Calibration and testing device and method based on electronic fuel dispenser for electric vehicles

Abstract

This application relates to the field of vehicle braking component testing technology, and particularly to a calibration and testing device and method based on an electric vehicle electronic fuel dispenser. The calibration and testing device includes a fixing fixture, a wiring harness connection unit, a host computer system, a transmission unit, and a PLC control system. The fixing fixture is used to hold the electric vehicle electronic fuel dispenser to be tested. The wiring harness connection unit includes a power supply and a calibration programmer. The host computer system is connected to the calibration programmer via a universal serial bus port. The transmission unit includes a positioning fixture, a telescopic cylinder, and a servo motor. One end of the positioning fixture is fixedly connected to the servo motor, and the servo motor is fixedly connected to the telescopic cylinder. One end of the PLC control system is connected to the host computer system via a network cable. This application ensures the synchronization and consistency of calibration and testing procedures for different fuel dispensers, and allows for intuitive comparison of line graphs of test results from different angles of the same fuel dispenser, achieving fully automated operation and quantitative performance evaluation.

Description

Technical Field

[0001] This application relates to the field of vehicle braking component testing technology, and in particular to a calibration testing device and testing method based on an electric vehicle electronic fuel dispenser. Background Technology

[0002] In the current testing process for electronic fuel dispensers in electric vehicles, the mainstream method is to use a multimeter. Technicians manually measure the voltage or resistance signal at the output of the fuel dispenser, and determine the product's passability solely based on whether the Hall sensor's output voltage value is within the normal range. Existing testing technologies generally lack the ability to simulate dynamic operating conditions, failing to reproduce the rotational movements of the electronic fuel dispenser in actual use, such as the rotation of the throttle arm. Only static parameter detection is possible. Even when some devices attempt to simulate dynamic operating conditions by manually rotating the throttle, it is difficult to guarantee uniform rotation speed, leading to distorted dynamic parameter detection data. The continuous change curve of the Hall voltage during rotation cannot be detected, making it difficult to identify parameter anomalies under dynamic conditions such as sudden changes in speed. Furthermore, manual or simple mechanically driven testing methods lack sufficient control precision, and the control of rotation angle and speed cannot meet the requirements for accurate testing. In addition, the calibration process for the mechanical zero position and maximum range of the electronic fuel dispenser is independent of the testing process. The fuel dispenser arm must be precisely rotated to the corresponding position for calibration before proceeding to the next process for testing, resulting in wasted steps and severely impacting production efficiency. The linearity and synchronization of the output characteristics of electronic fuel dispensers are directly related to the stability and safety of electric vehicles during operation. However, existing technologies lack dedicated equipment that can quickly, accurately, and quantitatively detect their output electrical performance. This makes it difficult to efficiently determine whether their output characteristics are linear and synchronized, as well as whether there are faults such as jamming or jumping, and thus fails to meet actual testing and production needs.

[0003] In summary, the technical problems existing in the relevant technologies need to be improved. Summary of the Invention

[0004] The main objective of this application is to propose a calibration and testing device and method based on an electric vehicle electronic fuel dispenser. This method can ensure the synchronicity and consistency of calibration and testing procedures for different fuel dispensers. Linear graphs of test results from different angles of the same fuel dispenser can be compared intuitively, improving the accuracy of the test results. It also achieves fully automated operation and quantitative evaluation of performance.

[0005] To achieve the above objectives, one aspect of this application proposes a calibration and testing device based on an electronic fuel dispenser for electric vehicles, the calibration and testing device comprising: A fixing clamp is used to hold the electric vehicle electronic fuel dispenser to be tested; A wiring harness connection unit, the wiring harness connection unit including a power supply and a calibration programmer, the power supply and the calibration programmer being respectively connected to the clamped electric vehicle electronic fuel dispenser; The host computer system is connected to the calibration programmer via a universal serial bus serial port; The transmission unit includes a positioning clamp, a telescopic cylinder, and a servo motor. One end of the positioning clamp is fixedly connected to the servo motor, the servo motor is fixedly connected to the telescopic cylinder, and the other end of the positioning clamp is movably connected to the rotating arm of the electric vehicle electronic fuel dispenser being held. The PLC control system has one end connected to the host computer system via a network cable, and the other end connected to the servo motor via a control drive harness.

[0006] In some embodiments, the calibration and testing device further includes a connecting plate and two tooling handles; The two tool handles are fixed to both sides of the connecting plate; The fixing clamp, the wire harness connection unit, the host computer system, the transmission unit, and the PLC control system are respectively fixedly connected to the connecting plate.

[0007] In some embodiments, the calibration and testing device further includes an industrial control integrated computer; The wiring harness connection unit, the host computer system, and the PLC control system are located inside the industrial control integrated machine; The industrial control all-in-one computer is equipped with two terminal blocks and a power switch. The two terminal blocks are respectively connected to the power supply and the calibration programmer. The industrial control all-in-one computer is fixedly connected to the connecting plate.

[0008] In some embodiments, the calibration and testing device further includes a touch screen and an operation button unit; The touch screen and the operation button unit are disposed on the surface of the industrial control all-in-one computer; The operation button unit includes a buzzer, a reset button, and an indicator light; The touch screen, the buzzer, the reset button, and the indicator light are all communicatively connected to the PLC control system.

[0009] In some embodiments, the calibration and detection device further includes two touch-activated buttons; The two touch-activated buttons are respectively located on both sides of the fixing fixture and the transmission unit; The two touch-activated buttons are fixedly connected to the connecting plate.

