A temperature rise test system and method for a direct current charging connection assembly of an electric vehicle

Abstract

The application discloses a temperature rise testing system and method for a direct-current charging connection assembly of an electric vehicle, and the temperature rise testing system comprises the following: a power supply and a vehicle socket gauge are connected to the input end and the output end of the measured direct-current charging connection assembly; a heating device and a reference temperature measuring device are arranged at the contact area between the vehicle socket gauge and the measured direct-current charging connection assembly; a self-temperature measuring device is arranged at the measured direct-current charging connection assembly; the power supply is used for simulating the output current of a charger; the vehicle socket gauge is used for simulating the charging socket of the electric vehicle; the heating device is used for simulating the heat generated by the increase of the contact impedance between the measured direct-current charging connection assembly and the vehicle socket gauge; the self-temperature measuring device is used for collecting the temperature of the measured direct-current charging connection assembly; and the reference temperature measuring device is used for collecting the temperature of the contact area between the measured direct-current charging connection assembly and the vehicle socket gauge.

Description

Technical Field

[0001] This invention relates to a temperature rise testing system and method for DC charging connection components of electric vehicles, belonging to the field of electric vehicle technology. Background Technology

[0002] Electric vehicle charging infrastructure is a crucial foundation for the development of electric vehicles, and charging connection components are an important part of this infrastructure. Standardization of charging connection components will promote the large-scale development of electric vehicles. During DC charging, the large charging current will generate heat in the connection components. Additionally, the contact resistance between the vehicle plug and the vehicle socket in the charging connection components will also generate additional heat. The charging connection components need to monitor the temperature using temperature sensors and be able to detect abnormal temperature rises, transmitting the temperature data to the charger to trigger protective actions and ensure the safety of the charging process.

[0003] Currently, IEC TS62196-3-1:2020 specifies temperature rise test methods for three types of charging connection components: AA, EE, and FF. This invention relates to GG type DC charging connection components. Since GG type charging connection components differ from AA, EE, and FF type charging connection components, the temperature rise test method specified in IEC 62196-3-1 is not applicable to GG type charging connection components. Therefore, there is an urgent need to improve the temperature sensing performance test method for GG type charging connection components.

[0004] Temperature sensing performance is a crucial performance indicator for charging connectors, directly reflecting their ability to detect abnormal temperature rises. High-performance charging connectors can promptly detect abnormal temperature increases and transmit the information to the charger for protective actions, ensuring safe and stable operation under high current for extended periods. Temperature sensing performance testing involves factors such as testing methods, temperature sensor placement, heating power, and testing procedures, all of which affect the test results. Currently, there is no specific testing method for the temperature sensing performance of GG-type charging connectors, thus necessitating a solution to this problem. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a temperature rise testing system and method for DC charging connection components of electric vehicles, which can objectively and accurately measure the temperature sensing performance of DC charging connection components.

[0006] To achieve the above objectives, the present invention is implemented using the following technical solution:

[0007] In a first aspect, the present invention provides a temperature rise testing system for a DC charging connection component of an electric vehicle, comprising a DC charging connection component under test, wherein a power supply and a vehicle socket gauge are respectively connected to the input and output ends of the DC charging connection component under test; a heating device and a reference temperature measuring device are provided in the contact area between the vehicle socket gauge and the DC charging connection component under test; and a self-temperature measuring device is provided at the DC charging connection component under test.

[0008] Optionally, the DC charging connection assembly under test includes a positive connection unit and a negative connection unit. The positive connection unit includes a positive pin and a positive cable that are electrically connected, and the negative connection unit includes a negative pin and a negative cable that are electrically connected. The vehicle socket gauge includes a positive socket and a negative socket. The DC charging connection assembly under test is detachably connected to the vehicle socket gauge, and the positive pin and the negative pin are respectively adapted to the positive socket and the negative socket.

[0009] Optionally, the power supply is a DC power supply or an AC power supply. The DC power supply includes a positive terminal DC+ and a negative terminal DC-, and the AC power supply includes an output terminal L and an output terminal N.

