EOL Testing System
EOL Testing System
I. Introduction
1.1 System Overview
The EOL testing system is primarily used for Final testing and quality control of battery modules or PACKs in electric vehicles, buses, container energy storage, home energy storage, and mobile energy storage. A comprehensive and intelligent testing platform developed to address various issues related to the automatic testing of lithium batteries offline, data recording integration and analysis, production efficiency, etc., providing a complete static testing solution for power battery modules or PACKs; Unique features include safe, fast, efficient, and customized test data output formats, the ability to interact with charging and discharging testing equipment, seamless integration with factory MES, and a simple software operation interface.
1.2 Basic Testing Process
1.3 Equipment Topology Diagram
II. Main Components of the Equipment
2.1 Main Configuration of the Equipment
| SN | Unit Name | Brand | Specifications/Model | Qty | Unit |
|---|---|---|---|---|---|
| 1 | Insulation Resistance Tester | KIKUISU | TOS9301S | 1 | Set |
| 2 | AC Internal Resistance Meter | Hioki | BT3563A | 1 | Set |
| 3 | Multimeter | Keysight | DMM6500 | 1 | Set |
| 4 | Power Supply | Meanwell or equivalent | EDR-75-24 | 1 | Set |
| 5 | Power Supply | Meanwell or equivalent | EDR-75-12 | 1 | Set |
| 6 | CAN Card | ZLG or equivalent | CANFDNET-400U | 1 | Set |
| 7 | Temperature and Humidity Meter | Jianda Rinke or equivalent | RJ45 Network Port Temperature and Humidity Recorder | 1 | Set |
| 8 | Switch | TP-Link or equivalent | TP-LINK 8-Port Switch TL-SF1008VE | 1 | Set |
| 9 | Computer | Dellor equivalent | CPU-i7/16G RAM/1TB Hard Drive | 1 | Set |
| 10 | Monitor | AOC or equivalent | ≥19.5 inches | 1 | Set |
| 11 | Barcode Scanner | Vision or equivalent | ICW-2180 | 1 | Set |
| 12 | High Voltage Measurement Unit | Repower | RP-EOL-HVUnit | 1 | Set |
| 13 | IO Module | Repower | RP-EIO-128CH | 1 | Set |
| 14 | Control Software | Repower | RP-EOL-S/W | 1 | Set |
| 15 | Cabinet | Repower | EOL Cabinet | 1 | Set |
| 16 | Device Wiring Harness | Repower | EOL-MOD-SBX | 1 | Set |
| 17 | Test Wiring Harness | Repower | EOL-MOD-CSX | 1 | Set |
| 18 | Master Resistor Box | Repower | RP-Master-01 | 1 | Set |
2.2 Dedicated Material List
| SN | Unit Name | Brand | Specifications/Model | Qty | Unit |
|---|---|---|---|---|---|
| 1 | Connector | Prototype Battery Plug Connector | 2 | Set | |
| 2 | Battery Pack | Prototype Battery Pack (For Use During Debugging) | 1 | Set |
2.3 Scope of Supply Description
| SN | Project | Buyer | Factory |
|---|---|---|---|
| 1 | Online Equipment Framework | V | |
| 2 | Plug-in Tooling (High and Low Voltage Connectors, etc.) | V | |
| 3 | Needle Plate Fixing Mechanism, Moving Servo | V | |
| 4 | RFID and Other Automatic Scanning | V | |
| 5 | Safety Light Curtain | V | |
| 6 | Testing Instruments and Test Cabinet (Including Internal Circuits) | V | |
| 7 | Handheld Scanners and Other Manual Scanning Devices | V | |
| 8 | Industrial Control Computer (Mouse/Keyboard/Monitor, etc.) | V | |
| 9 | Testing Software | V | |
| 10 | Testing Equipment MES Integration | V |
Note: The boundary of the equipment supply scope is as shown in the table above; during acceptance, the supply scope of the testing equipment shall be used as the boundary for separate acceptance.
2.4 Responsibility Party Description
| SN | Project | Buyer | Factory |
|---|---|---|---|
| 1 | Connector misalignment, poor docking, product scratches | V | |
| 2 | Institutional failure, servo positioning | V | |
| 3 | Insufficient instrument accuracy, circuit failure within the test cabinet | V | |
| 4 | Test results are thrown up, test machine MES interaction | V |
3. Applicable Product Specifications
3.1 Compatible Product Specifications
| Serial Number | Product Name | Voltage | Communication Protocol (This function requires the configuration of the corresponding communication conversion module) |
|---|---|---|---|
| 1 | Version A Module Blueprint | 300V | CAN/CANFD |
| 2 | Version B Module Blueprint | 300V | CAN/CANFD |
Note: The product models that need to be adjusted on-site are as shown in the table above. If the equipment meets the acceptance conditions but Party A or the final user of the equipment is still unable to provide the blueprint products listed in the table for Party B to carry out debugging work, the acceptance conditions required by the business shall prevail.