[0010] To achieve the above objectives, another aspect of this application proposes a detection method based on an electronic fuel dispenser for electric vehicles, the method comprising the following steps: It is confirmed that the electric vehicle electronic fuel dispenser to be tested is clamped on the fixing fixture in the calibration and testing device based on the electric vehicle electronic fuel dispenser described above; Connect the electric vehicle electronic fuel dispenser to the wiring harness connection unit and turn on the power; The PLC control system controls the transmission unit to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser to obtain the output range. Based on the output range, the PLC control system controls the transmission unit to perform two-channel Hall voltage detection on the rotating arm of the electric vehicle electronic fuel dispenser, and obtains a detection data table. The measured values ​​and standard values ​​in the test data table are calculated and compared to obtain the test results of the electric vehicle electronic fuel dispenser.

[0011] In some embodiments, the step of controlling the transmission unit to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser through the PLC control system to obtain the output range includes the following steps: The PLC control system controls the servo motor to rotate the arm to the mechanical zero position for position calibration, thus obtaining the initial position. The voltage value of the rotating arm at the initial position is obtained by the calibration programmer to obtain the zero-position reference voltage; The PLC control system controls the servo motor to rotate the rotating arm to the maximum range position for position calibration, thus obtaining the full range position. The voltage value of the rotating arm at the full-scale position is obtained by the calibration programmer to obtain the full-scale reference voltage; The initial position and the full-range position are saved to obtain the output range.

[0012] In some embodiments, the step of controlling the transmission unit to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser through the PLC control system to obtain the output range further includes the following steps: An anomaly alarm is triggered when the obtained initial position or full-range position is compared with the standard position and an anomaly is displayed.

[0013] In some embodiments, the step of controlling the transmission unit to perform two-channel Hall voltage detection on the rotating arm of the electric vehicle electronic fuel dispenser through the PLC control system according to the output range, and obtaining a detection data table, includes the following steps: The detection angle is set according to the output range to obtain multiple detection angles within the output range; The PLC control system controls the servo motor to rotate the rotating arm according to multiple detection angles, and the calibration programmer acquires two instantaneous voltage values ​​at each detection angle. The two instantaneous voltage values ​​obtained at each of the angles to be detected are summarized to obtain the detection data table.

[0014] In some embodiments, the step of calculating and comparing the measured values ​​with the standard values ​​in the test data table to obtain the test result of the electric vehicle electronic fuel dispenser includes the following steps: Each circuit signal in the two instantaneous voltage values ​​is compared with its corresponding standard value to obtain the absolute difference; The absolute difference is compared with the judgment threshold; When the absolute difference is less than or equal to the judgment threshold, the electric vehicle electronic fuel dispenser is determined to be qualified; When the absolute difference is greater than the judgment threshold, the electric vehicle electronic fuel dispenser is determined to be unqualified.

[0015] The embodiments of this application include at least the following beneficial effects: This application provides a calibration and testing device and method based on an electric vehicle electronic fuel dispenser. This scheme uses a fixed clamp to hold the electric vehicle electronic fuel dispenser, connects the wiring harness connection unit to the electric vehicle electronic fuel dispenser under test, and uses a PLC control system to control a telescopic cylinder and a servo motor to connect the clamping clamp to the rotating arm of the electric vehicle electronic fuel dispenser. A host computer system monitors and manages the data of the electric vehicle electronic fuel dispenser during the testing process. The calibration and testing device based on the electric vehicle electronic fuel dispenser achieves rapid and quantitative testing of the electronic fuel dispenser's performance through its simple structure, convenient operation, and accurate and reliable test results. The PLC control system enables closed-loop control of the rotational motion, avoiding speed fluctuations caused by manual or simple mechanical drive methods, ensuring the accuracy and repeatability of dynamic test data, providing a quantitative basis for judging the linearity and synchronization of the electronic fuel dispenser's output characteristics, and effectively identifying potential faults such as jamming and signal asynchrony. It reduces the tedious operation of manual measurement with a multimeter, reduces the impact of human error on the test results, and improves the standardization of the testing process. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the connection relationship of the calibration and testing device based on the electronic fuel dispenser for electric vehicles provided in the embodiments of this application; Figure 2 This is a schematic diagram of the structure of the transmission unit and the fixed clamp holding the electronic fuel dispenser of the electric vehicle; Figure 3This is a three-dimensional structural diagram of a calibration and testing device based on an electric vehicle electronic fuel dispenser. Figure 4 This is a front view structural schematic diagram of a calibration and testing device based on an electric vehicle electronic fuel dispenser; Figure 5 This is a schematic diagram of the display screen interface of a qualified electric vehicle electronic fuel dispenser; Figure 6 This is a schematic diagram of the display screen interface of an electric vehicle electronic fuel dispenser that failed the inspection. Figure 7 This is a schematic diagram of a table used by the host computer system to set fixed angle detection thresholds; Figure 8 This is a diagram illustrating a table for querying historical detection records in the host computer system database.

[0017] Figure 9 This is a flowchart of a detection method based on an electronic fuel dispenser for electric vehicles provided in an embodiment of this application; Figure 10 This is a logic diagram of a detection method based on an electronic fuel dispenser for electric vehicles. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit it. In the following description, when referring to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with those of this application; they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this application as detailed in the appended claims.

[0019] It is understood that the terms “first,” “second,” etc., used in this application may be used herein to describe various concepts, but unless otherwise stated, these concepts are not limited by these terms. These terms are only used to distinguish one concept from another. For example, without departing from the scope of the embodiments of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the words “if,” “when,” or “in response to a determination” as used herein may be interpreted as “when…” or “when…” or “in response to a determination.”

