New Energy Charger Maintenance and Testing Equipment

Abstract

The present invention relates to a maintenance and testing device for a new energy charger, which includes a processor unit and a DC electronic load system, a DC power supply system, a CAN protocol simulation system, and a system power supply module connected to the processor unit; the DC electronic load system includes a DC electronic load module, a voltage signal amplification circuit, and a DC electronic load signal processing circuit; the DC power supply system includes a DC power supply module, a filtering and amplification circuit, and a DC power supply signal processing circuit; the CAN protocol simulation system includes a CAN interface for simulating the communication protocols of various devices; the system power supply module is electrically connected to the DC power supply system and the DC electronic load module respectively. The present invention combines high-voltage DC power supply, high-voltage electronic load, and CAN protocol simulation for the first time, and can provide processes such as voltage, charging and discharging of a simulated battery pack during the charger testing process. By using CAN protocol simulation to control the operation of the charger, the testing is made more convenient and efficient.

Description

Technical Field

[0001] The present invention belongs to the technical field of new energy, and relates to a maintenance and test device for a new energy charger, in particular to an OTA-type multifunctional maintenance and test device for a new energy charger based on GD32. Background Art

[0002] With the increasing number of electric vehicles, the models of chargers on the current market are diverse, and the voltages, currents, protocols, etc. of different chargers are all different. In particular, the charger needs to identify the battery voltage before starting, have a load current after starting, and the charger also needs to cooperate with the CAN protocol to start, which brings great obstacles to maintenance personnel. This requires that the charger after-sales maintenance can update the charger protocol in a timely manner. Frequent updating of the charger protocol by the charger maintenance and test device is a complex and cumbersome matter, which not only affects the normal operation of the maintenance and test device, but also brings operation difficulties to non-professional maintenance and test personnel. Using the remote online upgrade function to update the charger protocol database in a timely manner has the characteristics of convenience, speed, intelligence and efficiency.

[0003] At the same time, the maintenance of the charger requires a starting voltage and a certain starting current. Currently, additional power sources are required for the maintenance of chargers on the market to start the charger. Based on this, there is an urgent need in the market for a multifunctional integrated platform that can provide a power supply with a voltage of 0 - 600V, an electronic load that can support a voltage range of 0 - 600V, and various CAN protocols.

[0004] Furthermore, during the traditional charger maintenance process, the charger is mainly tested. The main content of the test is the output performance test of the charger, which is tested by consuming electric energy through an electronic load. For electric vehicle electrical equipment, a DC power supply cannot be output. When the electrical appliances of an electric vehicle need to be powered by a DC power supply, an additional DC power supply is required, the operation is cumbersome, and there are many maintenance equipment, which increases a lot of manpower and material resources for maintenance. Summary of the Invention

[0005] The present invention aims to solve the problems of difficult charger maintenance and test, cumbersome operation, and many maintenance equipment caused by the diverse charger models in the traditional charger maintenance, and proposes a maintenance and test device for a new energy charger.

[0006] The present invention is achieved through the following technical solutions:

[0007] The above-mentioned new energy charger maintenance and test equipment, the equipment includes a DC electronic load system, a processor unit, a DC power supply system, a CAN protocol simulation system and a system power supply module; the DC electronic load system includes a DC electronic load module, a voltage acquisition and processing circuit and a DC electronic load signal processing circuit; the signal input end of the DC electronic load is connected through a voltage amplification circuit, and the signal output end is connected to the DC electronic load signal processing circuit; the DC power supply system includes a DC power supply module, a filtering and amplification circuit and a DC power supply signal processing circuit; the signal input end of the DC power supply module is connected through a filtering and amplification circuit, and the signal output end is connected to the DC power supply signal processing circuit; the processor unit is respectively connected to the DC electronic load through the GFIO port, the voltage amplification circuit through the DAC port, the DC electronic load signal processing circuit and the DC power supply signal processing circuit through the ADC port, the TIMER port is connected to the filtering and amplification circuit, and the CAN port is connected to the CAN interface for simulating various device communication protocols; the CAN protocol simulation system includes a CAN interface, and the CAN interface is used to simulate the communication protocols of various devices and is connected to the CAN port of the processor unit; the system power supply module is respectively electrically connected to the DC power supply system, the processor unit and the DC electronic load module.

