Test system of electric vehicle over-charging gun line liquid cooling device

Abstract

The invention discloses a test system for an electric vehicle over-charging gun line liquid cooling device, and the system comprises an oil tank which is used for storing oil and carrying out the operation and liquid charging of a tested cooling unit; the offline filtering unit is connected with the oil tank; the liquid filling unit is respectively connected with the tested cooling unit and the oil tank; the test unit is connected with the tested cooling unit; the testing unit is controlled by the testing platform electric control unit, and the electrical wiring of the tested cooling unit is connected with the testing platform electric control unit through the electrical interface, so that electrification and high efficiency of a testing process are realized, a result is automatically judged by logic in the testing process, human errors are avoided, and liquid filling is automatically completed; test records are automatically generated and archived, the product test digitization is improved, the test system is integrally closed, a filter device is arranged, external pollution is avoided, and the product cleanliness is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle supercharging piles, and in particular to a testing system for a liquid cooling device of an electric vehicle supercharging gun line. Background Art

[0002] With the demand for improved charging efficiency of electric vehicles, liquid-cooled super charging piles have become a hot topic in the industry. Tesla's fast charging piles were the earliest representative, and the number and increment of liquid-cooled charging piles are constantly increasing. For liquid-cooled gun lines, each gun line on the charging pile usually needs to be equipped with a liquid cooling device. The basic composition of the liquid cooling device is shown in the attached manual. Figure 1 As shown, the system includes a series of devices such as liquid level sensor, pump, overflow valve, pressure sensor, temperature sensor, radiator assembly, PLC, etc. Considering that the service object of the liquid cooling device is the gun line, there are more stringent reliability and safety requirements. Therefore, each product needs to be strictly tested. The test content includes not only the performance of the above-mentioned devices, but also the logic check of the PLC, the verification of the heat dissipation capacity, etc.

[0003] At present, the common testing method for this product is to temporarily build a test bench, short-circuit the inlet and outlet of the gun line to form a simple closed loop, and then start each device. The tester will conduct a visual inspection item by item. After the test is completed, manual filling is performed. This solution is not only inefficient, but may also result in human errors or missed detections, and cannot meet some test requirements.

[0004] Therefore, the present application proposes a testing system for a liquid cooling device of an electric vehicle supercharging gun line. Summary of the invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a test system for a liquid cooling device of a supercharging gun line of an electric vehicle.

[0006] In order to achieve the above-mentioned purpose, the main technical scheme adopted by the present invention includes: a test system for an electric vehicle supercharging gun line liquid cooling device, including: an oil tank, which is used to store oil and to operate and fill the cooling unit under test; an offline filter unit, which is connected to the oil tank, and is used to filter and remove condensed water and various small-diameter impurities in the oil; a filling unit, which is respectively connected to the cooling unit under test and the oil tank; a test unit, which is connected to the cooling unit under test, and is used to test various functions of the cooling unit under test; and a test platform electronic control unit, which is controlled by the test platform electronic control unit, and the electrical wiring of the cooling unit under test is connected to the test platform electronic control unit through an electrical interface.

[0007] Preferably, the offline filtering unit comprises a first oil tank filter, an offline filtering pump and an offline filtering assembly; a loop pipeline is fixedly connected to the oil tank; the first oil tank filter, the offline filtering pump and the first oil tank filter are all installed on the loop pipeline; the first oil tank filter is located at the liquid inlet end of the loop pipeline; the offline filtering assembly is located at the liquid outlet end of the loop pipeline; and the offline filtering pump is located between the first oil tank filter and the offline filtering assembly.

[0008] Preferably, a liquid level transmitter is installed inside the oil tank.

[0009] Preferably, the liquid filling unit includes a liquid filling pump, a first pressure sensor, a first flow meter and a liquid level switch, and the liquid filling pump, the first pressure sensor, the first flow meter and the liquid level switch are all installed on the liquid filling pipeline between the oil tank and the cooling unit under test, the liquid filling pump is located at the liquid inlet end of the liquid filling pipeline, the liquid level switch is located at the liquid outlet end of the liquid filling pipeline, and the first pressure sensor and the first flow meter are located between the liquid filling pump and the liquid level switch.

[0010] Preferably, a second oil tank filter is fixedly installed on the inlet front end pipeline of the charging pump.

[0011] Preferably, the test unit includes a test flow path pipeline, a second pressure sensor, an electric ball valve, a heater and a second flow meter, the second pressure sensor, the electric ball valve, the heater and the second flow meter are all installed on the test flow path pipeline, one end of the test flow path pipeline is connected to the liquid outlet of the cooling unit under test, and the other end is connected to the liquid inlet of the cooling unit under test.

