and power consumption mode of the traditional battery forming and testing equipment. Compared with the traditional secondary battery forming and capacity dividing equipment, the electric power is saved by 40% when the battery is used for charging, and the comprehensive power saving efficiency is more than 60%.

At present, Energy-saving power battery automatic detection equipment has been widely used in many domestic well-known manufacturers of lithium-ion batteries and Ni MH Ni Cd batteries, and is well received. From the perspective of application, the operation effect is very good. It is superior to other similar products in the current market in terms of power saving effect, power harmonic quality, heating capacity, reliability and stability of equipment and battery capacity sharing effect.

 

2. Product features

(1) Subverting the traditional battery charging and discharging mode

▲ The traditional linear regulated power supply charging mode is changed to PWM switching chopping charging mode, which greatly improves the charging conversion efficiency of the battery;

 

▲ The discharged electric energy of the battery is recycled to the AC power grid by the electric energy feedback technology to realize the electric energy reuse, which effectively overcomes the shortcomings of the traditional battery discharge mode. The traditional mode of discharge is to convert the discharged electric energy of the battery into heat and waste it.

 

▲ On the realization method of electric energy feedback, the high-frequency PWM rectifier technology can realize bidirectional energy transfer, which is ingeniously applied to the field of electric energy recovery. In principle, it can overcome the phenomenon that the traditional thyristor phase control device is prone to reverse and cause DC circuit.

 

(2) Significant power saving effect

According to the actual measurement, the power consumption of S2 ~ 4 series equipment is more than 40% less than that of traditional equipment when charging, the comprehensive power saving rate is more than 60%, and the power consumption is more than 60%, which saves a lot of costs for battery manufacturers.

 

(3) The temperature rise of equipment is obviously reduced

The temperature rise of equipment in operation is only 1 / 4 or lower than that of traditional equipment. When using this kind of equipment, especially in summer, the environmental temperature of customer's production site is no longer the same as that of sauna room, which makes workers reluctant to stay. The accuracy of capacity sharing is more guaranteed, and the failure rate of equipment is lower.

 

(4) Excellent power quality

At the AC input side, the bidirectional converter power supply based on high frequency PWM rectifier technology is used to realize the bidirectional conversion from AC to DC and from DC to AC. The current waveform injected into the power grid is sine wave, the harmonic distortion rate is less than 5%, and the power factor is greater than 0.99;

 

▲ Battery Tester with recaperate energy during discharger cycle functiont equipment can completely avoid the situation of huge fines or even no start-up caused by the unqualified power quality in the power quality inspection of the battery manufacturing enterprise.

 

(5) Battery voltage and current control is stable, fast and accurate

▲ Each channel adopts independent voltage and current hardware closed-loop control, current and voltage detection adopts instrument operation amplifier, independent CPU (lower computer), ad, DA system detection and control, single data recording speed is fast and detection accuracy is high;

The given control voltage and current adopt software closed-loop to automatically correct the current, and the voltage and current control accuracy is high;

 

(6) The operation is intuitive and simple, the human-machine interface is friendly, and the appearance is beautiful.

3.Basic Structure and Work Flow of the Device

3.1 structure and working principle of the device

The circuit part of the battery automatic detection device is designed with modular structure, which is mainly composed of 7 parts, including bidirectional AC / DC converter module, constant current and voltage control module, electrical control module, central controller module, communication module and human-machine operation interface module.

The schematic diagram of its composition is shown in the figure below. In addition, the battery detection cabinet also includes a battery clamp, a battery charging and discharging state indicator light, an AC power supply switch, etc.

The function and working principle of each circuit module: when the battery is charged with constant current and constant voltage, the bidirectional AC / DC converter module transforms the AC voltage of the power grid into the low-voltage DC with the DC voltage of 12V, and realizes the electrical isolation between the strong current and the weak current (to ensure the personal safety of the operator). Finally, the constant current and constant voltage charging control and detection of the battery are realized through the constant current and constant voltage control module When the battery is discharged, the process is just the opposite of charging. First, the battery voltage is increased to 12V by constant current and voltage control module, and then the DC is converted into AC by bidirectional AC / DC converter module and fed directly into the factory's AC distribution network, so as to realize the energy feedback of discharged battery energy.

 

Configuration:

(1) Bidirectional AC / DC converter module: 8 sets

(2) Constant current and constant voltage control modules: 64 (each constant current and constant voltage control module with 8 channels)

(3) Central controller: 1 set

(4) LED display: 2 sets

(5) Battery clamp / terminal block: 512 sets of four wire clamp

(6) RS-485 communication interface: 1

 

 

4. Main Performance and Technical Indexes of the Device

4.1 Control function

(1) Number of control channels: 256 or 512 channels in the whole cabinet.

(2) Channel control mode:

▲ It can realize the channel flow control of the whole machine through the upper computer (PC);

▲ The control of the whole machine channel flow can be realized through the central controller operation panel configured on the cabinet;

▲ Each channel can independently realize start, stop, pause, continue and protection;

▲ Each channel has independent constant voltage and current hardware control circuits, which do not affect each other;

▲ The accuracy of charging current and discharging current of each channel can be automatically calibrated by software.