[0008] The above-mentioned new energy charger maintenance and test equipment, wherein: the equipment further includes an OTA program; the OTA program includes a server, a mobile terminal and a Bluetooth module; the mobile terminal is respectively connected to the server and the Bluetooth module through signal connections, and realizes remote management and protocol upgrade of the system software through OTA technology; the Bluetooth module is connected to the USART port of the processing unit through signal connection.

[0009] The above-mentioned new energy charger maintenance and test equipment, wherein: the equipment is provided with a chassis; a display screen, buttons, a power switch, wiring terminals and a communication interface are arranged on the front shell of the chassis, a cooling fan is arranged on the rear shell, and cooling holes are arranged on both side walls and the top; the DC power supply module and the DC electronic load module are symmetrically arranged on both sides inside the chassis; the DC power supply module is electrically connected to the power switch of the chassis; the processor unit is arranged in the middle of the chassis, and the EXMC port of the processor unit is connected to the display screen; the system power supply module is arranged at the bottom of the middle of the chassis, below the processor unit, and is electrically connected to the power switch of the chassis.

[0010] The above-mentioned new energy charger maintenance and test equipment, wherein: the DC power supply module includes a rectification circuit, a Buck circuit, an inversion circuit, a voltage doubling circuit, a DC power supply protection circuit, a voltage acquisition and processing circuit and a current detection circuit.

[0011] The described new energy charger repair and test equipment, wherein: the inverter circuit is provided with two isolation drive circuits and dead time.

[0012] The described new energy charger repair and test equipment, wherein: the main function of the voltage multiplier circuit is to boost the high-frequency high-voltage AC square wave output by the upper-level circuit again to obtain the expected output voltage value, and play a certain role in rectification and filtering.

[0013] The described new energy charger repair and test equipment, wherein: the DC electronic load module includes a constant current control circuit, a constant voltage control circuit, and a protection circuit for the DC electronic load.

[0014] The described new energy charger repair and test equipment, wherein: the constant current control circuit is responsible for hardware constant current control, including an integration circuit and a current output control circuit.

[0015] The described new energy charger repair and test equipment, wherein: the constant voltage control circuit first reduces the sampled voltage by 0.2 times through the non-inverting proportional amplifier composed of the first-stage operational amplifier, and then sends it to the non-inverting input terminal of the voltage comparator composed of the second-stage integrated operational amplifier to compare with the reference voltage DA applied to the inverting input terminal. When the input voltage increases and is greater than the reference voltage, the comparator outputs a high level, increasing the conduction amount of the power tube, and the grid-drain resistance decreases, and the input voltage decreases to achieve constant voltage operation.

[0016] The described new energy charger repair and test equipment, wherein: in the DC electronic load signal processing circuit, the load module uses two IRFP250 field effect transistors as the load transistors of the electronic load, the current detection amplifier uses the INA180A3 device, and R1 and R2 are the gate resistors of the power switch tube MOSFET, and the resistance parameters are preferably 510Ω.

[0017] Beneficial effects:

[0018] The present invention combines a high-voltage DC power supply, a high-voltage electronic load, and CAN protocol simulation for the first time, and can provide processes such as voltage, charging and discharging of an analog battery pack during the charger test. By using CAN protocol simulation to control the actions of the charger, the test is made more convenient and efficient.

[0019] This system combines an adjustable DC high-voltage DC power supply with a DC electronic load. Compared with mainly testing the charger during the traditional charger repair process, this system integrates the two into one system, reducing unnecessary costs and time for charger repair and test personnel, and the operation is simple.

