Analysis of the working principle and core technology of BMS test equipment system

In today's increasingly important world of battery management systems (BMS), BMS test equipment systems play an indispensable role as a key tool to safeguard their performance and reliability. Understanding its working principle and core technology is crucial to the in-depth understanding of the battery management testing process.

I. Working Principle

The main work of BMS test equipment system is to conduct comprehensive and accurate testing of the battery management system to ensure that the BMS can effectively manage the battery in practical applications. The working process can be roughly divided into three stages: data acquisition, analysis and processing, and output.

Data Acquisition

First of all, all kinds of high-precision sensors are connected to the battery or BMS to collect key parameters of the battery. These sensors include voltage sensors, which are used to accurately measure the voltage value of the battery cell or battery pack, and can detect abnormal voltage conditions such as overcharging and over-discharging in a timely manner; current sensors are responsible for monitoring the size of the battery's charging and discharging currents, whether it is a high-current rapid charging or a small-current trickle charging, which can provide accurate data to analyze the characteristics of the battery's charging and discharging to provide a basis for the analysis of battery charging and discharging; there are also temperature sensors, which pay attention to the temperature change of the battery, because the battery temperature is too high. Temperature sensor, always pay attention to the battery temperature changes, because the battery temperature is too high or too low will affect its performance and life, accurate temperature monitoring can be taken in advance to dissipate heat or insulation measures.

Analyzing and Processing

The collected analog signal data is then transferred to the data acquisition card, which converts it into digital signals for further processing. At this stage, with the help of specialized data processing software and algorithms, the data is pre-processed with filtering, calibration and other operations to remove noise and interference and improve the accuracy of the data. Then, specific algorithms are applied to estimate and analyze key parameters such as the state of charge (SOC) and state of health (SOH) of the battery. For example, the Kalman filtering algorithm combines historical and currently collected data to continuously optimize the assessment of the battery state, thus providing a comprehensive understanding of the battery's performance and state.

Results Output

After analysis and processing, the BMS test equipment system outputs the test results in a visual form. This can be in the form of parameter values, graphs, etc. on the display, or through a communication interface that transmits the data to a host computer or other related equipment for further viewing, analysis and archiving by the operator. If abnormalities are found in the battery or BMS during the test, the system will also send out an alarm signal to remind the relevant personnel to take timely action.

Second, the core technology analysis

High-precision Sensor Technology

High-precision sensor is the “sense organ” of BMS test equipment system, and its precision directly determines the quality of collected data. As mentioned above, voltage, current, temperature and other sensors need to have characteristics such as high resolution, fast response and good linearity. For example, advanced Hall effect voltage sensors can achieve millivolt-level precision measurement in a wide voltage range; high-precision shunt or Hall current sensors can accurately measure changes in different current ranges; thermistor or thermocouple temperature sensors can quickly and accurately sense subtle changes in battery temperature.

Data Acquisition and Processing Technology

The performance of the data acquisition card is critical, it needs to have a high sampling rate and high resolution characteristics. High sampling rate ensures that important transient data will not be missed when the battery state changes rapidly (e.g., during pulse charging and discharging); high resolution can refine the collected data to a more accurate degree, such as voltage measurement accuracy to the microvolt level. At the same time, the algorithms in the data processing software are also key, such as filtering algorithms to remove noise in the data, Kalman filtering and other algorithms used to accurately estimate the key parameters of the battery, which are constantly optimized to adapt to different battery types and application scenarios.

Intelligent control and communication technology

Intelligent controllers play the role of the “brain” in the BMS test equipment system, which makes decisions based on the results of analysis and processing. When abnormal battery conditions are detected, commands can be issued quickly, such as cutting off the charging and discharging circuits and starting the heat dissipation device. The communication technology guarantees stable and efficient data transmission between the test equipment system and external equipment (such as the host computer, other monitoring equipment, etc.). Common communication methods include CAN bus, Ethernet, Bluetooth, etc. By following the corresponding communication protocols, it ensures accurate and error-free data interaction.

In summary, through its unique working principle and a series of core technologies, the BMS test equipment system realizes accurate testing and effective monitoring of the battery management system, providing solid technical support for the safe and efficient use of batteries. With the continuous development of battery technology, the related technology of BMS test equipment system will also be continuously optimized and innovated.