4. Technical Parameters
4.1 Basic Equipment Parameters
| SN | Project Name | Technical Parameters |
|---|---|---|
| 1 | Device Size | ≤640*850*2000mm(W*D*H) |
| 2 | Number of Device Channels | 1 Channel |
| 3 | Operating Mode | Manual Wiring, Automatic Testing, can test one product at most simultaneously |
| 4 | Communication Method (Internal to Device) | LAN/RS232 |
| 5 | Communication Method with Product | CAN/CANFD (subject to configuration list) |
| 6 | Input Power Supply | AC220V±10%,50HZ |
| 7 | Input Power | ≤3500W |
| 8 | Dustproof, Heat Dissipation | Equipped with Dustproof and Heat Dissipation Devices |
| 9 | Cooling method | Air cooling |
| 10 | Security level | Meets the requirements of EN60950 and GB4943 |
| 11 | noise | According to the method of IEC62040-3 for testing noise, the noise level should be less than 75dBA. The sound level meter used should meet the requirements of Type I in IEC804, and the accuracy should be better than ± 0.5dB. |
| 12 | Equipment working environment temperature | 0℃～45℃ |
| 13 | Device storage temperature | -10℃～70℃ |
| 14 | Maximum relative humidity during equipment operation | 30% to 80% (RH non condensing) |
4.2 Equipment functional parameters
| SN | Unit Name | Brand | Model | Specification |
|---|---|---|---|---|
| 1 | Insulation Resistance Tester | KIKUISU | TOS9301S |
1) AC withstand voltage (ACW): 5kV/101mA; 2) DC withstand voltage (DCW): 6kV/10mA; 3) Insulation resistance (IR): 6kV/50G Ω; |
| 2 | IR Meter | Hioki | BT3563A |
1) Voltage range: 300VDC; 2) Resistance range: 3000 Ω; |
| 3 | Multimeter | Keysight | DMM6500 |
1) Resolution: 6 1/2; 2) Voltage range: 1000VDC; 3) Resistance range: 100M Ω; |
| 4 | High Voltage Measurement Unit | Repower | RP-EOL-HVUnit |
1) Modular design, with effective electrical isolation for high-voltage testing circuits; 2) 4CH high voltage measurement, of which 2CH supports four wire measurement (measurement function requires additional configuration of corresponding measuring instruments); 3) All outputs are equipped with fuses to prevent short circuits or overloads; 4) The relay board supports quick disassembly and quick replacement, with expandable channels; |
| 5 | IO Module | Repower | RP-EIO-128CH |
1) Equipped with digital output module, high voltage isolation technology, and breakdown prevention; 2) Using high-speed MCU chips for fast response; 3) TCP/IP communication protocol, secure and stable; |
| 6 | Master Resistor Box | Repower | RP-Master-01 |
1) Insulation resistance values of 50M Ω, 200M Ω, 500M Ω, and 800M Ω; 2) DC withstand voltage resistance values of 1M Ω and 4M Ω; 3) AC withstand voltage resistance values of 500k Ω and 1M Ω; 4) ACR resistors 10m Ω and 100m Ω; 5) External, manual wiring, automatic inspection by upper computer software; |
| 7 | Control Software | Repower | RP-EOL-S/W |
1) 1 set of Ruineng EOL testing software; 2) Support local data export, MES data upload and other services; 3) Support quick formula switching for different products under test; 4) By default, two sets of testing product debugging services are provided; |
4.3 System testing project
| SN | Testing Item | Function | Meter |
|---|---|---|---|
| 1 | Positioning Fixture | Test fixture to battery module fixed point | Manual |
| 2 | Single cell voltage test | According to the predetermined test plan, read (or measure with a multimeter) the voltage of the module unit through CAN | CAN Card |
| 3 | Manually remove the wiring harness | Manually remove the low-voltage interface harness, and then click "Continue Testing" on the upper computer; | Manual |
| 4 | Module total voltage/total internal resistance test | According to the predetermined testing plan, measure the total voltage/total internal resistance of the module by switching the internal resistance meter through a relay; | IR Meter |
| 5 | Module total positive/total negative test for shell insulation | According to the predetermined testing plan, the positive/negative terminal of the voltage tester is connected to the total positive/total negative terminal of the relay switching module, and the negative terminal of the voltage tester is connected to the module housing. The upper computer controls the instrument to perform the test. | Insulation Resistance Tester |
| 6 | Module total positive/total negative to shell withstand voltage test | According to the predetermined testing plan, the positive/negative terminal of the voltage tester is connected to the total positive/total negative terminal of the relay switching module, and the negative terminal of the voltage tester is connected to the module housing. The upper computer controls the instrument to perform the test. | Insulation Resistance Tester |
| 7 | Test data upload | Upload test data to MES system. |
Note: The EOL testing system is a customized equipment, and the equipment configuration and functions shall be subject to the testing items specified in the table above. Any additional items shall be evaluated and confirmed by Party B, and shall not be considered as acceptance criteria for this agreement
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