[0020] The system combines a DC electronic load and a high-voltage DC power supply, and has the output performance test of new energy chargers, including constant current mode, constant voltage mode, and constant current followed by constant voltage mode, as well as the high-voltage DC power supply output mode for testing electrical equipment such as motors in new energy vehicles. Combining with the relatively advanced over-the-air technology in the current automotive field, the WeChat mini-program can upgrade the device firmware and the charger protocol database online via Bluetooth, and at the same time support custom protocols to achieve data interaction, with rich functions, convenience, speed, and greater intelligence, improving the maintenance work efficiency and user experience.

[0021] This system can be applied to the maintenance and testing of multiple products in electric vehicles. Brief Description of the Drawings

[0022] Figure 1 It is the principle block diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0023] Figures 2 - 4 It is the structural schematic diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0024] Figure 5 It is the constant current control circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0025] Figure 6 It is the constant voltage control circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0026] Figure 7 It is the protection circuit diagram of the DC electronic load of the maintenance and testing equipment for the new energy charger of the present invention;

[0027] Figure 8 It is the voltage acquisition and processing circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0028] Figure 9 It is the DC electronic load signal processing circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0029] Figure 10 It is the Buck circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0030] Figure 11 It is the inverter circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0031] Figure 12 It is the voltage acquisition and processing circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention;

[0032] Figure 13 It is the current detection circuit diagram of the maintenance and testing equipment for the new energy charger of the present invention. Detailed Embodiments

[0033] As Figures 1 to 4 shown, the new energy charger maintenance and test equipment of the present invention includes a chassis 1 and a DC electronic load system 2, a DC power supply system 3, a GD32F303VCT6 processor unit 4, an OTA system 5, a CAN protocol simulation system 6 and a system power supply module 7 provided on the chassis 1. Among them, the processor unit 3 outputs a voltage signal through a DAC and controls the constant current and constant voltage modes of the DC electronic load through a voltage amplification circuit. The electronic load current and voltage signals are fed back to the processor through a signal processing circuit.

[0034] The front shell of the chassis 1 is provided with a power switch 11, a display screen 12, buttons 13, a communication interface 14 and a terminal block 15. The rear shell is provided with a cooling fan 16, a terminal block 17 and a power interface 18. Heat dissipation holes are provided on both side walls and the top, and a bracket 19 is provided at the bottom.

[0035] The DC electronic load system 2 includes a DC electronic load module 21, a voltage signal amplification circuit 22 and a DC electronic load signal processing circuit 23;

[0036] The signal input end of the DC electronic load module 21 is connected through the voltage signal amplification circuit 22, and the signal output end is connected to the DC electronic load signal processing circuit 23; the DC electronic load module 21 is arranged on one side inside the chassis 1 and includes a constant current control circuit 211, a constant voltage control circuit 212, a protection circuit 213 of the DC electronic load, and a DC electronic load voltage acquisition and processing circuit 214;

[0037] The constant current control circuit 211 is responsible for hardware constant current control. This part of the circuit mainly includes an integral circuit and a current output control circuit. As Figure 5 shown, C3, C8, R16 and R20 form an inverting proportional integrator, which is used to limit the rising and falling speed of the op-amp output and suppress overshoot or oscillation; due to the influence of the amplifier offset voltage and the offset of the DAC zero potential, when the DAC outputs 0 voltage, the load current is not 0 (about a few milliamps of leakage current), resulting in the inability to turn off the electronic load only by the DAC outputting 0 voltage. Therefore, D3, D1, R13 and R18 are added to form a simple voltage boosting circuit. When it is necessary to turn off the electronic load, the field effect transistor can be completely turned off by outputting a high level through the "OFF" network and the DAC outputting 0 voltage;