[0012] Preferably, the electronic control unit of the test platform is a PLC controller, and the offline filtering unit, the liquid filling unit and the test unit are all controlled by the PLC controller.

[0013] Preferably, an oil temperature sensor is fixedly installed inside the oil tank.

[0014] Preferably, the offline filter assembly comprises a filter housing, the filter housing is connected to the loop pipeline, a sealing ring is provided at the connection portion, and a filter screen is installed inside the filter housing.

[0015] Preferably, an audible and visual alarm is fixedly mounted on the oil tank, and the audible and visual alarm, the oil temperature sensor and the liquid level transmitter are all controlled by the electronic control unit of the test platform.

[0016] The present invention has at least the following beneficial effects:

[0017] By setting up the oil tank, offline filter unit, filling unit, test unit and the coordinated use of the test platform electronic control unit, the test process is electrified and efficient. The test process uses logic to automatically determine the results to avoid human errors. The filling is completed automatically, with less leakage and good filling consistency. The test records are automatically generated and archived, which improves the digitization of product testing. The test system is overall closed and has its own filtering device to avoid external pollution and improve product cleanliness. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0019] Figure 1 A schematic diagram of a cooling unit to be tested of a test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to the present invention;

[0020] Figure 2 It is a schematic diagram of the overall structure of the test system of the electric vehicle supercharging gun line liquid cooling device of the present invention.

[0021] Description of Figure Numbers:

[0022] 1. Oil tank; 11. Oil temperature sensor; 12. Liquid level transmitter; 13. First oil tank filter; 14. Offline filter pump; 15. Offline filter assembly; 16. Second oil tank filter; 17. Filling pump; 18. First pressure sensor; 19. Flow meter; 20. Liquid level switch; 21. Second pressure sensor; 22. Electric ball valve; 23. Heater; 24. Flow meter; 25. Test platform electronic control unit; 26. Cooling unit under test. DETAILED DESCRIPTION

[0023] The following will describe the implementation methods of the present application in detail with the help of accompanying drawings and examples, so that the implementation process of how the present application uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0024] Please refer to Figure 1 to Figure 2As shown, an embodiment of the present invention provides a test system for a liquid cooling device of an electric vehicle supercharger line, comprising: an oil tank 10, the oil tank 10 is used for storing oil and for running and filling a cooling unit 26 under test; an offline filtering unit, the offline filtering unit is connected to the oil tank 10, and the offline filtering unit is used to filter and remove condensed water and various small-diameter impurities in the oil; a filling unit, the filling unit is respectively connected to the cooling unit 26 under test and the oil tank 10; a test unit, the test unit is connected to the cooling unit 26 under test, and the test unit is used to test various functions of the cooling unit 26 under test; and a test platform electronic control unit 25. The test unit is controlled by the test platform electronic control unit 25. The electrical wiring of the tested cooling unit 26 is connected to the test platform electronic control unit 25 through an electrical interface. By setting up the oil tank 10, the offline filtering unit, the filling unit, the test unit and the test platform electronic control unit 25, the test process is electrified and efficient. The test process uses logic to automatically determine the results to avoid human errors. The filling is automatically completed with less leakage and good filling consistency. The test records are automatically generated and archived to improve the digitization of product testing. The test system is closed as a whole and has its own filtering device to avoid external pollution and improve product cleanliness.

[0025] Specifically, the offline filtering unit includes a first fuel tank filter 13, an offline filtering pump 14 and an offline filtering assembly 15. A loop pipeline is fixedly connected to the fuel tank 10. The first fuel tank filter 13, the offline filtering pump 14 and the first fuel tank filter 13 are all installed on the loop pipeline. The first fuel tank filter 13 is located at the liquid inlet end of the loop pipeline, the offline filtering assembly 15 is located at the liquid outlet end of the loop pipeline, and the offline filtering pump 14 is located between the first fuel tank filter 13 and the offline filtering assembly 15. The system integrates an offline filtering unit at the fuel tank 10. Regardless of whether the test platform is working or not, the offline filtering pump 15 is always running to extract a certain flow of liquid from the fuel tank 10 into the offline filtering assembly 15. The offline filtering assembly 15 mainly filters and removes condensed water and various small-diameter impurities that may exist in the oil, so that the oil in the fuel tank 10 always maintains a low water content and a high cleanliness. The first fuel tank filter 13 in the bypass is mainly to improve the working conditions of the offline filtering pump 14 and extend its service life.