[0020] As used in this application, the terms "at least one", "multiple", "each", "any", etc., "at least one" includes one, two or more, "multiple" includes two or more, "each" refers to each of the corresponding multiples, and "any" refers to any one of the multiples.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0022] Before providing a detailed description of the embodiments of this application, some of the nouns and terms involved in the embodiments of this application will be explained first. The nouns and terms involved in the embodiments of this application are subject to the following interpretations.

[0023] Modbus TCP communication: An industrial communication protocol based on TCP / IP, used in the device for data interaction between the host computer and PLC, calibration programmer, and supports the sending of detection parameters and the uploading of voltage deviation data.

[0024] Visual Studio is a development tool for writing C# code. It is used to develop the host computer software for devices, enabling functions such as touch screen interface, data storage, and detection curve display.

[0025] Huichuan Easy521-0808TN: Huichuan Technology's PLC model, serving as the device's main controller, integrates 8 inputs / outputs, enabling precise control of servo motors and reception of touch button signals.

[0026] EtherCat communication interface: A high-speed industrial Ethernet interface used in the device for real-time communication between the PLC and the servo motor, ensuring precise control of the boom's rotation angle / speed.

[0027] EEPROM: Electrically Erasable Programmable Read-Only Memory, which stores calibration parameters (such as standard voltage values) in electronic fuel dispensers. The detection device can read and write the parameters of this storage unit through a programmer.

[0028] In related technologies, technicians manually measure the voltage or resistance signal at the output of the fuel dispenser using a multimeter. This method is limited to determining product qualification based on whether the Hall sensor output voltage value is within the normal range. This approach not only suffers from low operational efficiency and poor adaptability but also lacks dynamic operating condition simulation capabilities. Existing devices cannot simulate the rotational movements of electric vehicle electronic fuel dispensers in actual use, such as the arm rotation process; they can only detect parameters in a static state. While some testing devices attempt to simulate dynamic conditions by manually rotating the throttle, they cannot guarantee uniform rotation speed, leading to distorted dynamic parameter detection data. During production, the electric vehicle electronic fuel dispenser needs mechanical zero-position and maximum range calibration before testing, resulting in wasted steps and reduced production efficiency. In summary, existing technologies cannot simulate the actual rotational movements of electric vehicle electronic fuel dispensers, cannot detect the continuous change curve of the Hall voltage during rotation, and struggle to detect parameter anomalies under dynamic conditions, such as voltage fluctuations during sudden changes in speed. Manual or simple mechanical drive methods cannot precisely control the rotation angle, and manual or simple mechanical rotation errors are often... Errors of more than 2° and speed are often within The calibration process requires precisely rotating the arm of the electric vehicle's electronic fuel dispenser to the mechanical zero position and maximum range position sequentially. Performing testing after calibration in the next process results in wasted steps and impacts production efficiency. Current technology cannot efficiently determine whether its output characteristics are linear, synchronized, or whether there are faults such as jamming or jumps.

[0029] In view of this, this application provides a calibration and testing device based on an electric vehicle electronic fuel dispenser. This solution uses a servo motor 150 to drive the rotating arm 122 of the electric vehicle electronic fuel dispenser 121 to rotate at a constant speed, a PLC control system to precisely control the motion parameters, a calibration and testing programmer to complete the calibration and testing in a single process, and a host computer system to collect the switch Hall voltage data in real time and automatically determine whether the detection angle voltage is within the qualified threshold. This realizes the system calibration and testing of the dual-output electric vehicle electronic fuel dispenser 121, outputs dual-line linearity curves, and ensures the stability and safety performance of the electric vehicle electronic fuel dispenser 121 during the refueling process.

[0030] like Figure 1 As shown, Figure 1This is a schematic diagram of the connection relationship of the calibration and testing device based on an electric vehicle electronic fuel dispenser provided in this application embodiment. This calibration and testing device integrates four major functional modules: mechanical clamping, electrical connection, power transmission, and intelligent control. The overall structure is compact and highly efficient. The device is equipped with a dedicated fixing clamp 110 to securely clamp the electric vehicle electronic fuel dispenser 121 under test, ensuring its position remains fixed during calibration and testing. The wiring harness connection unit includes a power supply and a calibration programmer. The power supply provides a stable operating voltage to the electric vehicle electronic fuel dispenser 121 under test, while the calibration programmer is directly connected to the electric vehicle electronic fuel dispenser 121 and is responsible for calibrating the parameters of the mechanical zero position and maximum range position. The host computer system establishes a communication connection with the calibration programmer through a universal serial bus serial port, and can send calibration parameter commands downwards while simultaneously receiving and storing data information during the calibration process. The transmission unit of the calibration and testing device consists of a clamping fixture 130, a telescopic cylinder 140, and a servo motor 150. The servo motor 150 is fixedly connected to the telescopic cylinder 140. One end of the clamping fixture 130 is rigidly fixed to the output shaft of the servo motor 150, and the other end is movably connected to the rotating arm 122 of the electric vehicle electronic fuel dispenser 121 in the clamping state. The precise docking or separation of the clamping fixture 130 and the rotating arm 122 is achieved through the telescopic movement of the telescopic cylinder 140. Then, the servo motor 150 drives the clamping fixture 130 to rotate the rotating arm 122 at a preset angle and speed, simulating the dynamic working conditions of the electric vehicle electronic fuel dispenser 121 in actual operation. The PLC control system, as the main controller of the device, communicates bidirectionally with the host computer system through a network cable on one end to receive control commands issued by the host computer, and is connected to the servo motor 150 through a control drive harness on the other end to achieve precise control of the rotation angle and speed of the servo motor 150.