[0038] The constant voltage control circuit 212 is as Figure 6 shown. The constant voltage working mode means that no matter how the current flowing into the DC electronic load changes, the voltage across it will remain unchanged. As Figure 4As shown, the reference voltage DA_V generated due to the voltage value set by the button is relatively low, not exceeding 5 V, while the required constant voltage range in this design is 1 - 20 V, that is, the sampling voltage is relatively large. In order to be in the same order of magnitude as the reference voltage, the sampling voltage is first reduced by 0.2 times through the non-inverting proportional amplifier composed of the first-stage operational amplifier, that is, U = 0.2Ui = (0.2 - 4)V, and then sent to the non-inverting input terminal of the voltage comparator composed of the second-stage integrated operational amplifier to be compared with the reference voltage DA applied to the inverting input terminal. When the input voltage increases and is greater than the reference voltage, the comparator outputs a high level, increasing the conduction amount of the power transistor, and the gate-drain resistance decreases, the input voltage decreases, and constant voltage operation is achieved;

[0039] The protection circuit 213 of the DC electronic load is as Figure 7 shown. The high threshold voltage of the window comparator can be adjusted according to the resistors R90, R91 and the potentiometer R88, and the low threshold voltage can be adjusted according to the resistors R125, R126 and the potentiometer R107.

[0040] The voltage acquisition and processing circuit 214 of the DC electronic load is as Figure 8 shown. When collecting high voltage, the bus voltage needs to be collected and processed by resistor voltage division to obtain an appropriate voltage, and then the voltage signal is processed by the differential subtraction amplifier circuit to obtain a voltage signal that can be collected by the single-chip microcomputer.

[0041] The signal processing circuit 23 of the DC electronic load is as Figure 9 shown. It mainly collects and processes the load current and voltage signals. The load module uses two IRFP250 field effect transistors as the load transistors of the electronic load. P1 is the power input terminal 14 of the power supply under test. R3 and R4 are current detection sampling resistors. The current detection amplifier uses the INA180A3 device, which has a voltage gain of 100V / V and an input offset voltage of 25uV; R1 and R2 are the gate resistors of the power switch tube MOSFET, mainly to reduce the gate drive current, relieve gate oscillation, and protect the gate. The resistance value parameter is preferably 510Ω; preferably, metal film resistors or constantan wires are used as current sampling resistors; the ground of the power part and the ground of the measurement and control part are isolated and separated, and the two grounds are connected through the 0Ω resistor of R21, which can reduce the measurement noise interference caused by voltage drop or noise.

[0042] The DC power supply system 3 includes a DC power supply module 31, a filter amplification circuit 32 and a DC power supply signal processing circuit 33; the signal input terminal of the DC power supply module 31 is connected through the filter amplification circuit 32, and the signal output terminal is connected to the DC power supply signal processing circuit 33;

[0043] The DC power supply module 31 and the DC electronic load module 21 are symmetrically arranged on the other side inside the chassis 1, and are electrically connected to the power switch 13 of the chassis 1. It is provided with a rectification circuit, a Buck circuit, an inverter circuit, a voltage doubling circuit, a DC power protection circuit, a voltage acquisition and processing circuit, and a current detection circuit;

[0044] The rectification circuit rectifies 220V to obtain direct current available for the subsequent stage;

[0045] The Buck circuit is as Figure 10 shown, and a MOSFET is selected as the switching tube;

[0046] The inverter circuit is as Figure 11 shown, and is driven by MOSFET tubes. The driving chip selects the IR2101 type chip; in this circuit, when HO is at a high level, through the bootstrap capacitor function of the IR2101 driving chip, the upper bridge arm VD1 switching tube is turned on. At this time, LO is at a low level, the lower bridge arm switching tube VD2 is in the off state, and at the same time the switching tube VD4 is turned on and the switching tube VD3 is turned off, so that the inverter circuit forms a path; conversely, the switching tubes VD2 and VD3 are turned on, so that the four switching devices are alternately turned on and off in an orderly manner; in order to prevent the inverter circuit from having a through phenomenon, a dead time is increased to protect the entire system; this inverter circuit is provided with two isolation driving circuits;

