In the operation of the battery management system (BMS), the safety of the BMS test equipment system is crucial. In order to ensure that it can work reliably in various application scenarios and ensure the safety of batteries and related equipment, a complete set of safety test methods and standards is essential.

1. Safety test methods

(I) Electrical safety test

Insulation resistance test: Use an insulation resistance tester to measure the insulation resistance value between the live parts of the BMS test equipment system and the non-live parts such as the shell. It is generally required that under the specified test voltage, the insulation resistance should reach a certain value, such as above the megohm level, to prevent leakage and avoid the risk of electric shock to personnel.

Withstand voltage test: Apply an AC or DC voltage that is a certain multiple of the normal operating voltage to the equipment for a certain period of time to observe whether the equipment can withstand it without breakdown or flashover. This can effectively test the insulation withstand voltage capability of the equipment and ensure that no electrical safety accidents will occur under voltage fluctuations.

(II) Overcharge and over-discharge protection test

Overcharge test: Simulate the battery in an overcharged state, and adjust the charging equipment to make the battery voltage continue to rise above the normal charging cut-off voltage. Observe whether the BMS test equipment system can detect overcharging in time and accurately trigger the overcharging protection mechanism, such as cutting off the charging circuit, etc., to prevent the battery from bulging, heating, or even catching fire and exploding due to overcharging.

Overdischarge test: On the contrary, set the battery to over-discharge so that its voltage is lower than the normal discharge cut-off voltage. Detect whether the BMS test equipment system can quickly identify the over-discharge state and then take corresponding protection measures, such as limiting the discharge current or stopping the discharge, to protect the performance and safety of the battery and avoid irreversible capacity loss of the battery due to over-discharge.

(III) Short-circuit protection test

Intentionally short-circuit the positive and negative poles of the battery to simulate an extreme short-circuit fault. At this time, observe whether the BMS test equipment system can detect the occurrence of a short circuit in a very short time and immediately activate the short-circuit protection function, such as cutting off the circuit, to prevent excessive short-circuit current from causing serious damage to the battery and the equipment itself, such as battery overheating and circuit burning.

(IV) Temperature abnormality test

High temperature test: Place the BMS test equipment system in a high temperature environment box, set different high temperature values, such as 60℃, 80℃, etc., for a certain period of time, and monitor the operation of the equipment under high temperature. Check whether there will be performance degradation, data transmission errors, protection mechanism failure and other problems, and observe whether the equipment's own heat dissipation measures can play an effective role to ensure that the equipment can still operate safely and reliably in a high temperature environment.

Low temperature test: Similarly, put the equipment into a low temperature environment box, set low temperature conditions such as -20℃, -40℃, etc. After a certain period of time, check whether the equipment can start normally, whether all functions are normal, and whether the low temperature will cause the performance of electronic components to deteriorate, battery management to deviate, etc., to ensure that the equipment is also safe in a cold environment.

II. Safety test standards

(I) International standards

International organizations such as the International Electrotechnical Commission (IEC) have formulated relevant standards, such as IEC 62619, which puts forward standard requirements for the safety of battery management systems for energy storage systems, including specific indicators for BMS test equipment systems in electrical safety, battery protection, etc., providing an important reference for equipment safety testing worldwide.

(II) National standards

Different countries have also formulated corresponding national standards based on their own national conditions and industry development. For example, my country's GB/T 36276 stipulates the safety requirements for battery management systems for lithium-ion battery energy storage systems, and clarifies the qualification standards for BMS test equipment systems in various safety tests, such as the minimum value of insulation resistance, the voltage value and time of withstand voltage test, the response time of overcharge and over-discharge protection, and other specific parameters, providing a clear basis for domestic companies to produce and test BMS test equipment systems.

(III) Industry standards

Various industry associations will also issue some industry standards to regulate the safety testing of BMS test equipment systems. These standards often combine industry characteristics and put forward more detailed requirements for equipment safety in specific application scenarios. For example, in the electric vehicle industry, relevant industry standards will focus on the battery management safety during vehicle driving, and make provisions for the real-time response speed and fault diagnosis capabilities of BMS test equipment systems.

In summary, through scientific and reasonable safety testing methods and strict testing in accordance with relevant international, national and industry standards, the safety of the BMS test equipment system can be effectively guaranteed, enabling it to play a reliable role in the field of battery management and safeguarding the safe operation of batteries and related equipment.

With the continuous advancement of battery technology, BMS test equipment will also be continuously upgraded to meet the needs of more efficient, safer and smarter battery management. All test equipment in the KC-BMS test system is independently developed by Kingcable's own instrument brand. The overall architecture is modular, and the communication protocol and communication interface adopt unified standards to facilitate later expansion and maintenance. The KC-BMS test system has high integration and wide application coverage. The system adopts software and hardware integrated design and is rich in functions. While ensuring the stable operation of the system, it can quickly meet more than 90% of the BMS project testing needs of various types in various industries such as power batteries, energy storage systems, and power tools.