[0010] If the power supply is a DC power supply, the positive terminal DC+ and the negative terminal DC- are respectively connected to the positive cable and the negative cable; or the positive terminal DC+ and the negative terminal DC- are respectively connected to the negative cable and the positive cable.

[0011] If the power supply is an AC power source, the output terminal L and the output terminal N are respectively connected to the positive cable and the negative cable; or the output terminal L and the output terminal N are respectively connected to the negative cable and the positive cable.

[0012] Optionally, the positive terminal and the negative terminal are electrically connected.

[0013] Optionally, the temperature rise testing system further includes a heating control module, and the heating device is connected to the heating control module.

[0014] Optionally, the heating device includes a positive heating module and a negative heating module. The positive heating module is disposed in the contact area between the positive pin and the positive socket, and the negative heating module is disposed in the contact area between the negative pin and the negative socket. Both the positive heating module and the negative heating module are connected to the heating control module.

[0015] Optionally, the temperature rise testing system further includes a temperature monitoring instrument, and the reference temperature measuring device and the self-temperature measuring device are respectively connected to the temperature monitoring instrument.

[0016] Optionally, the reference temperature measuring device includes a positive reference temperature sensor and a negative reference temperature sensor. The positive reference temperature sensor is disposed in the contact area between the positive pin and the positive socket, and the negative reference temperature sensor is disposed in the contact area between the negative pin and the negative socket. The positive reference temperature sensor and the negative reference temperature sensor are respectively connected to the temperature monitoring instrument.

[0017] Optionally, the self-temperature measuring device includes a positive electrode self-temperature sensor and a negative electrode self-temperature sensor, which are respectively disposed at the positive electrode connection unit and the negative electrode connection unit, and are respectively connected to the temperature monitoring instrument.

[0018] Secondly, the present invention provides a temperature rise testing method based on the above-mentioned temperature rise testing system, comprising:

[0019] Obtain the rated current and test current of the DC charging connection component under test;

[0020] The test heating power of the heating device is obtained based on the rated current and the test current.

[0021] The power supply and heating device are started based on the test current and test heating power, respectively.

[0022] The power supply and heating device will shut off after the preset time has elapsed.

[0023] The temperature value at the DC charging connection component under test is collected by its own temperature measuring device during the process from start-up to shutdown of the power supply and heating device.

[0024] The rate of temperature change of the tested DC charging connection component is calculated based on the temperature values ​​at the tested DC charging connection component when the power supply and heating device are started and stopped.

[0025] Optionally, obtaining the test heating power of the heating device based on the rated current and the test current includes:

[0026] Power supply starts based on rated current;

[0027] The temperature value of the contact area between the vehicle socket gauge and the DC charging connection component under test is collected by the reference temperature measuring device after the power supply is started.

[0028] Once the temperature of the contact area between the vehicle socket gauge and the DC charging connection component under test stabilizes, start the heating device.

[0029] Adjust the real-time heating power of the heating device to stabilize the temperature of the contact area between the vehicle socket gauge and the DC charging connection component under test at the preset temperature, and record the current heating power of the heating device.

[0030] Calculate the critical failure resistance value of the contact area between the vehicle socket gauge and the DC charging connection component under test based on the current heating power and rated current:

[0031]

[0032] In the formula, P Hrated I represents the current heating power of the heating device. rated For the rated current, ΔR failure This is the critical value for the failure resistance;

[0033] The test heating power is calculated based on the test current and the critical failure resistance value of the contact area between the vehicle socket gauge and the DC charging connection component under test.

[0034]

[0035] In the formula, P Htest To test the heating power, I test For testing current.

[0036] Optionally, the temperature rise test method further includes obtaining a temperature change rate limit of the DC charging connection component under test. If the temperature change rate of the DC charging connection component under test is greater than the temperature change rate limit, the DC charging connection component under test is determined to have passed the temperature rise test.

[0037] Optionally, the rated current of the DC charging connection component under test is greater than the test current.