[0047] The main function of the voltage doubling circuit is to boost the high-frequency high-voltage AC square wave output by the previous-stage circuit again to obtain the expected output voltage value. Moreover, in order to obtain a more stable DC voltage, the voltage doubling circuit has a certain rectification and filtering effect;

[0048] The DC power protection circuit is to avoid short circuit or overvoltage and overcurrent phenomena when a power failure occurs during the operation of the system. When a system failure occurs, the system stops working immediately to protect the high-voltage power supply itself and the load;

[0049] The voltage acquisition and processing circuit is as Figure 12 shown. Since the output voltage at the voltage doubling rectification point is too high, a voltage dividing circuit composed of high-precision resistors R19 and R20 is used to obtain a proportionally reduced sampled voltage signal. The voltage sampling signal is input to the follower circuit UA11A, and then passes through the signal processing circuit U12A and the isolation chip HCNR201. After isolation, the acquired voltage signal is input to the U13A operational amplifier circuit; in this embodiment, the operational amplifiers in the voltage acquisition all use TL082, and a 3.3V limiting circuit needs to be set before connecting to the main control chip to prevent the single-chip microcomputer from being broken down;

[0050] The current detection circuit first passes through the differential operational amplifier circuit U6A, then through the signal processing circuit U9AA and is input into the isolation chip HCNR201. After isolation, it is input into the operational amplifier U17A, and finally, after passing through the limiting protection circuit composed of D19 and D20, it is input into the ADC channel. Its sampling principle is as Figure 13 shown.

[0051] The processor unit 4 is set in the middle of the chassis 1. The mainstream processor GD32F303VCT6 of GigaDevice Semiconductor Inc. is used as the controller. It is connected to the DC electronic load module 21 through the GFIO port, the DAC port is connected to the voltage signal amplification circuit 22, the ADC port is respectively connected to the DC electronic load signal processing circuit 23 and the DC power supply signal processing circuit 33, and the TIMER port is connected to the filter amplification circuit 32; the processor unit 4 controls the constant current and constant voltage modes of the DC electronic load through the voltage signal output by the DAC and passing through the voltage signal amplification circuit 22. The current and voltage signals of the DC electronic load are fed back to the processor unit through the DC electronic load signal processing circuit 23; similarly, the DC power supply module 31 is controlled through the signal output by the TIMER and passing through the filter amplification circuit 32, and the current and voltage signals of the DC power supply are fed back to the processor unit 4 through the signal processing circuit;

[0052] The processor unit 4 is additionally connected to the FLASH through the SPI port and the LCD display screen 11 through the EXMC port, increasing the interactivity of the system through the screen display.

[0053] The OTA program 5 includes a server 51, a mobile terminal 52, and a Bluetooth module 53; the mobile terminal 52 is respectively connected to the server 51 and the Bluetooth module 53 through signal connections, and realizes the remote management and protocol upgrade of the system software through OTA technology; the Bluetooth module 53 is connected to the USART port of the processor unit 4 through a signal connection; by setting up a server, developing a WeChat mini-program, and through OTA technology, the remote management and protocol upgrade of the system software can be realized.

[0054] The CAN protocol simulation system 6 includes a CAN interface, which is used to simulate the communication protocols of various devices and is connected to the CAN port of the processor unit 4.

[0055] The system power supply module 7 is set at the bottom of the middle part of the chassis 1, below the processor unit 4, and is electrically connected to the DC electronic load module 21, the DC power supply module 31, and the processor unit 4 respectively.

