Wani da aka duba a fannonin tattalin kasa na gwamnati da kasuwanci?

A cikin yakin da na yi labari, ina koyarwa da tattalin da na iya da suka fito da shirya takalmomi. Ina jin da ma amfani da su ga wasu rukuni masu zafi mai kyau. Idan ana fi saki da hanyoyi, yanayin aiki na musamman ya zama muhimmanci ga tsarin zarfi da al'adun kasuwanci. Idan an samu fittoci a kan ziyartar da na yi, abubuwan da ba su dace ba sun fi hada da ROI—da 57% daga cikin take da suka fito da shirya takalmomi suka bayyana cewa an sa shiga aiki a shekarar 2023, tare da 80% daga cikinsu suna nuna cewa wadannan suna lalace saboda abubuwan da ba su dace ba, matsaloli, ko kuma babban da suka gine da su. A nan, ina bayar da ma aiki masu tsarin bayani game da kungiyoyin bincike (battarya, BMS, PCS, tsarin yawan mutum, EMS) da kuma tsarin bincike uku (bincike na ranar, inganta, bincike mai zurfi) don in taimaka waɗanda suke da ma aiki.

1. Tsarin Bincike Kungiyoyin Bincike
1.1 Kungiya na Battarya: "Zuci" na Shirya Takalmomi

Battaryar su ne karkashin zafi, domin haka an bukatar binciken masu kammala a kan tsohon lokaci:

(1) Bincike Masu Zafi Mai Yawanci

• Bincike Tsarin Zafi: Yi amfani da GB/T 34131—fito battarya a 0.2C har zuwa hanyar fitowa (25±2℃), karshe tsarin zafi da tsarin zafi mai sarrafa don in tabbatar da “haliyar.”

• Bincike Tsarin Hanya: Amfani da faɗa na AC (sine wave na 1kHz, wanda ya fi yawa amma ya fi yawa da karfin haɗin kai), faɗa na AC discharge conductance, ko kuma tsarin DC. Ina maimaita cewa a yi amfani da Kalman filtering don in kama tsari don adadin da ya fi yawa.

• Ikkira SOC/SOH: Haɗa ampere-hour integration, open-circuit voltage, da electrochemical impedance spectroscopy. Ampere-hour integration mai yin ƙarfin (da ta ƙunshi tsari da yanayin fito da shirya) yana ƙara irin da ya fi yawa SOC <1%.

(2) Bincike Masu Zafi Mai Inganta

• Bincike Tsarin Yawan Mutum: Yi amfani da UL 9540A&mdash;yi bincike a cell, module, da system levels don in tabbatar da haliyar tsarin yawan mutum da halayyar gas (wanda ya fi muhimmanci ga haliyar tsarin yawan mutum).

• Bincike Overcharge/Overdischarge: Tabbata hanyoyin inganta a cikin GB/T 36276 don in tabbatar da hanyoyin inganta.

• Bincike Short-Circuit Protection: Tabbata short-circuit wajen tsarin yawan mutum don in tabbatar da hanyoyin inganta (wanda ya fi muhimmanci ga tsarin yawan mutum).

(3) Bincike Tsarin Yawan Musamman

• Bincike Cikakken Mata: Tabbata wajen dole, gafara, da rubutu mai girma (wadannan abubuwa masu tsabta suna nuna tsabton da ya fi yawa).

• Bincike Connector: Tabbata wajen oxidation, corrosion, ko kuma hankali; kada tsarin contact resistance (wadannan abubuwa suna nuna tsabton da ya fi yawa).

• Bincike Tsarin Yawan Inganta (IP): Yi amfani da GB/T 4208 don in tabbatar da tsarin yawan inganta a cikin tsabton da ya fi yawa (tsirri, ruwa, etc.).