[0038] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0039] This invention provides a temperature rise testing system and method for a DC charging connection assembly of an electric vehicle. The temperature rise testing system includes: simulating the output current of a charger using a power supply; simulating an electric vehicle charging socket using a vehicle socket gauge; simulating the heat generated by the increased contact resistance between the tested DC charging connection assembly and the vehicle socket gauge using a heating device; collecting the temperature of the tested DC charging connection assembly using its own temperature measuring device; and collecting the temperature of the contact area between the tested DC charging connection assembly and the vehicle socket gauge using a reference temperature measuring device. The temperature rise testing method involves using a test current I... test and rated current I rated Obtain the test heating power P of the heating device test By testing the heating power P testThe heating device is controlled to obtain the temperature change rate k. The temperature change rate k of the DC charging connection component under test is compared with the temperature change rate limit K to determine whether the test is passed.

[0040] In summary, this invention can objectively and accurately measure the temperature sensing performance of DC charging connection components, overcome the influence of human factors, and its test results are more scientific and can accurately reflect the rationality of the temperature sensor arrangement and fault response capability of the charging connection components. Applying this invention can provide testing technology and technical support for the safe application of charging connection components. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the temperature rise test system for a DC charging connection component of an electric vehicle provided in Embodiment 1 of the present invention;

[0042] Figure 2 This is a flowchart of a temperature rise testing method based on the temperature rise testing system in Embodiment 1, provided in Embodiment 2 of the present invention;

[0043] Figure 3 This is a flowchart of a method for obtaining the test heating power of a heating device according to Embodiment 2 of the present invention;

[0044] The diagram is marked as follows:

[0045] 1. DC charging connection assembly under test; 11. Positive connection unit; 12. Positive cable; 13. Positive pin; 14. Negative connection unit; 15. Negative pin; 16. Negative cable; 2. Power supply; 3. Vehicle socket gauge; 31. Positive socket; 32. Negative socket; 33. Cable; 4. Heating device; 41. Positive heating module; 42. Negative heating module; 43. Heating control module; 5. Reference temperature measuring device; 51. Positive reference temperature sensor; 52. Negative reference temperature sensor; 6. Self-temperature measuring device; 61. Positive self-temperature sensor; 62. Negative self-temperature sensor; 7. Temperature monitoring instrument; 8. Heat exchange device. Detailed Implementation

[0046] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0047] Example 1:

[0048] This invention provides a temperature rise testing system for a DC charging connection component of an electric vehicle. The system includes a DC charging connection component 1 to be tested, a power supply 2 and a vehicle socket gauge 3 connected to the input and output ends of the DC charging connection component 1, respectively. A heating device 4 and a reference temperature measuring device 5 are provided in the contact area between the vehicle socket gauge 3 and the DC charging connection component 2. A self-temperature measuring device 6 is provided at the DC charging connection component 1.

[0049] Among them, the power supply 2 is used to simulate the output current of the charger; the vehicle socket gauge 3 is used to simulate the electric vehicle charging socket; the heating device 4 is used to simulate the heat generated by the increased contact resistance between the electric vehicle plug (the DC charging connection component 1 under test) and the electric vehicle socket (vehicle socket gauge 3); the self-temperature measuring device 5 is used to collect the temperature of the DC charging connection component 1 under test; and the reference temperature measuring device 6 is used to collect the temperature of the contact area between the DC charging connection component 1 under test and the vehicle socket gauge 3.

[0050] Specifically,

[0051] (1) The DC charging connection assembly under test 1 includes a positive connection unit 11 and a negative connection unit 14. The positive connection unit 11 includes a positive pin 13 and a positive cable 12 that are electrically connected. The negative connection unit 14 includes a negative pin 15 and a negative cable 16 that are electrically connected. The vehicle socket gauge 3 includes a positive socket 31 and a negative socket 32. The DC charging connection assembly under test 1 and the vehicle socket gauge 3 are detachably connected. The positive pin 12 and the negative pin 15 are respectively adapted to the positive socket 31 and the negative socket 32. The positive socket 31 and the negative socket 32 ​​are electrically connected. In specific implementation, a cable 33 or a copper busbar can be used as a connector.