[0031] like Figure 2As shown, the mechanical execution part of the calibration and testing device based on the electric vehicle electronic fuel dispenser 121 consists of a fixed clamp 110 and a transmission unit that are tightly fitted together. The fixed clamp 110 can be adapted to electric vehicle electronic fuel dispensers 121 of different specifications. It has an anti-slip positioning groove on its inner side, which can firmly fix the outer shell of the electric vehicle electronic fuel dispenser 121 and ensure that the electric vehicle electronic fuel dispenser 121 maintains a stable installation posture during the calibration and testing process, avoiding positional displacement due to vibration or external impact. The transmission unit consists of a positioning clamp 130, a telescopic cylinder 140 and a servo motor 150 connected in sequence. The output shaft of the servo motor 150 is rigidly fixed to the cylinder body of the telescopic cylinder 140, and the piston rod of the telescopic cylinder 140 is connected to one end of the positioning clamp 130. The other end of the fixture 130 is provided with a slot that matches the rotating arm 122 of the electric vehicle electronic fuel dispenser 121. When the piston rod of the telescopic cylinder 140 extends, the positioning clamp 130 can accurately engage the rotating arm 122 of the electric vehicle electronic fuel dispenser 121, realizing the mechanical linkage between the transmission unit and the electric vehicle electronic fuel dispenser 121. After the calibration and testing process is completed, the piston rod of the telescopic cylinder 140 retracts, and the positioning clamp 130 separates from the rotating arm 122, making it easy to pick up and put down the electric vehicle electronic fuel dispenser 121 under test. The entire transmission unit is precisely driven by the servo motor 150, which can drive the rotating arm 122 of the electric vehicle electronic fuel dispenser 121 to rotate at a constant speed according to the preset angle and speed, perfectly simulating the working state of the electric vehicle electronic fuel dispenser 121 in actual use.

[0032] In some embodiments, such as Figure 3 and Figure 4 As shown, the calibration and testing device based on the electric vehicle electronic fuel dispenser constructs a load-bearing frame with a connecting plate 210 as its core, and is equipped with convenient tooling operation components. The calibration and testing device features an integrated connecting plate 210, with two tooling handles 220 symmetrically fixed on both sides of the connecting plate 210. Operators can use the tooling handles 220 to move and adjust the position of the entire device, improving its mobility and ease of operation. The fixing fixture 110, wiring harness connection unit, host computer system, transmission unit, and PLC control system in the core functional modules are all installed and fixed in their preset installation positions on the connecting plate 210. Each module forms a stable rigid connection with the connecting plate 210, ensuring that no component will shift position due to vibration or power transmission during the calibration and testing process, thus guaranteeing the stability and accuracy of the testing process.

[0033] The calibration and testing device for electric vehicle electronic fuel dispensers is equipped with a dedicated industrial control computer 500 for integrated storage and management of electrical modules, improving the device's structural compactness and electrical safety. The wiring harness connection unit, host computer system, and PLC control system are all built into the internal cavity of the industrial control computer 500, preventing external dust, moisture, and other impurities from corroding the precision electrical components and simplifying external wiring. The surface of the industrial control computer 500 also features two terminal blocks 311 and a power switch 312. The two terminal blocks 311 establish corresponding connections with the power supply and calibration programmer inside the wiring harness connection unit, respectively. Operators can quickly establish circuit connection between the electric vehicle electronic fuel dispenser 121 under test and the power supply and calibration programmer through the terminal blocks 311. The power switch 312 controls the overall power supply to the electrical components inside the industrial control computer 500. Furthermore, the industrial control computer 500 is fixedly connected to the connecting plate 210, forming an organic whole between the electrical control unit and the mechanical execution unit, ensuring efficient coordination of command transmission and power transmission.

[0034] The industrial control all-in-one computer 500 also integrates a touch screen 410 and operation button unit on its surface, creating an intuitive and efficient human-machine interface to meet the operator's needs for command input and status monitoring. The operation button unit specifically includes a buzzer 422, a reset button 421, and indicator lights 423. The touch screen 410 displays calibration and testing parameters, real-time data curves, and equipment operating status, while also supporting operator input of control parameters such as target speed and testing angle range. The buzzer 422 provides audible and visual alarms when abnormal operating conditions occur or testing results are unqualified. The reset button 421 restores the device to its initial standby state after a malfunction or the completion of a single testing cycle. The indicator lights 423 use different colored light signals to reflect the equipment's operating, standby, and alarm status. The touch screen 410, buzzer 422, reset button 421, and indicator lights 423 all establish communication connections with the PLC control system, enabling rapid command issuance and real-time feedback of equipment status.

[0035] The calibration and testing device for electric vehicle electronic fuel dispensers features a touch-activated start button 431 on each side of the fixed clamp 110 and the transmission unit. Both touch-activated start buttons 431 are fixedly connected to the connecting plate 210, forming a dual-safety start control mechanism. This design requires the operator to press both touch-activated start buttons 431 simultaneously to trigger the calibration and testing process, effectively preventing accidental start-up due to a single person accidentally pressing only one button. This reduces the risk of operator injury from mechanical transmission components during device operation and improves operational safety. Furthermore, the installation position of the touch-activated start buttons 431 matches the working area of ​​the fixed clamp 110 and the transmission unit, allowing the operator to directly trigger the start command after clamping and debugging the electric vehicle electronic fuel dispenser 121 under test, thus optimizing the operation process.

