A low-power consumption aging method for a large-current device

Abstract

The present application relates to the technical field of equipment aging, in particular to a low-power aging method for high-current equipment, wherein an output end of a power frequency transformer is connected to an AC input end of a high-current equipment control panel, the power frequency transformer outputs low-voltage high-current to the high-current equipment control panel, an AC output end of the high-current equipment control panel is connected to an analog load, the low-voltage high-current output by the power frequency transformer flows through the high-current equipment control panel and is output to the analog load, thereby completing the low-power high-current aging of the high-current equipment. Compared with the prior art, the low-power aging method for high-current equipment can effectively reduce the aging cost of the high-current equipment, the hardware cost of the whole aging equipment is only a few hundred yuan; the electric energy consumed in the aging process is reduced by hundreds of times, the electricity bill is greatly reduced, energy can be effectively saved; the heating is small, the method is safe and reliable, and there is no risk of fire due to overheating; the voltage is low, and there is no risk of electric shock for the operator.

Description

[Technical Field]

[0001] This invention relates to the field of equipment aging technology, and in particular to a low-power aging method for high-current equipment. [Background Technology]

[0002] Before leaving the factory, charging piles and other high-current equipment need to withstand high current for several hours or even longer to ensure the reliability of the circuits that can withstand high current. This high-current aging test checks the reliability of the circuits and prevents problems such as insufficient copper thickness or poor soldering from going undetected before leaving the factory, resulting in short service life and greater losses after entering the market.

[0003] The existing aging method for high-current equipment involves connecting a high-power simulated load device, connecting the control board output of the equipment to the high-power simulated load, and then performing aging. This aging method is not only costly, but also consumes a lot of electrical energy, resulting in a huge waste of energy. [Summary of the Invention]

[0004] To overcome the above problems, this invention proposes a low-power aging method for high-current devices that can effectively solve the above problems.

[0005] The present invention provides a technical solution to solve the above-mentioned technical problems: a low-power aging method for high-current equipment, wherein the output terminal of a power frequency transformer is connected to the AC input terminal of a high-current equipment control board, the power frequency transformer outputs low voltage and high current to the high-current equipment control board, and the AC output terminal of the high-current equipment control board is connected to a simulated load.

[0006] The AC input live wire of the high-current equipment control board is connected to the relay, and the AC output live wire is connected to the current transformer. The relay is connected to the current transformer.

[0007] The relay is connected to a first resistor, the first resistor is connected to a second resistor, and a variable voltage is externally connected at the connection point of the first resistor and the second resistor;

[0008] The AC input terminal and relay of the high-current equipment control board are connected to another transformer. The transformer is connected to a rectifier bridge, which is connected to the relay. A filter capacitor is connected between the rectifier bridge and the relay, and the filter capacitor is connected to an external power supply.

[0009] A transistor is connected between the relay and the current transformer. The transistor is connected to a third resistor to connect the relay control signal output terminal.

[0010] The low-voltage, high-current output from the power frequency transformer flows through the control board of the high-current equipment and is output to the simulated load, thereby completing the low-power, high-current aging of the high-current equipment.

[0011] Preferably, there are multiple high-current device control boards. The AC output terminals and AC input terminals of the multiple high-current device control boards are connected in series. Then, the AC input terminal of the first high-current device control board is connected to the output terminal of the power frequency transformer, and the AC output terminal of the last high-current device control board is connected to the simulated load. The low-voltage high current output by the power frequency transformer flows through the multiple high-current device control boards and is output to the simulated load, thus completing the low-power high-current aging of the multiple high-current devices.

[0012] Preferably, the simulated load consists of multiple cement resistors connected in parallel.

[0013] Preferably, the resistance of the first resistor is at least one hundred times the resistance of the second resistor.

[0014] Preferably, the variable voltage is used to simulate the input voltage.

[0015] Preferably, the external power supply provides operating power to the high-current device control board.

[0016] Compared with existing technologies, the low-power aging method for high-current equipment of the present invention can effectively reduce the aging cost of high-current equipment. The hardware cost of the entire aging equipment is only a few hundred yuan. The power loss during the aging process is reduced by hundreds of times, greatly reducing electricity expenses and effectively saving energy. It generates little heat, is safe and reliable, and there is no need to worry about overheating and fire. The voltage is low, so there is no need to worry about electric shock to operators. [Attached Image Description]

[0017] Figure 1 A simplified schematic diagram of normal aging of charging piles in existing technology;

[0018] Figure 2 This is a simplified schematic diagram of the simulated aging of a charging pile using the low-power aging method for high-current equipment of the present invention.

[0019] Figure 3 This is a schematic diagram of the simultaneous aging of multiple boards in a charging pile using the low-power aging method for high-current devices according to the present invention.

Detailed Implementation Methods

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention.