[0052] (2) The power supply 2 is a DC power supply or an AC power supply. The DC power supply includes a positive terminal DC+ and a negative terminal DC-. The AC power supply includes an output terminal L and an output terminal N.

[0053] If the power supply 2 is a DC power supply, the positive terminal DC+ and the negative terminal DC- are connected to the positive cable 12 and the negative cable 16 respectively; or the positive terminal DC+ and the negative terminal DC- are connected to the negative cable 16 and the positive cable 12 respectively.

[0054] If the power supply 2 is an AC power supply, the output terminal L and the output terminal N are connected to the positive cable 12 and the negative cable 16 respectively; or the output terminal L and the output terminal N are connected to the negative cable 16 and the positive cable 12 respectively.

[0055] Since the positive terminal 31 and the negative terminal 32 in the vehicle socket gauge 3 are electrically connected by cable 33 or copper busbar, there is no need to distinguish between positive and negative terminals during testing, and the connection method of the power supply 2 is relatively flexible.

[0056] (3) The temperature rise testing system also includes a heating control module 43, and the heating device 4 is connected to the heating control module 43. The heating device 4 includes a positive heating module 41 and a negative heating module 42. The positive heating module 41 is disposed in the contact area between the positive electrode pin 12 and the positive electrode socket 31, and the negative heating module 42 is disposed in the contact area between the negative electrode pin 15 and the negative electrode socket 32. Both the positive heating module 41 and the negative heating module 42 are connected to the heating control module 43. The heating control module 43 is used to control the heating power of the heating device.

[0057] (4) The temperature rise test system also includes a temperature monitoring instrument 7, a reference temperature measuring device 5 and a self-temperature measuring device 6, which are respectively connected to the temperature monitoring instrument 7.

[0058] The reference temperature measuring device 5 includes a positive reference temperature sensor 51 and a negative reference temperature sensor 52. The positive reference temperature sensor 51 is disposed in the contact area between the positive pin 12 and the positive socket 31, and the negative reference temperature sensor 52 is disposed in the contact area between the negative pin 15 and the negative socket 32. The positive reference temperature sensor 51 and the negative reference temperature sensor 52 are respectively connected to the temperature monitoring instrument 7.

[0059] The self-temperature measuring device 6 includes a positive self-temperature sensor 61 and a negative self-temperature sensor 62. The positive self-temperature sensor 61 and the negative self-temperature sensor 62 are respectively disposed at the positive connection unit 11 and the negative connection unit 14. The positive self-temperature sensor 61 and the negative self-temperature sensor 62 are respectively connected to the temperature monitoring instrument 7. The temperature monitoring instrument 7 is used to display and store the collected temperature in real time.

[0060] Example 2:

[0061] like Figure 2 As shown, this embodiment of the invention provides a temperature rise testing method based on the temperature rise testing system in Embodiment 1, including the following steps:

[0062] 1. Obtain the rated current I of the DC charging connection component 1 under test. rated and test current I test Rated current I rated and test current I test It can be obtained from the manufacturer. The rated current I of the DC charging connection component 1 under test. rated Greater than the test current I test .

[0063] 2. Based on the rated current I rated and test current I test Obtain the test heating power P of heating device 4 Htest ;

[0064] like Figure 3 As shown, this embodiment obtains the test heating power P. Htest The method is as follows:

[0065] 2.1 Based on rated current I rated Start power supply 2;

[0066] 2.2 The temperature value of the contact area between the vehicle socket gauge 3 and the DC charging connection component 1 under test is collected by the reference temperature measuring device 5 after the power supply 2 is started;

[0067] 2.3 After the temperature value of the contact area between the vehicle socket gauge 3 and the DC charging connection component 1 under test stabilizes, start the heating device 4;