(3) Charging mode: constant current charging, constant voltage charging, constant current and constant voltage charging

(4) Charging cut-off conditions: voltage, current, time and capacity

(5) Discharge mode: constant current discharge

(6) Discharge cut-off conditions: voltage, time and capacity

(7) The sampling inspection and control time of the battery is less than 1-8 seconds, which makes the battery start and stop more quickly, makes the battery capacity detection more accurate, and the abnormal battery control more quickly. Time for the whole cabinet data to be uploaded to the central computer ≤ 15 seconds

 

4.2 Detection and Protection Function

(1) Detection function: charging voltage, charging current, discharging current, discharging voltage, constant current charging time, constant voltage charging time, constant current discharging time, charging capacity, discharging capacity, etc

 

(2) Protection function:

▲ Over voltage, under voltage, over current, under current and over capacity protection;

 

▲ Battery reverse connection protection: when the battery is reverse connected, the hardware circuit will automatically disconnect the battery circuit, and there will be no short circuit, discharge, reverse charging and other phenomena of the battery, nor damage the battery charging and discharging circuit;

 

Equipment power-off protection: in case of abnormal power failure of the equipment, the current process steps can be continued; in case of long-term communication interruption or PC failure, the equipment will automatically enter the waiting state, and continue the current process steps after communication recovery;

 

▲ Voltage disconnection protection, abnormal battery charging protection, communication interruption protection, etc

 

4.3 Main Functions of Software

(1) It can run under the windows system and conduct man-machine dialogue on the PC display screen. The man-machine interface is simple. The operator only needs to input a few instructions to query whether the set control program is wrong in real time and reduce human errors.

(2) It has real-time monitoring function of charge and discharge voltage and current curve, and prompt function of fault information (fluctuation point protection) after the protection stops.

(3) Process settings: up to 32 / 64 steps can be set.

(4) Record contents: charge / discharge current, charge / discharge voltage, battery charge / discharge capacity and energy, shelving voltage, first charge / discharge efficiency, charge constant voltage capacity value and percentage, battery discharge capacity attenuation rate, absolute time, relative time, average voltage, median voltage.

(5) It can draw the dynamic curve of each battery test process in real time, including voltage / time curve, current / time curve, capacity / time curve, energy / time curve, capacity / voltage curve and other function menus.

(6) It has the function of automatically saving data files during battery charging and discharging.

(7) It has the function of history online search and query.

(8) Data output mode: the collected data can be converted into Excel or TXT format, and can be saved and printed into reports.

(9) Offline test function: after the upper computer has problems or communication is interrupted, the equipment can continue to test, and can automatically connect and recover key data (work step data and cycle data) after communication is restored.

(10) Call recovery function: in case of power failure in the plant area, the equipment can automatically save and stop at the current work step, and can be continued from the breakpoint after the call.

(11) Barcode function: it has two-dimensional barcode scanning start function, supports MES database management, and is used to trace the detection information of battery. The software data interface is open, which can cooperate with the third party to meet the needs of Party A, and the data can be imported into the database. (with a wireless code scanning gun, able to identify one-dimensional code and two-dimensional code)

Each control computer can be connected with cabinet 1-10.

 

Specifications

Equipment failure rate	＜ 1%
Voltage measurement range	0V-5V, Accuracy: ± 0.1% (FS + RD), Resolution: 1mV;
Constant voltage setting range	DC 1V-5V, Accuracy ± (0.1% FS0.1% + RD), Resolution: 1mV;
Charging constant current	0.05-5A or 0.05-6A Accuracy: ± (0.1% FS + 0.1% RD), Resolution: 1mA
Time range	0-3000 min / work step; Accuracy: ± 0.1%
Sampling inspection cycle	1S-60S optional
Charging efficiency of the whole machine	≥ 75%
Recaperate energy during discharger cycle   efficiency	≥ 70%
AC input power	AC380V ± 10%, 50Hz (three-phase four wire system)
Maximum input power	About 8KW
AC current distortion rate (THD)	≤ 5%
Power factor	≥ 0.99
Communication mode	RS485, baud rate 57.6K
Working environment: ambient temperature	- 10-40 ℃, relative temperature ≤ 90% RH

 

5. Cabinet structure and opening mode

6. Equipment Reliability Assurance Measures

6.1 The machine adopts automatic calibration function to ensure that the current and voltage at each point meet the requirements of technical indicators for a long time. After the automatic calibration function is adopted, the potentiometer is cancelled on the circuit board, and the problem of current and voltage deviation caused by potentiometer drift is eliminated.

6.2 Low temperature drift alloy resistance is used for current sampling and it is sorted by high precision resistance value. High precision and high stability imported chip elements are used for voltage and current detection chip, which can effectively reduce temperature drift and time drift and ensure long-term stability and precision requirements of current.

6.3 All power devices are imported, and the margin of power device voltage and current quota selection is large, generally more than 2 times, which effectively ensures the reliability of the main circuit of each link hardware.