[0026] A liquid level transmitter 12 is installed inside the oil tank 10, an oil temperature sensor 11 is fixedly installed inside the oil tank 10, and an audible and visual alarm is fixedly installed on the oil tank 10. The audible and visual alarm, the oil temperature sensor 11 and the liquid level transmitter 12 are all controlled by the test platform electronic control unit 25. The oil temperature sensor 19 and the liquid level transmitter 16 monitor the temperature and real-time liquid level of the oil in the oil tank 10 respectively. When the oil temperature is too high or the oil level is too low, an alarm message can be issued in time through the audible and visual alarm to remind the operator to take timely measures and replenish fluid, etc. The model of the oil temperature sensor 11 is PT1000, the model of the liquid level transmitter 16 is FX-UZ, and the model of the audible and visual alarm is SL-125.

[0027] The filling unit includes a filling pump 17, a first pressure sensor 18, a first flowmeter 19 and a liquid level switch 20. The filling pump 17, the first pressure sensor 18, the first flowmeter 19 and the liquid level switch 20 are all installed on the filling pipeline between the oil tank 10 and the cooling unit 26 under test. The filling pump 17 is located at the liquid inlet end of the filling pipeline, and the liquid level switch 20 is located at the liquid outlet end of the filling pipeline. The first pressure sensor 18 and the first flowmeter 19 are located between the filling pump 17 and the liquid level switch 20. The system integrates a filling unit, wherein the filling pump 17 adopts a PMW control mode, the speed is adjustable in real time, and can provide a speed feedback function, and feed back the speed of the pump to the test platform electronic control unit 25 in real time. When the cooling unit 26 under test needs to be filled with liquid, the test platform electronic control unit 25 starts the filling pump 17. The flow meter 19 is used to monitor the flow rate of the filling liquid in real time, and the liquid level switch 20 is used to monitor the liquid level in the tested cooling unit 26. When the liquid level is low, the test platform electronic control unit 25 controls the speed of the filling pump 17 to be faster, the flow rate is larger, and the filling speed is fast. As the liquid level gradually increases, the speed of the filling pump 17 will gradually decrease, and the flow rate and the filling speed will gradually decrease to avoid the liquid overflowing from the filling port due to excessive liquid flow speed. The first pressure sensor 18 is mainly used to monitor the real-time pressure at the outlet of the filling pump 17. When the pressure is too high, it means that there is a blockage problem in the filling flow path. The test platform electronic control unit 25 will promptly remind the operator to check the flow path and close the filling function when necessary. The filter has a pressure difference signaling function. When the filter element is gradually blocked by contaminants and the filtering capacity is reduced, an alarm signal will be issued to prompt the replacement of the filter element.

[0028] A second oil tank filter 16 is fixedly installed on the inlet front end pipeline of the filling pump 17. The second oil tank filter 16 is mainly used to improve the working conditions of the filling pump 18 and extend its service life. The filter has a pressure difference signaling function. When the filter element is gradually blocked by pollutants and the filtering capacity is reduced, an alarm signal will be issued to prompt the replacement of the filter element.

[0029] The test unit includes a test flow path pipeline, a second pressure sensor 21, an electric ball valve 22, a heater 23 and a second flow meter 24. The second pressure sensor 21, the electric ball valve 22, the heater 23 and the second flow meter 24 are all installed on the test flow path pipeline. One end of the test flow path pipeline is connected to the liquid outlet of the tested cooling unit 26, and the other end is connected to the liquid inlet of the tested cooling unit 26. The flow path is mainly used to test the various functions of the tested cooling unit 26. The model of the electric ball valve 22 is DN40, and the model of the second pressure sensor 21 is QBE2103-P25.

[0030] The test platform electronic control unit 25 is a PLC controller. The offline filtering unit, the liquid filling unit and the test unit are all controlled by the PLC controller. The model of the PLC controller is Siemens s7-300 series.

[0031] The off-line filter assembly 15 comprises a filter housing, which is connected to the loop pipeline, and a sealing ring is provided at the connection part, and a filter screen is installed inside the filter housing.

[0032] The working principle of the present invention is:

[0033] 1. Liquid filling and device function testing:

[0034] Before the filling pump 17 is started, the test platform electronic control unit 25 first checks the following status: the tested system is in a non-working state, the corresponding terminal of the tested cooling unit 26 is fed back to the test platform electronic control unit 25, the electric ball valve 22 should be operated to the fully open position, i.e., fully open feedback, the filling fixture liquid level switch 20 is in the initial state, i.e., closed state, and the test platform electronic control unit 25 has no alarm state;

[0035] Before the filling pump 17 is started, the system first tests the initial status of the following components, determines the test results, and displays them in the final test record:

[0036] a. PT1000 function test: The readings of PT1000 8.1-8.3 of the tested system are recorded in the table and compared with the reading of the platform oil temperature sensor 11. When the maximum difference is less than the set value, it is judged as qualified.