[0036] A pressure regulating filter 440 is also installed next to the industrial control integrated computer 500. The pressure regulating filter 440 is fixedly connected to the connecting plate 210 and becomes the core control component of the device's pneumatic system. The input end of the pressure regulating filter 440 is connected to an external compressed air source, and the output end is connected to the telescopic cylinder 140 in the transmission unit. It has dual functions of pressure stabilization and filtration. On the one hand, it can filter out contaminants such as moisture, oil, and impurities in the compressed air, preventing impurities from entering the cylinder and causing malfunctions such as wear of seals and valve core jamming, thus ensuring the smoothness and accuracy of the telescopic cylinder 140's operation. On the other hand, it can flexibly adjust the output air pressure according to the working requirements of the telescopic cylinder 140, thereby accurately controlling the action force and speed of the clamping fixture 130 and the rotating arm 122 of the electric vehicle electronic fuel filler 121 when they dock or separate. This prevents problems such as deformation of the rotating arm 122 due to excessive air pressure and insecure docking due to insufficient air pressure. It works in coordination with the PLC control system and servo motor 150 to further improve the stability of the entire calibration and testing device and the reliability of the test results.

[0037] In some embodiments, the servo motor 150 is electrically connected to the PLC control system, receives control commands from it, and drives the rotating arm 122 of the electronic fuel dispenser 121 of the electric vehicle under test to rotate at a constant speed or according to a preset program through the transmission component, simulating the refueling action of a human hand. The telescopic cylinder 140 is used to avoid the clamp placement position, and extends after the electronic fuel dispenser 121 of the electric vehicle under test is placed. It quickly locks into place with the rotating arm 122 through the contour positioning clamp, which also avoids the product being taken away midway during the production process before the product inspection is completed, resulting in untested products being discharged. The clamping clamp 130 is a fixed clamp for the rotating arm 122 of the electronic fuel dispenser 121 of the electric vehicle under test. The fixed clamp presses radially against the head seat of the rotating arm 122, clamping the rotating arm 122 in its static initial position. The servo motor 150 drives the clamping clamp 130 to rotate, realizing the output range angle (generally 0-35°) rotation angle adjustment (accuracy). 0.1°), rotation speed adjustment (precision) (0.1° / s), and can set motion modes such as uniform rotation and stepped rotation (pausing for 1 second every 5°); The industrial control all-in-one computer is installed on the front of the fixture, with the screen tilted at 45° towards the user. It loads the host computer software and connects to the PLC control system via Ethernet cable and a calibration programmer via USB cable. This allows for human-machine interaction, displaying test results (such as characteristic curves, test data, test steps, and test structures) and receiving user commands. The calibration programmer is installed inside the industrial control all-in-one computer and includes calibration and testing functions. The calibration function writes the first calibration point to the EEPROM when the electric vehicle electronic fuel filler 121 is in its initial position (0°). Rotating the electric vehicle electronic fuel filler 121 to its highest position (35°) writes the second calibration point to the EEPROM, completing the calibration of the electric vehicle electronic fuel filler 121. The testing function can simultaneously test both A and B channels, detecting supply voltage and output voltage. Through communication with the host computer system, it can acquire test values ​​in real time, used to test whether the output voltage value meets requirements when rotating the electric vehicle electronic fuel filler 121.

[0038] The PLC controller, model Huichuan Easy521-0808TN, connects to the servo drive module via an EtherCat communication interface, sending commands for rotation angle, speed, and motion mode. Simultaneously, it establishes Modbus TCP communication via Ethernet to link with the host computer system and calibration programmer. When the servo motor 150 rotates to the set angle, the PLC control system sends a corresponding signal to the host computer system. The host computer system then calls the calibration programmer to perform calibration and testing, collecting and recording dual-channel Hall voltage data, and simultaneously performing threshold judgments on the data. The PLC's touchscreen 410 is used to adjust servo control parameters, display the testing process flow, and display results. For example, the rotation angle and speed of the servo motor 150 can be set on the touchscreen 410 interface, and it can be manually positioned to a specific angle. The touchscreen also displays the motor's current position angle, speed, and torque status parameters in real time, enabling rapid on-site operation and status monitoring. The under-screen operation buttons include a reset button 421, an indicator light 423, and a buzzer 422. The reset button 421 is a physical button operation for alarm or system initialization. The indicator light 423 is used to indicate that the test is completed and qualified. The buzzer 422 is used to alarm and emit a beeping alarm sound when the test is NG or the system is abnormal.

[0039] like Figure 5 and Figure 6As shown, the host computer system is developed based on C# and VISIO Studio. It communicates with the PLC control system via Modbus TCP through a network cable, receiving dual-channel Hall voltage data in real time. The data is displayed on the interface as a linear curve (horizontal axis: arm rotation angle / time; vertical axis: Hall voltage). The detected values ​​are output in list format and automatically compared with the set allowable error threshold. Passing items are marked in green (PASS), and failing items are marked in red (NG). Figure 7 and Figure 8 As shown, it supports setting product inspection thresholds for process parameters (setting high and low allowable error values ​​corresponding to different angles), data storage (Excel format), historical data query and backtracking, and abnormal data marking.

[0040] By adopting the above technical solution, firstly, it is possible to realize dual power input and Hall voltage output acquisition for the electric vehicle electronic fuel dispenser 121; secondly, it is possible to complete the calibration and testing of the electric vehicle electronic fuel dispenser 121 in a single process, eliminating human and system errors and ensuring the comparability and consistency of results between different fuel dispensers and different tests during the production process; thirdly, it is possible to obtain the linear spectrum of the rotation angle and Hall voltage of the electric vehicle electronic fuel dispenser 121, providing an intuitive method for judging and analyzing the consistency and stability of the output signal.

[0041] Figure 9 This is an optional flowchart of the detection method based on an electronic fuel dispenser for electric vehicles provided in the embodiments of this application. Figure 9 The method may include, but is not limited to, steps S510 to S550.