[0021] It should be noted that in the embodiments of the present invention, all directional indications (such as up, down, left, right, front, back, etc.) are limited to relative positions on the specified view, rather than absolute positions.

[0022] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0023] Please see Figure 1 When the charging station is working normally, it is connected to AC mains power, the output is connected to the electric vehicle, and the AC input neutral wire is connected to the power ground. The diagram only shows the basic principle, and there will be differences between the actual situation and the diagram.

[0024] from Figure 1 As can be seen, the charging pile control board controls the current flow through relays or electronic switches, and the voltage is sampled through a voltage divider connected to R1 and R2, with the resistance of R1 being hundreds of times that of R2. The current is sampled through a current transformer. During production, the charging pile control board cannot be connected to an electric vehicle for charging; instead, the output is connected to an equivalent load for aging. This aging method results in significant energy loss from the load.

[0025] The input voltage of a charging pile is usually 220V / 110V, and the output current during charging is tens of A or even hundreds of A, which is very high. If a high-power simulated load is used for aging, the aging cost will be very high. Here, we will take a 22kW charging pile as an example to illustrate the full-power aging process for 8 hours.

[0026] If resistive load aging is used, the cost of a single aging equipment is a few hundred yuan, which is acceptable. However, completing one aging cycle consumes 22kW x 8h = 176kWh of electricity. At an electricity price of 0.6 yuan, the electricity cost for one aging cycle is 176kWh x 0.6 yuan / h = 105.6 yuan. This means that the cost of each aging cycle exceeds 100 yuan. Aging 10,000 charging piles would cost more than one million yuan. Moreover, the electricity consumed by aging is wasted, resulting in a huge energy waste.

[0027] The equivalent load has high cost and consumes a lot of electrical energy. Figure 1 It can be seen that the charging pile control board only controls the on / off state of the charging circuit. Although the controlled current is large, the voltage drop of the charging pile control board circuit itself is very small, almost zero. The actual voltage loss is all applied to the load. Therefore, this invention proposes a low-power aging method for high-current equipment. When aging high-current equipment, the load loss voltage is reduced by using low voltage and high current for aging, which can reduce the power loss during aging by hundreds of times.

[0028] Please see Figure 2To facilitate a detailed explanation of the implementation method of this invention, we selected a 500W / 220V input / 1.5V output power frequency AC transformer to design a 22kW charging pile full power aging verification prototype. We will use this prototype as an example to illustrate a low-power aging method for high-current equipment according to this invention.

[0029] Under 220V voltage, the current I1 when the charging pile outputs 22kW power is 22kW ÷ 220V = 100A.

[0030] The maximum output current of the power frequency AC transformer is I2 = 500W ÷ 1.5V = 333A.

[0031] The current I1 is one-third of the current I2, leaving ample margin.

[0032] When the power frequency AC transformer outputs 100A, the output power P1 = 1.5V × 100A = 150W.

[0033] The power P1 is one-third of 500W, leaving ample margin.

[0034] The input-output voltage ratio is 220:1.5 = 146.

[0035] Connect the output terminal of the 220V input / 1.5V output AC transformer to the AC input terminal of the charging pile control board. The input will then be AC ​​1.5V. Simulate the load using parallel 1Ω 10W cement resistors. Each 1Ω 10W resistor can provide 1.5A of current, theoretically providing 100A of current for 66 circuits. The output power is 1.5V × 100A = 150W, simulating an equivalent 22kW power current, reducing power loss by 146 times.

[0036] At this time, the AC input is 1.5V, and the transformer output cannot meet the 12V power supply requirement. Therefore, an external 12V power supply needs to be connected to the 12V power supply location to provide working power to the charging pile control board.

[0037] The AC input of 1.5V is almost zero after being divided by resistors R1 and R2. The charging pile control board will think that the input voltage is zero. At this time, a variable voltage needs to be connected to the voltage signal position to simulate the input voltage.

[0038] The current transformer detects the current value passing through the transformer wire. At this time, the current is the same as the actual aging current and does not affect the output of the current transformer.

[0039] Please see Figure 3In practical applications, an aging device can be adjusted to age multiple control boards simultaneously. We connect the output of the first board to the input of the second board, the output of the second board to the input of the third board, and so on, until the output of the (n-1)th board is connected to the input of the nth board. These boards are connected in series and aged using the same current.

[0040] When there are a sufficient number of control boards connected in series, the internal resistance of the control board circuit needs to be considered. Adjusting the number of control boards connected in series to an appropriate value can eliminate the need for a load cement resistor.

[0041] The low-power aging method for high-current devices of the present invention is applicable to high-current devices such as charging piles to perform high-current aging in a low-power state, so as to realize the reliability aging verification of circuits in the device that need to withstand high current for a long time.