[0037] b. Determination of liquid level switch state 1: Before filling, the liquid level switch 3 of the system under test is at the lowest point. At this time, the state should be displayed in red, and both liquid level feedback signals are in the disconnected state. If the detection is consistent, the first state of the liquid level switch function is determined to be qualified, waiting for subsequent testing and determination. After all the test items involving the device are qualified, the overall judgment result is qualified. If any of the intermediate steps are not satisfied, the overall judgment result is unqualified.

[0038] After the above steps are tested and qualified, the system under test is filled with liquid, and the filling pump 17 is started and stopped when the state of the liquid level switch 20 of the filling tool is switched to the disconnected state;

[0039] During this process, the test platform electronic control unit 25 detects the following system device functions:

[0040] a. Liquid level switch status 2 and final judgment:

[0041] As the filling progresses, the liquid level of the system under test continues to rise. At this time, the low liquid level Alarm signal of the liquid level switch 3 should be switched first, that is, switched from disconnected to on. After a period of time, the low liquid level Warning signal should be switched, that is, switched from disconnected to on. If the above process occurs before the filling is completed, the state 2 of the liquid level switch function is judged to be qualified. If the sequence is correct, the sequence is judged to be qualified. If the above process lacks an action or the sequence is incorrect, the overall result is unqualified;

[0042] b. Heater function determination: After the filling pump 17 stops, start the heater of the system under test, measure its current value and record it. If the current value is normal, the connected state is determined to be qualified. Then disconnect the heater, the current value should be 0, and the disconnected state is determined to be qualified.

[0043] After the above steps are tested and qualified, the first stage is completed and enters the next stage: system function testing stage.

[0044] 2. System function test:

[0045] After the first stage is completed, the test platform electronic control unit 25 tests the following functions:

[0046] a. Perform functional detection on the operation of the fan and the oil pump: the electronic control unit connects test resistors of different resistance values, i.e., PT1000 resistance values ​​simulating different temperatures, to the tested cooling unit 26 respectively, and then issues an operation instruction to the tested system: according to the different test resistance values, the oil pump and the fan should be in different working states. According to the corresponding program, if the actual speed of the two is within the speed range set by the logic, it is judged that the function is operating normally, otherwise it is judged to be unqualified.

[0047] b. Withstand pressure test and fault function determination: After the above steps are tested and qualified, the electric ball valve 22 is switched from fully open to fully closed. At this time, the test platform electronic control unit 25 records the reading of the second pressure sensor 21, and records the highest pressure value in this process into the line of withstand pressure and overflow protection in the table. If the reading is within the set value ±0.5 of the withstand pressure test pressure setting value, it is determined to be qualified. At this time, the test platform electronic control unit 25 should also receive the cooling unit fault information fed back by the tested system. If the feedback has been received, it does not need to exist continuously, and the alarm status feedback should be determined to be qualified, otherwise the item is unqualified;

[0048] After the test steps are completed, the electric ball valve 22 is switched from fully closed to fully open. At this time, the reading of the second pressure sensor 21 should drop, and the fault information fed back by the tested system should be eliminated, that is, it will no longer appear, and the normal operating status feedback should be judged as qualified, but it is unqualified.

[0049] c. System heat dissipation capacity detection: After the above steps are tested and qualified, keep the status of each device unchanged, then start the test to control the heater 23 to start, and after running for three minutes, record the readings of the three PT1000 of the system under test, i.e. 8.1-8.3, the first flow meter 19 of the test platform and the oil temperature sensor 11.

[0050] The test system automatically substitutes each parameter into the following formula for calculation and automatically calculates the Pcoe value.

[0051] Pcoe=1.6*Q*(T1-T2) / [60*(T1-T3)])

[0052] Among them, Q is the reading of the flow meter, the unit is L / min; T1 is the temperature of the sensor 8.2 of the cooling unit 26 under test and the sensor 8.3 of the cooling unit 26 under test, that is, the higher one; T2 is the temperature of the sensor 8.1 in the cooling unit 26 under test; T3 is the temperature of the oil temperature sensor 11. When the Pcoe value ≥ the heat dissipation capacity coefficient K is set in advance according to actual requirements, the heat dissipation capacity is judged to be qualified, otherwise it is unqualified.