[0042] Step S510: Determine that the electric vehicle electronic fuel dispenser to be tested is already clamped on the fixing fixture in the calibration and testing device based on the electric vehicle electronic fuel dispenser. Step S520: Connect the electric vehicle electronic fuel dispenser to the wiring harness connection unit and turn on the power; Step S530: The PLC control system controls the transmission unit to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser to obtain the output range. Step S540: Based on the output range, the PLC control system controls the transmission unit to perform two-channel Hall voltage detection on the rotating arm of the electric vehicle electronic fuel dispenser, and obtains the detection data table. Step S550: Calculate and compare the measured values ​​and standard values ​​in the test data table to obtain the test results of the electric vehicle electronic fuel dispenser.

[0043] In the embodiments of this application, steps S510 to S550 are implemented to achieve uniform rotation and precise angle control of the rotating arm 122 of the electric vehicle electronic fuel dispenser 121 through the servo motor 150 + PLC control system. The upper computer system is used to calibrate the arm 122 with a calibration programmer and to collect the two-channel Hall voltage output data during the rotation process. Combined with the electrical wiring of the original automated detection device, the electric vehicle electronic fuel dispenser 121 is automatically calibrated and its dynamic performance is tested with high precision. Finally, after calibration, the output voltage value of the Hall sensor of the electric vehicle electronic fuel dispenser 121 is obtained synchronously. After calculation and comparison, the detection result is obtained.

[0044] In some embodiments, in steps S510 to S520, the operator first places the electronic fuel dispenser 121 of the electric vehicle under test into the fixing fixture 110 of the calibration and testing device. The locking structure of the fixture is used to position and fix the electronic fuel dispenser, ensuring that it will not shift or shake during subsequent calibration and testing. After clamping, it is necessary to manually confirm whether the installation posture of the electronic fuel dispenser 121 is correct, focusing on whether the rotating arm 122 of the electronic fuel dispenser 121 is in a natural relaxed state and does not interfere with surrounding components, thus laying the foundation for subsequent position calibration and voltage testing. The operator establishes corresponding connections between the signal interface of the electronic fuel dispenser 121 and the power supply and calibration programmer in the wiring harness connection unit through the wiring terminals 311 on the surface of the industrial control integrated computer 500. The power supply provides a stable operating voltage for the electronic fuel dispenser 121, and the calibration programmer is used for subsequent voltage signal acquisition and reading. After completing the electrical connection, the operator presses the power switch 312 on the industrial control all-in-one computer 500 to connect the power supply circuit of the entire device. At this time, the electric vehicle electronic fuel dispenser 121 enters standby mode. The calibration programmer and the host computer system synchronously complete self-test to ensure that the electrical link of the equipment is fault-free. Simultaneously, the operator touches the two touch start buttons 431 on both sides to start the calibration test. Since the electric vehicle electronic fuel dispenser 121 requires a 5V voltage input, the power supply voltage of the power supply system is 5V.

[0045] In some embodiments, step S530 is the core step in calibrating the reference parameters of the electric vehicle electronic fuel dispenser 121, and it is divided into three stages: zero-position calibration, full-range calibration, and anomaly detection. In the zero-position calibration stage, the PLC control system sends a drive command to the servo motor 150, controlling the servo motor 150 to drive the clamping fixture 130 and the rotating arm 122 of the electric vehicle electronic fuel dispenser 121 to rotate until the rotating arm 122 reaches the mechanical zero position, which is the initial position of the fully relaxed rotating arm 122. The PLC control system records the position parameters at this time as the initial position; simultaneously, the calibration programmer collects the voltage signal of the rotating arm 122 at the initial position to obtain the zero-position reference voltage. In the full-range calibration stage, the PLC control system continues to drive the servo motor 150, causing the rotating arm 122 to rotate to the maximum range position, which is the limit working position of the rotating arm 122. The PLC control system records the position parameters at this time as the full-range position; the calibration programmer synchronously collects the voltage signal at this position to obtain the full-range reference voltage. Subsequently, the PLC control system stores the initial position, full-range position, and corresponding reference voltage to form the output range of the electric vehicle electronic fuel dispenser 121. During this process, the PLC control system compares the measured initial position and full-range position with the preset standard position. If the comparison result exceeds the allowable deviation range, the device's abnormal alarm mechanism is triggered, alerting the operator by sounding the buzzer 422 and changing the color of the indicator light 423. The device is then recalibrated after the fault is cleared.

[0046] In some embodiments, step S540 completes the acquisition and data aggregation of voltage signals at multiple detection points based on the output range obtained in step S530. First, the operator sets multiple uniformly distributed detection angles within the output range (from the initial position to the full-range position) using a host computer system or touchscreen 410. The number of detection angles can be adjusted according to the required detection accuracy. Then, the PLC control system sends angle drive commands to the servo motor 150 sequentially according to the preset sequence of detection angles, controlling the servo motor 150 to drive the rotating arm 122 to precisely rotate to each detection angle and maintain a stable position. At each angle position, the calibration programmer simultaneously acquires the instantaneous voltage values ​​of the two signals from the electric vehicle electronic fuel dispenser 121 and associates and stores the angle parameters with the corresponding two voltage values. After the voltage acquisition of all detection angles is completed, the calibration programmer integrates all angle-voltage data to generate a detection data table containing the detection angle, the first instantaneous voltage value, and the second instantaneous voltage value, which is then simultaneously uploaded to the host computer system for display and archiving.