[0068] 2.4. By adjusting the real-time heating power of the heating device 4, the temperature of the contact area between the vehicle socket gauge 3 and the DC charging connection component 1 under test is stabilized at a preset temperature (generally 90℃), and the current heating power P of the heating device 4 is recorded. Hrated ;

[0069] 2.5. Based on the current heating power P Hrated and rated current I rated Calculate the critical failure resistance ΔR of the contact area between the vehicle socket gauge 3 and the DC charging connection component 1 under test. failure :

[0070]

[0071] In the formula, P rated I represents the current heating power of the heating device. rated For the rated current, ΔR failure This is the critical value for the failure resistance;

[0072] 2.6. Based on the test current I test Calculate the critical failure resistance value of the contact area between the vehicle socket gauge 3 and the DC charging connection component 1 under test, and calculate the test heating power:

[0073]

[0074] In the formula, P Htest To test the heating power, I test For testing current.

[0075] 3. Based on the test current I test and test heating power P Htest Turn on the power supply 2 and the heating device 4 respectively;

[0076] 4. The power supply 2 and heating device 4 will be turned off after the preset time t has elapsed since they started.

[0077] 5. The temperature (T) at the DC charging connection component 1 under test is collected by the self-temperature measuring device 6 when the power supply 2 and heating device 4 are started and stopped. S0 T St );

[0078] 6. Calculate the rate of temperature change of the tested DC charging connection component 1 based on the temperature values ​​at the tested DC charging connection component 1 when the power supply 2 and heating device 4 are started and turned off;

[0079] Rate of temperature change k:

[0080]

[0081] In the formula, T S0 T St These are the temperature values ​​at the DC charging connection component 1 being measured, representing the start and end points of a preset time period t (i.e., when the power supply 2 and heating device 4 are started and turned off, respectively).

[0082] 7. Obtain the temperature change rate limit K of the DC charging connection component 1 under test (which can be obtained from the manufacturer). If the temperature change rate of the DC charging connection component 1 under test is greater than the temperature change rate limit (k < K), then the DC charging connection component 1 under test is determined to have passed the temperature rise test.

[0083] In addition, since some manufacturers now offer DC charging connection components 1 under test that can be equipped with a heat exchange device 8, thereby reducing the temperature of the DC charging connection component 1 under test during operation. To accommodate the DC charging connection component 1 under test equipped with the heat exchange device 8, in step 2.1 of the above method, based on the rated current I... rated Simultaneously with starting the power supply 2, the heat exchange device 8 is also started, and the power of the heat exchange device 8 is set to the maximum, thereby taking into account the temperature effect of the heat exchange device 8 on the DC charging connection component 1 under test.

[0084] This method can objectively and accurately measure the temperature sensing performance of DC charging connection components. Its test results more scientifically reflect the rationality of the temperature sensor arrangement and fault response capability of the charging connection components, and can provide effective testing methods and tools for professional testing institutions or charging connection device manufacturers.

[0085] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0086] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A temperature rise testing method for a temperature rise testing system of a DC charging connection component for an electric vehicle, comprising a DC charging connection component under test, characterized in that, A power supply and a vehicle socket gauge are connected to the input and output terminals of the DC charging connection component under test, respectively; a heating device and a reference temperature measuring device are provided in the contact area between the vehicle socket gauge and the DC charging connection component under test. A self-temperature measuring device is provided at the DC charging connection component under test. The temperature rise test method includes: Obtain the rated current and test current of the DC charging connection component under test; The test heating power of the heating device is obtained based on the rated current and the test current. The power supply and heating device are started based on the test current and test heating power, respectively. The power supply and heating device will shut off after the preset time has elapsed. The temperature value at the DC charging connection component under test is collected by its own temperature measuring device during the process from start-up to shutdown of the power supply and heating device. The rate of temperature change of the tested DC charging connection component is calculated based on the temperature values ​​at the tested DC charging connection component when the power supply and heating device are started and turned off. The step of obtaining the test heating power of the heating device based on the rated current and the test current includes: Power supply starts based on rated current; The temperature value of the contact area between the vehicle socket gauge and the DC charging connection component under test is collected by the reference temperature measuring device after the power supply is started. Once the temperature of the contact area between the vehicle socket gauge and the DC charging connection component under test stabilizes, start the heating device. Adjust the real-time heating power of the heating device to stabilize the temperature of the contact area between the vehicle socket gauge and the DC charging connection component under test at the preset temperature, and record the current heating power of the heating device. Calculate the critical failure resistance value of the contact area between the vehicle socket gauge and the DC charging connection component under test based on the current heating power and rated current: ； In the formula, This represents the current heating power of the heating device. Rated current, This is the critical value for the failure resistance; The test heating power is calculated based on the test current and the critical failure resistance value of the contact area between the vehicle socket gauge and the DC charging connection component under test. ； In the formula, To test the heating power, For testing current.

2. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 1, characterized in that, The DC charging connection assembly under test includes a positive connection unit and a negative connection unit. The positive connection unit includes a positive pin and a positive cable that are electrically connected, and the negative connection unit includes a negative pin and a negative cable that are electrically connected. The vehicle socket gauge includes a positive socket and a negative socket. The DC charging connection assembly under test is detachably connected to the vehicle socket gauge, and the positive pin and the negative pin are respectively adapted to the positive socket and the negative socket.

3. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 2, characterized in that, The power supply is a DC power supply or an AC power supply. The DC power supply includes a positive terminal DC+ and a negative terminal DC-. The AC power supply includes an output terminal L and an output terminal N. If the power supply is a DC power supply, the positive terminal DC+ and the negative terminal DC- are respectively connected to the positive cable and the negative cable; or the positive terminal DC+ and the negative terminal DC- are respectively connected to the negative cable and the positive cable. If the power supply is an AC power source, the output terminal L and the output terminal N are respectively connected to the positive cable and the negative cable; or the output terminal L and the output terminal N are respectively connected to the negative cable and the positive cable.

4. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 2, characterized in that, The positive terminal and the negative terminal are electrically connected.

5. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 2, characterized in that, The temperature rise testing system also includes a heating control module, and the heating device is connected to the heating control module.

6. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 5, characterized in that, The heating device includes a positive heating module and a negative heating module. The positive heating module is disposed in the contact area between the positive electrode pin and the positive electrode socket, and the negative heating module is disposed in the contact area between the negative electrode pin and the negative electrode socket. Both the positive heating module and the negative heating module are connected to the heating control module.

7. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 2, characterized in that, The temperature rise testing system also includes a temperature monitoring instrument, and the reference temperature measuring device and the self-temperature measuring device are respectively connected to the temperature monitoring instrument.

8. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 7, characterized in that, The reference temperature measuring device includes a positive reference temperature sensor and a negative reference temperature sensor. The positive reference temperature sensor is disposed in the contact area between the positive pin and the positive socket, and the negative reference temperature sensor is disposed in the contact area between the negative pin and the negative socket. The positive reference temperature sensor and the negative reference temperature sensor are respectively connected to the temperature monitoring instrument.

9. The temperature rise testing method of the temperature rise testing system for a DC charging connection component of an electric vehicle according to claim 7, characterized in that, The self-temperature measuring device includes a positive electrode self-temperature sensor and a negative electrode self-temperature sensor. The positive electrode self-temperature sensor and the negative electrode self-temperature sensor are respectively disposed at the positive electrode connection unit and the negative electrode connection unit, and are respectively connected to the temperature monitoring instrument.

10. The temperature rise testing method of the electric vehicle DC charging connection component temperature rise testing system according to claim 1, characterized in that, The temperature rise test method further includes obtaining the temperature change rate limit of the DC charging connection component under test. If the temperature change rate of the DC charging connection component under test is greater than the temperature change rate limit, the DC charging connection component under test is determined to have passed the temperature rise test.

11. The temperature rise testing method of the electric vehicle DC charging connection component temperature rise testing system according to claim 1, characterized in that, The rated current of the DC charging connection component under test is greater than the test current.

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