[0042] The low-power aging method for high-current equipment of the present invention connects the output terminal of the power frequency transformer to the AC input terminal of the high-current equipment control board, the power frequency transformer outputs low voltage and high current to the high-current equipment control board, and the AC output terminal of the high-current equipment control board is connected to a simulated load.

[0043] The AC input live wire of the high-current equipment control board is connected to the relay, and the AC output live wire is connected to the current transformer. The relay is connected to the current transformer.

[0044] The relay is connected to a first resistor R1, the first resistor R1 is connected to a second resistor R2, and a variable voltage is externally connected at the connection point of the first resistor R1 and the second resistor R2.

[0045] The AC input terminal and relay of the high-current equipment control board are connected to another transformer. The transformer is connected to a rectifier bridge, which is connected to the relay. A filter capacitor is connected between the rectifier bridge and the relay, and the filter capacitor is connected to an external 12V power supply.

[0046] A transistor is connected between the relay and the current transformer. The transistor is connected to a third resistor to connect the relay control signal output terminal.

[0047] The low-voltage, high-current output from the power frequency transformer flows through the control board of the high-current equipment and is output to the simulated load, thereby completing the low-power, high-current aging of the high-current equipment.

[0048] The number of high-current equipment control boards can be multiple. The AC output terminals and AC input terminals of multiple high-current equipment control boards are connected in series. Then, the AC input terminal of the first high-current equipment control board is connected to the output terminal of the power frequency transformer, and the AC output terminal of the last high-current equipment control board is connected to the simulated load. The low-voltage high current output by the power frequency transformer flows through multiple high-current equipment control boards and is output to the simulated load, thereby enabling the low-power high-current aging of multiple high-current equipment to be completed simultaneously.

[0049] The simulated load consists of multiple cement resistors connected in parallel. The number of cement resistors connected in parallel can be adjusted according to the number of control boards for high-current equipment connected in series.

[0050] The resistance of the first resistor R1 is at least one hundred times the resistance of the second resistor R2.

[0051] The variable voltage is used to simulate the input voltage. The external 12V power supply provides operating power to the high-current device control board.

[0052] Compared with existing technologies, the low-power aging method for high-current equipment of the present invention can effectively reduce the aging cost of high-current equipment. The hardware cost of the entire aging equipment is only a few hundred yuan. The power loss during the aging process is reduced by hundreds of times, greatly reducing electricity expenses and effectively saving energy. It generates little heat, is safe and reliable, and there is no need to worry about overheating and fire. The voltage is low, so there is no need to worry about electric shock to operators.

[0053] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any modifications, equivalent substitutions and improvements made within the concept of the present invention should be included within the patent protection scope of the present invention.

Claims

1. A low-power aging method for high-current devices, characterized in that, Connect the output terminal of the power frequency transformer to the AC input terminal of the high current equipment control board. The power frequency transformer outputs low voltage and high current to the high current equipment control board. Connect the AC output terminal of the high current equipment control board to the simulated load. The AC input live wire of the high-current equipment control board is connected to the relay, and the AC output live wire is connected to the current transformer. The relay is connected to the current transformer. The relay is connected to a first resistor, the first resistor is connected to a second resistor, and a variable voltage is externally connected at the connection point of the first resistor and the second resistor; The AC input terminal and relay of the high-current equipment control board are connected to another transformer. The transformer is connected to a rectifier bridge, which is connected to the relay. A filter capacitor is connected between the rectifier bridge and the relay, and the filter capacitor is connected to an external power supply. A transistor is connected between the relay and the current transformer. The transistor is connected to a third resistor to connect the relay control signal output terminal. Under the condition that the power frequency transformer outputs low voltage and high current, the variable voltage is used to simulate the input voltage, and the external power supply is used to provide working power to the control board of the high current equipment. The low-voltage, high-current output from the power frequency transformer flows through the high-current equipment control board and the current transformer before being output to the simulated load, so as to complete the low-power, high-current aging of the high-current equipment without affecting the output of the current transformer.

2. The low-power aging method for high-current devices as described in claim 1, characterized in that, The number of high-current equipment control boards is multiple. The AC output terminals and AC input terminals of multiple high-current equipment control boards are connected in series. Then, the AC input terminal of the first high-current equipment control board is connected to the output terminal of the power frequency transformer, and the AC output terminal of the last high-current equipment control board is connected to the simulated load. The low-voltage high current output by the power frequency transformer flows through multiple high-current equipment control boards and is output to the simulated load, completing the low-power high-current aging of multiple high-current equipment.

3. The low-power aging method for high-current devices as described in claim 1, characterized in that, The simulated load consists of multiple cement resistors connected in parallel.

4. The low-power aging method for high-current devices as described in claim 1, characterized in that, The resistance of the first resistor is at least one hundred times the resistance of the second resistor.

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