1.2 BMS: "Gargajiya" na Iya Kamantan Battarya

BMS tattauna da kuma ya ƙara battaryar&mdash;kafofin amfani da tsarin yawan mutum, state estimation, da kuma inganta:

(1) Bincike Tsarin Yawan Amfani Da Protocol

BMS ya kamata a yi amfani da PCS/EMS via protocols kamar Modbus/IEC 61850. Yi amfani da CAN analyzers (misali, Vector CANoe) da kuma protocol converters don in bincike:

• Latency: &le;200ms

• Success Rate: &ge;99%

• Tsarin Data Integrity: Ba za a gama data ba/corruptio.

Ina amfani da finite-state machine (FSM)-based test case generation don in kafa duk yadda ake amfani da tsarin yawan amfani.

(2) Validation Algorithmin SOC/SOH

Tabbata cewa irin da ya fi yawa SOC &le;&plusmn;1% da SOH &le;&plusmn;5% (GB/T 34131):

• Offline Calibration: Karshe estimatin BMS da lab-measured capacity / Internal Resistance

• Online Testing: Simulate real-world charge-discharge cycles.

• Battery simulators and BMS interface emulators automate this for efficiency.

(3) Cell Balancing Testing

• Active Balancing: Simulate cell mismatches to validate BMS strategies.

• Passive Balancing: Track long-term mismatch trends.
  Use results to judge if balancing meets system needs.

(4) Safety Protection Testing

Trigger overcharge, overdischarge, and thermal protection:

• Example: Overcharge test&mdash;continue charging a full battery to verify BMS disconnects the circuit.
  Must meet GB/T 34131 requirements.

1.3 PCS: "Power Hub" for Energy Conversion

PCS converts AC/DC&mdash;test efficiency, protection, and power quality:

(1) Efficiency Testing

Meet GB/T 34120 (&ge;95% efficiency at rated power):

• Input-Output Comparison: Measure power at both ends to calculate efficiency.

• Load Profiling: Test across loads to map efficiency curves.
  Use high-precision analyzers (e.g., Fluke 438-II) at 25&plusmn;2℃ for accuracy.

(2) Protection Testing

Validate overload (110% rated load), short-circuit, and overvoltage responses. Must meet GB/T 34120.

(3) Harmonic Analysis

Ensure THD &le;5% (GB/T 14549/GB/T 19939):

• Direct Measurement: Use power quality analyzers (e.g., Fluke 438-II) to test waveforms.

• FFT Analysis: Calculate harmonic amplitudes from current signals.

• Test across loads and operating conditions.

(4) Output Stability Testing

Measure voltage, frequency, and power factor stability under varying loads. Use high-precision scopes/analyzers to verify compliance.

1.4 Thermal Management System: The "Cooling Guardian"

Maintains optimal battery temperature&mdash;test cooling, temperature control, and ruggedness:

(1) Cooling Performance Testing

• Air-Cooled Systems: Test filter clogging (pressure drop) and fan life (vibration analysis).

• Liquid-Cooled Systems: Test pipeline pressure (hydraulic sensors) and coolant flow (flowmeters).
  Must meet GB/T 40090. Example: CATL uses modified K-means clustering + wavelet denoising to predict SOH with <3% error.

(2) Temperature Control Precision Testing

• Uniformity: Deploy sensors across the battery pack, ensure max &Delta;T &le;5℃ (GB/T 40090; liquid-cooled systems target &le;2℃).

• Response Time: Measure time to stabilize temperature after environmental changes.

(3) Ruggedness Testing

Conduct IP (GB/T 4208), vibration (GB/T 4857.3), and salt-spray (GB/T 2423.17) tests. Critical for extreme environments (e.g., Huawei&rsquo;s Red Sea project uses distributed cooling for 50℃ conditions).

(4) Leak Detection (Liquid-Cooled Only)

• Fluorescent Tracer: Add dye, inspect with UV light.

• Pressure Testing: Pressurize lines to check seals.

• Ensure no leaks and stable coolant pressure.

