چه جوانه‌هایێک دەگرێت لە هەڵسەنگاندنی نەخۆشەوەزی ئینداستری و کۆمێرسی؟

Wê îmîn testî ya paşîya, her roza bi sîsteman derbendkirina wêjeya li ser projeyên endamî û komersîyan dibeşim. Ezmûna min reyî e ku çawa şekastî yên operasyonan ji bo efektivîyetî enerjî û karîdarî yên biznesî taybetand. Di dema ku kapasîteyên sazandin hêsan dihêvîne, çokîkên cihedan da bîraînên ROI—da, di salê 2023 de, yê 57% dan sîsteman derbendkirina wêjeya destûr nake wekî ku beşdariyên 80% ji xebitandî yên cihedan, anormaleên sîsteman, û integrasyonan welat. Ji ber vê yekê, ez digelî yanî yên pratîkî yên testî yên penîn yên penîn (batarya, BMS, PCS, riyazîya termal, EMS) û pelengên pargîdanê yên sê (têkerdanan rojan, pêkhatinên demgirî, teşhîsên derîn) jêbiribim bi tenê ku yarbudan.

1. Pratîkî yên Testî yên Penînên Penîn
1.1 Sîstem Batarya: "Dil" derbendkirina wêjeya

Bataryan zafînên energiya ne, u hewceyên testî yên têkiliyên sê:

(1) Testî yên Performansa Elektrokîmîkî

• Testî Capacity: Bi GB/T 34131—discharge bide 0.2C derketina voltaj (25±2℃), parçav bike kapasîtek din vs. kapasîtek rêkî bi bo axoyî “dayîn”.

• Testî Internal Resistance: Karberdenî AC injection (sinus wave 1kHz, most representative but prone to interference), AC discharge conductance, û metoda DC discharge. Ez destûrim kara AC injection bigerîne bi Kalman filtering bi bo redkirina noise ji bo rastînî.

• SOC/SOH Monitoring: Birhate ampere-hour integration, open-circuit voltage, û electrochemical impedance spectroscopy. Modified ampere-hour integration (accounting for temperature and charge-discharge states) keeps SOC errors <1%.

(2) Testî yên Performansa Herêmî

• Thermal Runaway Testing: Bi UL 9540A&mdash;test bikin ji cell, module, û sîstem level bi bo karakterîzasyona thermal runaway behavior û gas combustion properties (critical for hazard assessment).

• Overcharge/Overdischarge Testing: Simulate extreme conditions per GB/T 36276 to verify safety thresholds.

• Short-Circuit Protection Testing: Directly simulate external shorts to validate protective responses (a must-have for system safety).

(3) Testî yên Şertî Fîzikî

• Visual Inspection: Jîneyîn ji bo deformasyon case, leaks, û labeling legible (small details hide big risks).

• Connector Testing: Inspect for oxidation, corrosion, or looseness; measure contact resistance (poor connections cause operational failures).

• Ingress Protection (IP) Testing: Follow GB/T 4208 to ensure reliability in harsh environments (dust, moisture, etc.).

1.2 BMS: "Mîn" Battery Management

BMS monitors and protects batteries&mdash;focus on communication, state estimation, and protection:

(1) Communication Protocol Compatibility Testing

BMS must integrate with PCS/EMS via protocols like Modbus/IEC 61850. Use CAN analyzers (e.g., Vector CANoe) and protocol converters to test:

• Latency: &le;200ms

• Success Rate: &ge;99%

• Data Integrity: No loss/corruption.

I use finite-state machine (FSM)-based test case generation to cover all communication scenarios.

(2) SOC/SOH Algorithm Validation

Ensure SOC errors &le;&plusmn;1% and SOH errors &le;&plusmn;5% (GB/T 34131):

• Offline Calibration: Compare BMS estimates to 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: The "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.