[0047] In some embodiments, the core of step S550 is to determine the pass / fail status of the electric vehicle electronic fuel dispenser 121 through data comparison. First, the host computer system retrieves each set of two instantaneous voltage values ​​from the detection data table, calculates the difference between each value and a preset corresponding standard voltage value, and obtains the absolute difference of each voltage signal at the corresponding detection angle through absolute value calculation. Then, the calculated absolute difference is compared with a preset judgment threshold, which is the maximum allowable deviation value set based on the performance indicators of the electric vehicle electronic fuel dispenser 121. If the absolute difference between the two voltage signals at all detection angles is less than or equal to the judgment threshold, the electric vehicle electronic fuel dispenser 121 under test is determined to be a qualified product; if the absolute difference of any voltage signal at any detection angle is greater than the judgment threshold, the electric vehicle electronic fuel dispenser 121 under test is determined to be a non-qualified product. Simultaneously, the system records the non-qualified detection angles and the corresponding deviation data to facilitate subsequent fault analysis by the operator.

[0048] In some embodiments, such as Figure 10 As shown, the measurement benchmark of the testing device is first established to eliminate initial errors caused by individual differences or installation of different electric vehicle electronic fuel dispensers 121. Specifically, the electric vehicle electronic fuel dispenser 121 to be tested is securely mounted on the fixing fixture 110, and its signal output terminal is reliably connected to the signal acquisition port of the testing device. After the testing system is ready, the start-up process is initiated by touching the touch start button 431 with both hands. The PLC control system controls the servo motor 150 to precisely rotate the arm 122 of the electric vehicle electronic fuel dispenser 121 to the mechanical zero position (i.e., the 0° starting position). The PLC control system triggers the host computer system to perform position 1 calibration, recording the voltage value Vref0 read by the signal acquisition module at this time as the zero-position reference voltage. The calibration programmer automatically binds this position with the voltage value and writes the calibration data into ERROR1. The PLC control system controls the servo motor 150 to precisely rotate the arm 122 to the maximum range position (e.g., 35°). The PLC control system triggers the host computer to perform position 1 calibration, recording the voltage value Vref35 read by the signal acquisition module at this time as the "full-scale reference voltage". The calibration programmer automatically associates this position with the voltage value and writes the calibration data to ERROR2. The system saves the reference point data for Vref0 and Vref35. Successful calibration means that the device has "learned" the output range of this specific fuel dispenser, laying the foundation for subsequent accurate measurements.

[0049] Following successful calibration, the calibration and testing device automatically performs high-precision linear Hall voltage detection. Specifically, after successful calibration, the PLC control system controls the servo motor 150 to precisely rotate the arm 122 of the electric vehicle electronic fuel dispenser 121 to the mechanical zero position (i.e., the 0° starting position) to begin the automatic detection process. The PLC control system controls the servo motor 150 to drive the arm 122 to rotate uniformly from 0° to 35°, precisely stopping at the set angle. At each set angle, sampling is performed at fixed intervals, with adjustable sampling time, adjustable sampling point positions, and adjustable number of sampling points. The system collects the output data of the dual-channel Hall voltage at the current position. Although this sampling method is slower, the tested data is more stable. The host computer system records the instantaneous voltage values ​​of the arm 122 at key preset angle points: 0°, 5°, 10°, 15°, 20°, 25°, 30°, and 35°. It also checks whether the voltage value at the current location is within the preset detection threshold. If it is qualified, it passes and the detection item turns green; if it fails, it is NG and the item turns red.

[0050] Alternatively, an alternative implementation involves a PLC control system controlling a servo motor 150 to drive the rotating arm 122 to rotate continuously and at a constant speed from 0° to 35°. Importantly, during rotation, the signal acquisition module does not sample only at specific points but continuously acquires voltage data. The host computer system continuously records the instantaneous voltage values ​​of the rotating arm 122 as it passes through key angle points of 0°, 5°, 10°, 15°, 20°, 25°, 30°, and 35°. The system automatically generates a data table that completely records the output voltage value of each angle point of the two outputs of the electric vehicle electronic fuel dispenser 121.

[0051] Finally, the host computer system analyzes the collected data and generates an intuitive test report. Specifically, all data points collected by the host computer system (e.g., from 0° to 35°, one point every 5°, for a total of 8 points) are connected to obtain a linear curve. The system simultaneously collects two signals (V1 and V2), calculates the absolute difference between the measured value and the standard value for each point, and calculates the difference between the measured value and the standard value using the following formula: ; Where V1 represents the first signal and V2 represents the second signal. This represents the absolute difference of the first signal at the i-th monitoring point. This represents the absolute difference between the second signal at the i-th monitoring point. This represents the actual measured voltage value of the first signal at the i-th detection point. This represents the standard reference voltage value of the first signal at the i-th detection point. This represents the actual measured voltage value of the second signal at the i-th detection point. This represents the standard reference voltage value of the second signal at the i-th detection point.

[0052] Perform a pass / fail assessment on each output: determine whether the absolute difference of all 8 measurement points of each output meets the requirements.

[0053] The qualification requirements for Route 1 are: ≤ For all i = 1, 2, ..., 8; Judgment result: ; Qualification criteria for Route 2: ΔV2(i)≤ For all i = 1, 2, ..., 8; Judgment result: ; Final comprehensive judgment: The entire electronic throttle product is only deemed qualified when both outputs are deemed qualified.

[0054] Overall judgment result: ; Final output: After completing the above calculations, display the voltage values, output error values, and judgment results for all angles in a numerical table format; plot the two-channel "angle-voltage" characteristic curves (see appendix). Figure 5 and Figure 6 As shown, the nonlinear situation and the co-position error of the two curves are clearly visible; the overall test result is output, the qualified indicator light 423 shows green, and the unqualified buzzer 422 alarms.

