Lithium Battery 5V 3A 5A 6A 256/512 Channel Charge And Discharge Testing Equipment With Energy Regenerative Function

Main Introduction

512 Channel Battery Capacity Tester is mainly used to detect whether the parameters such as cell capacity, magnification and cycle times meet the use requirements. Test each single cell’s capacity to make sure the battery has good quality. Because different batches of batteries made by many battery manufacturers will have inconsistent capacity, internal resistance, open circuit voltage and charge discharge performance. The production of battery pack needs to ensure the consistency of battery.

1. 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 70%, 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.

2.Basic Structure and Work Flow of the Device

2.1 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

 

 

3. Main Performance and Technical Indexes of the Device

3.1 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

 

3.2 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.Specification:

Number of Device Channels	The whole machine has 256/ 512 channels in total
Workflow Control Mode	Whole cabinet control
Charging Mode	Constant current and constant voltage
Charging Cut-off Conditions	Voltage, current, time, capacity
Discharge Mode	Constant current
Discharge Cut-off Conditions	Voltage, time and capacity
Sampling Inspection Cycle	≤10s
Voltage Measurement Range	0 ~ 5V, Resolution 1mV
Battery Voltage Range	Charging: 0 ~ 4.5V, Discharging: 4.5 ~ 2V
Constant Voltage Range	3~4.5V
Voltage Accuracy	±（0.05%RD+0.1%FS）
Current Range	Charge 0.025-6A, Discharge 0.025-6A, Resolution 1mA
Current Accuracy	±（0.1%RD+0.1%FS）
Time Frame	Any setting within 0 ~ 30000 minutes, time unit is min
Time Accuracy	≤±0.1%
Fixture Type	Cylindrical four wire fixture
Fixture Spacing	35mm
Support Battery Height	0~90mm
Working Power Supply	Three phase four wire system, AC380V ± 5%, 50Hz,  power consumption ≤14KW for 256 channel and  ≤28KW for 512 channel
Communication Mode	RS485, baud rate 57600
Overall Dimension	720mm（Width）*500mm（Deep）*1840mm（High）for 256 channel 1440mm（Width）*500mm（Deep）*1840mm（High） for 512 channel
Work Environment	Temperature: 0-40 ℃, relative temperature ≤ 85%
Full Load Operating Current	he maximum phase line is 30A, and the maximum zero line is 3A
Equipment Starting Current	The closing moment of air switch is about 60A
Machine weight	About 100kg for 256 channel/ 250 kg for 512 channel

 

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.