1.5 EMS: The "Commander" of Energy Management

Optimizes operation and dispatching&mdash;test algorithms, communication, and security:

(1) Algorithm Accuracy Testing

Validate load forecasting, charge-discharge optimization, and economics:

• Historical Backtesting: Use past data to verify models.

• Live Testing: Validate with real-time operations.

• Example: CATL&rsquo;s AI cuts fault detection time by 7 days, boosting efficiency by 3% and reducing losses by 25%.

(2) Communication Protocol Compatibility Testing

Ensure support for IEC 61850/Modbus (IEC 62933-5-2):

• Conformance Testing: Verify compliance with standards.

• Interoperability Testing: Test integration with BMS/PCS.

(3) Data Security Testing

Validate SM4 encryption, access control, and integrity (per national crypto standards):

• Encryption: Test SM4 key exchange.

• Access Control: Verify user permission enforcement.

• Integrity: Ensure no data loss/corruption during transit/storage.

(4) Response Time Testing

Ensure system response &le;200ms (GB/T 40090) to handle grid demands. Trigger EMS actions and measure latency.

2. Three-Tiered Inspection Framework
2.1 Daily Checks (Rapid Fault Detection)

Conducted per shift to catch issues early:

• Scope: Battery temp/voltage/SOC, BMS communication, PCS parameters, thermal cooling, EMS data.

• Tools: Thermal cameras, multimeters, oscilloscopes, communication testers.

• Focus: System status and anomalies&mdash;address issues immediately.

2.2 Periodic Maintenance (Preventive Care)

Scheduled to extend lifespan:

• Scope: Battery internal resistance (AC injection), BMS firmware updates/SOC calibration, PCS efficiency/harmonics, thermal system seals/IP, EMS algorithm updates/security checks.

• Tools: Dedicated resistance meters, CAN analyzers, power analyzers, encryption tools.

• Cadence: Tailor to equipment (e.g., quarterly battery tests, semi-annual BMS updates).

2.3 Deep Diagnostics (Root-Cause Analysis)

Triggered by recurring issues (e.g., frequent thermal runaway alerts, BMS communication failures):

• Scope: Thermal runaway (UL 9540A), BMS fault diagnosis, PCS protection/efficiency deep dives, thermal system leak/vibration tests, EMS algorithm validation/security scans.

• Tools: Thermal runaway chambers, vibration analyzers, encryption scanners, fault injectors.

• Goal: Identify root causes for targeted repairs/upgrades.

3. Best Practices: Standardization, Data-Driven Testing, Prevention
3.1 Standardization

Follow IEC 62933-5-2/GB/T 40090-2021:

• Process: Define preparation (scope, tools, environment), execution (testing + data logging), and analysis (reporting).

• Reports: Include equipment specs, test conditions, data, results, and recommendations (per GB/T 40090 requirements for traceability).

3.2 Data-Driven Testing

Build a unified data pipeline (battery temp, voltage, SOC, PCS efficiency, THD, etc.). Use AI (LSTM, random forests) and digital twins:

• Example: CATL&rsquo;s AI predicts SOC errors <1% and SOH decay with >95% accuracy, issuing 7-day advance thermal runaway alerts.

• Example: Huawei uses digital twins to simulate extreme conditions, pre-identifying failures.

3.3 Preventive Testing

Schedule proactive checks based on equipment behavior:Cadence: Quarterly cell balancing, semi-annual BMS updates, annual PCS harmonics/thermal seals checks, quarterly EMS algorithm updates.

• Triggers: Deep diagnostics for &ge;5% internal resistance rise (3 consecutive tests) or recurring communication failures.

Frontline testing demands rigor, expertise, and practical know-how. Mastering these subsystems, tools, and strategies ensures energy storage systems deliver reliability and efficiency&mdash;safeguarding business and grid operations. This guide distills years of hands-on experience&mdash;I hope it empowers fellow testers to raise the bar in energy storage reliability.