Claims

1. A maintenance and test device for a new energy charger, characterized in that: the device includes a DC electronic load system, a processor unit, a DC power supply system, a CAN protocol simulation system, and a system power supply module; the DC electronic load system includes a DC electronic load module, a voltage signal amplification circuit, and a DC electronic load signal processing circuit; the signal input end of the DC electronic load is connected through the voltage amplification circuit, and the signal output end is connected to the DC electronic load signal processing circuit; the DC power supply system includes a DC power supply module, a filtering and amplification circuit, and a DC power supply signal processing circuit; the signal input end of the DC power supply module is connected through the filtering and amplification circuit, and the signal output end is connected to the DC power supply signal processing circuit; the processor unit is respectively connected to the DC electronic load through the GFIO port, the voltage amplification circuit through the DAC port, the DC electronic load signal processing circuit and the DC power supply signal processing circuit through the ADC port, the TIMER port is connected to the filtering and amplification circuit, and the CAN port is connected to the CAN interface for simulating various device communication protocols; the CAN protocol simulation system includes a CAN interface, and the CAN interface is used to simulate the communication protocols of various devices and is connected to the CAN port of the processor unit; the system power supply module is electrically connected to the DC power supply system, the processor unit, and the DC electronic load module respectively.

2. The maintenance and test device for a new energy charger according to claim 1, characterized in that: the device further includes an OTA program; the OTA program includes a server, a mobile terminal, and a Bluetooth module; the mobile terminal is respectively connected to the server and the Bluetooth module through signal connections, and realizes remote management and protocol upgrade of the system software through OTA technology; the Bluetooth module is connected to the USART port of the processor unit through a signal connection.

3. The maintenance and test device for a new energy charger according to claim 1, characterized in that: the device is provided with a chassis; a display screen, buttons, a power switch, wiring terminals, and a communication interface are provided on the front shell of the chassis, a cooling fan is provided on the rear shell, and cooling holes are provided on both side walls and the top; the DC power supply module and the DC electronic load module are symmetrically arranged on both sides inside the chassis; the DC power supply module is electrically connected to the power switch of the chassis; the processor unit is arranged in the middle of the chassis, and the EXMC port of the processor unit is connected to the display screen; the system power supply module is arranged at the bottom in the middle of the chassis, below the processor unit, and is electrically connected to the power switch of the chassis.

4. The maintenance and test device for a new energy charger according to any one of claims 1-3, characterized in that: the DC power supply module includes a rectification circuit, a Buck circuit, an inversion circuit, a voltage doubling circuit, a DC power supply protection circuit, a voltage acquisition and processing circuit, and a current detection circuit.

5. The maintenance and test device for a new energy charger according to claim 4, characterized in that: the inversion circuit is provided with two isolation drive circuits and a dead time.

6. The maintenance and test device for a new energy charger according to claim 5, characterized in that: The main function of the voltage multiplier circuit is to boost the high-frequency high-voltage AC square wave output by the upper-level circuit again to obtain the expected output voltage value, and play a certain role in rectification and filtering.

7. The new energy charger maintenance and test equipment according to any one of claims 1-3, characterized in that: The DC electronic load module includes a constant current control circuit, a constant voltage control circuit, and a protection circuit for the DC electronic load.

8. The new energy charger maintenance and test equipment according to claim 7, characterized in that: The constant current control circuit is responsible for hardware constant current control, including an integration circuit and a current output control circuit.

9. The new energy charger maintenance and test equipment according to claim 7, characterized in that: The constant voltage control circuit first reduces the sampled voltage by 0.2 times through the non-inverting proportional amplifier composed of the first-stage operational amplifier, and then sends it to the non-inverting input terminal of the voltage comparator composed of the second-stage integrated operational amplifier, where it is compared with the reference voltage DA applied to the inverting input terminal. When the input voltage increases and is greater than the reference voltage, the comparator outputs a high level, increasing the conduction amount of the power transistor and reducing the grid-drain resistance R DS to decrease, and the input voltage to decrease, achieving constant voltage operation.

10. The new energy charger maintenance and test equipment according to any one of claims 1-3, characterized in that: In the DC electronic load signal processing circuit, the load module uses two IRFP250 field effect transistors as the load transistors of the electronic load, the current detection amplifier uses an INA180A3 device, and R1 and R2 are the gate resistors of the power switch tube MOSFET, and the resistance value parameter is 510Ω.

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