Battery Cluster Testing Verification
The battery cluster, as the fundamental functional unit of an energy storage system, consists of battery modules connected in series, parallel, or a combination thereof. When integrated with a power conversion system (PCS) and auxiliary facilities, it forms an independently operational battery assembly. Conducting comprehensive testing and verification of battery clusters before system integration is essential. These tests are categorized into three main types: basic tests, fundamental performance tests, and safety performance tests.
II. Basic Performance Testing
During basic performance testing of high-voltage cabinets, we adhere to rigorous procedures and standards to ensure the proper operation of each component and system. Below is a detailed explanation of each test:
1. Power-On Test
After assembling the high-voltage cabinet, the first step is the power-on test. By supplying power and closing the switch, we observe the status of the main control indicator. A steady light confirms the cabinet is operational.
2. BMS Software/Hardware Version Check
To prevent version mismatches, we use an upper computer to read and record the main control’s software and hardware versions. These must align with project archives to ensure system stability.
3. BMS System Verification
After connecting the battery management system (BMS) to the battery monitoring unit, we verify configuration parameters, battery masks, and temperature masks, ensuring no system faults are reported—a critical step for normal operation.
4. Main Control Insulation Test
Given the high energy and voltage of battery systems, we continuously monitor insulation resistance. This test validates the BMS’s insulation detection function, ensuring safety.
5. Relay Function Test
Relays play a vital role in battery systems. We open/close relays following specific logic and measure their on/off states or output voltages with a multimeter to confirm functionality.
6. Total Voltage & Error Detection
The upper computer reads and records the battery cluster’s total voltage to verify configuration accuracy. Voltage error detection ensures measurement precision.
7. Static Cell Voltage & Voltage Difference Test
To evaluate cell consistency, we measure static cell voltages and voltage differences, identifying performance variations that could impact overall system performance.
8. Static Cell Temperature & Temperature Difference Test
Cell temperatures within the cluster are measured, and differences between cells are calculated to assess operational conditions.
9. Current Accuracy Test & DCR Test
Using high-precision charge/discharge equipment, we test the cluster at varying currents to evaluate the BMS’s current accuracy. DC resistance (DCR) tests reveal internal resistance.
10. Dynamic Voltage Difference & Cell Temperature Rise Test
During charge/discharge cycles, we record maximum dynamic voltage differences and cell temperature rises, analyzing performance under dynamic conditions.
11. Initial Charge/Discharge Capacity/Energy Test
Finally, initial capacity/energy tests are conducted to determine whether the cluster meets performance requirements.
Conclusion
These fundamental performance tests collectively ensure the stability and safety of high-voltage cabinets and associated systems.