[0055] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0056] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0057] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0058] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0059] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or apparatus.

[0060] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0061] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of the units described above is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0062] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0063] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0064] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A calibration and testing device based on an electronic fuel dispenser for electric vehicles, characterized in that, The calibration and testing device includes: A fixing clamp is used to hold the electric vehicle electronic fuel dispenser to be tested; A wiring harness connection unit, the wiring harness connection unit including a power supply and a calibration programmer, the power supply and the calibration programmer being respectively connected to the clamped electric vehicle electronic fuel dispenser; The host computer system is connected to the calibration programmer via a universal serial bus serial port; The transmission unit includes a positioning clamp, a telescopic cylinder, and a servo motor. One end of the positioning clamp is fixedly connected to the servo motor, the servo motor is fixedly connected to the telescopic cylinder, and the other end of the positioning clamp is movably connected to the rotating arm of the electric vehicle electronic fuel dispenser being held. The PLC control system has one end connected to the host computer system via a network cable, and the other end connected to the servo motor via a control drive harness.

2. The calibration and testing device based on an electronic fuel dispenser for electric vehicles according to claim 1, characterized in that, The calibration and testing device also includes a connecting plate and two tooling handles; The two tool handles are fixed to both sides of the connecting plate; The fixing clamp, the wire harness connection unit, the host computer system, the transmission unit, and the PLC control system are respectively fixedly connected to the connecting plate.

3. The calibration and testing device based on an electric vehicle electronic fuel dispenser according to claim 2, characterized in that, The calibration and testing device also includes an industrial control integrated computer; The wiring harness connection unit, the host computer system, and the PLC control system are located inside the industrial control integrated machine; The industrial control all-in-one computer is equipped with two terminal blocks and a power switch. The two terminal blocks are respectively connected to the power supply and the calibration programmer. The industrial control all-in-one computer is fixedly connected to the connecting plate.

4. The calibration and testing device based on an electronic fuel dispenser for electric vehicles according to claim 3, characterized in that, The calibration and testing device also includes a touch screen and an operation button unit; The touch screen and the operation button unit are disposed on the surface of the industrial control all-in-one computer; The operation button unit includes a buzzer, a reset button, and an indicator light; The touch screen, the buzzer, the reset button, and the indicator light are all communicatively connected to the PLC control system.

5. The calibration and testing device based on an electronic fuel dispenser for electric vehicles according to claim 3, characterized in that, The calibration and testing device also includes two touch-activated buttons; The two touch-activated buttons are respectively located on both sides of the fixing fixture and the transmission unit; The two touch-activated buttons are fixedly connected to the connecting plate.

6. A detection method based on an electronic fuel dispenser for electric vehicles, characterized in that, The method includes the following steps: It is determined that the electric vehicle electronic fuel dispenser to be tested is clamped on the fixing fixture in the calibration and testing device based on the electric vehicle electronic fuel dispenser according to any one of claims 1 to 5; Connect the electric vehicle electronic fuel dispenser to the wiring harness connection unit and turn on the power; The PLC control system controls the transmission unit to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser to obtain the output range. Based on the output range, the PLC control system controls the transmission unit to perform two-channel Hall voltage detection on the rotating arm of the electric vehicle electronic fuel dispenser, and obtains a detection data table. The measured values ​​and standard values ​​in the test data table are calculated and compared to obtain the test results of the electric vehicle electronic fuel dispenser.

7. The method according to claim 6, characterized in that, The step of controlling the transmission unit through the PLC control system to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser to obtain the output range includes the following steps: The PLC control system controls the servo motor to rotate the arm to the mechanical zero position for position calibration, thus obtaining the initial position. The voltage value of the rotating arm at the initial position is obtained by the calibration programmer to obtain the zero-position reference voltage; The PLC control system controls the servo motor to rotate the rotating arm to the maximum range position for position calibration, thus obtaining the full range position. The voltage value of the rotating arm at the full-scale position is obtained by the calibration programmer to obtain the full-scale reference voltage; The initial position and the full-range position are saved to obtain the output range.

8. The method according to claim 7, characterized in that, The step of controlling the transmission unit to calibrate the range of the rotating arm of the electric vehicle electronic fuel dispenser through the PLC control system to obtain the output range also includes the following steps: An anomaly alarm is triggered when the obtained initial position or full-range position is compared with the standard position and an anomaly is displayed.

9. The method according to claim 6, characterized in that, The step of controlling the transmission unit to perform two-channel Hall voltage detection on the rotating arm of the electric vehicle electronic fuel dispenser through the PLC control system according to the output range, and obtaining a detection data table, includes the following steps: The detection angle is set according to the output range to obtain multiple detection angles within the output range; The PLC control system controls the servo motor to rotate the rotating arm according to multiple detection angles, and the calibration programmer acquires two instantaneous voltage values ​​at each detection angle. The two instantaneous voltage values ​​obtained at each of the angles to be detected are summarized to obtain the detection data table.

10. The method according to claim 9, characterized in that, The step of calculating and comparing the measured values ​​with the standard values ​​in the test data table to obtain the test results of the electric vehicle electronic fuel dispenser includes the following steps: Each circuit signal in the two instantaneous voltage values ​​is compared with its corresponding standard value to obtain the absolute difference; The absolute difference is compared with the judgment threshold; When the absolute difference is less than or equal to the judgment threshold, the electric vehicle electronic fuel dispenser is determined to be qualified; When the absolute difference is greater than the judgment threshold, the electric vehicle electronic fuel dispenser is determined to be unqualified.

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