[0053] d. Fluid replacement:

[0054] The test platform electronic control unit 25 sends a shutdown command to the system under test. At this time, the oil pump and the fan should be in a stopped state, PT1000, that is, 8.1-8.3 has normal readings, and the state feedback of the system under test is normal. At this time, the liquid level switch 20 of the filling fixture is in a closed state;

[0055] The filling pump 17 is started to perform the filling operation. When the state of the filling tooling liquid level switch 20 is switched to the disconnected state, the filling 17 stops running;

[0056] After all test items are qualified, the test completion light, that is, the green light flashes as a prompt. The operator enters the product serial number and clicks "Test Complete". The relevant table is automatically saved to the corresponding storage area of ​​the test platform electronic control unit 25 according to the naming rule of date plus serial number. Otherwise, a prompt "Product serial number not entered" will pop up.

[0057] The above description shows and describes several preferred embodiments of the present invention, but as mentioned above, it should be understood that the present invention is not limited to the form disclosed herein, and should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications and environments, and can be modified within the scope of the invention concept described herein through the above teachings or the technology or knowledge of the relevant field. Changes and variations made by those skilled in the art do not depart from the spirit and scope of the present invention, and should be within the scope of protection of the claims attached to the present invention.

Claims

1. A test system for a liquid cooling device of an electric vehicle supercharging gun line, characterized in that: include: An oil tank (10), the oil tank (10) being used for storing oil and for operating and filling the cooling unit (26) under test; An offline filtering unit, the offline filtering unit being connected to the oil tank (10), and the offline filtering unit being used to filter and remove condensed water and impurities present in the oil; A liquid filling unit, the liquid filling unit being connected to the cooling unit (26) to be tested and the oil tank (10) respectively; A testing unit, the testing unit being connected to the cooling unit (26) under test, the testing unit being used to test the function of the cooling unit (26) under test; as well as A test platform electronic control unit (25), wherein the test unit is controlled by the test platform electronic control unit (25), and the electrical connection of the tested cooling unit (26) is connected to the test platform electronic control unit (25) via an electrical interface.

2. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 1, characterized in that: The offline filtering unit comprises a first oil tank filter (13), an offline filtering pump (14) and an offline filtering assembly (15); a loop pipeline is fixedly connected to the oil tank (10); the first oil tank filter (13), the offline filtering pump (14) and the first oil tank filter (13) are all installed on the loop pipeline; the first oil tank filter (13) is located at the liquid inlet end of the loop pipeline; the offline filtering assembly (15) is located at the liquid outlet end of the loop pipeline; and the offline filtering pump (14) is located between the first oil tank filter (13) and the offline filtering assembly (15).

3. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 2, characterized in that: A liquid level transmitter (12) is installed inside the oil tank (10).

4. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 1, characterized in that: The liquid filling unit comprises a liquid filling pump (17), a first pressure sensor (18), a first flow meter (19) and a liquid level switch (20); the liquid filling pump (17), the first pressure sensor (18), the first flow meter (19) and the liquid level switch (20) are all installed on a liquid filling pipeline between the oil tank (10) and the tested cooling unit (26); the liquid filling pump (17) is located at the liquid inlet end of the liquid filling pipeline, the liquid level switch (20) is located at the liquid outlet end of the liquid filling pipeline, and the first pressure sensor (18) and the first flow meter (19) are located between the liquid filling pump (17) and the liquid level switch (20).

5. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 4, characterized in that: A second oil tank filter (16) is fixedly installed on the inlet front end pipeline of the charging pump (17).

6. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 1, characterized in that: The test unit comprises a test flow path pipeline, a second pressure sensor (21), an electric ball valve (22), a heater (23) and a second flow meter (24); the second pressure sensor (21), the electric ball valve (22), the heater (23) and the second flow meter (24) are all installed on the test flow path pipeline; one end of the test flow path pipeline is connected to the liquid outlet of the tested cooling unit (26), and the other end is connected to the liquid inlet of the tested cooling unit (26).

7. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 3, characterized in that: The test platform electronic control unit (25) is a PLC controller, and the offline filtering unit, the liquid filling unit and the test unit are all controlled by the PLC controller.

8. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 7, characterized in that: An oil temperature sensor (11) is fixedly installed inside the oil tank (10).

9. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 2, characterized in that: The offline filter assembly (15) comprises a filter housing, which is connected to the loop pipeline and has a sealing ring at the connection position. A filter screen is installed inside the filter housing.

10. A test system for a liquid cooling device for a supercharging gun line of an electric vehicle according to claim 8, characterized in that: An audible and visual alarm is fixedly mounted on the oil tank (10); the audible and visual alarm, the oil temperature sensor (11) and the liquid level transmitter (12) are all controlled by the test platform electronic control unit (25).

Images