New energy vehicle fast charging test system and method
The hardware-in-the-loop test system for new energy vehicles simulates fast charging conditions to verify the BMS protocol, improving the reliability and stability of fast charging systems by addressing the lack of effective simulation testing in existing methods.
Patent Information
- Application Number
- CN202411151345.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-21
- Publication Date
- 2024-12-27
AI Technical Summary
Existing fast charging technologies for new energy vehicles lack effective simulation testing methods, leading to potential software crashes and serious issues like power overload and short circuits, and real vehicle testing is costly and time-consuming.
A hardware-in-the-loop test system using a HIL test cabinet with Mat lab models to simulate fast charging conditions, testing BMS master-slave boards, and configuring interactive messages to verify the fast charging protocol before factory delivery.
Enhances the stability and reliability of fast charging systems by simulating various conditions, reducing the risk of errors in actual use and enabling automated test result determination without manual intervention.
Smart Images
Figure CN119199304A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of fast charging testing, and in particular to a new energy vehicle fast charging testing system and method. Background Art
[0002] With the continuous advancement of science and technology, new energy vehicles and their charging technologies are also developing rapidly. Although the traditional slow charging method is relatively safe, it is undoubtedly not very friendly to users who are in urgent need of a car or drive for a long time. Especially in urban traffic, the commuting pace is fast, and the need for fast charging and energy replenishment is particularly urgent. The emergence of fast charging technology has met consumers' demand for charging convenience and further promoted the expansion of the new energy vehicle market.
[0003] During fast charging, the vehicle and the fast charging pile will continue to interact with each other through fast charging messages. The interactive content includes charging parameters, maximum output capacity of the charger, battery charging requirements, battery charging status, etc. Once unexpected content appears during this message interaction, it may cause the vehicle software system to crash, or even very serious consequences such as power overload and short circuit. Therefore, it is very necessary to test the fast charging protocol of the vehicle before the vehicle leaves the factory. In the testing of new energy in the prior art, real vehicle testing and simulation testing are often used. The cost of real vehicle testing is high and the cycle is long. Therefore, more simulation testing solutions are used in the prior art. However, the prior art does not involve fast charging testing solutions in vehicle testing, and cannot meet the needs of fast charging function testing. Summary of the invention
[0004] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a new energy vehicle fast charging test system and method, which tests the new energy vehicle fast charging protocol by means of simulation testing, thereby testing and verifying the fast charging protocol before leaving the factory, and improving the stability and reliability of the fast charging system.
[0005] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a new energy vehicle fast charging test system, including using a hardware-in-the-loop test cabinet to build the hardware and bus closed-loop working environment required for the fast charging test for the BMS, and then connecting the BMS master-slave boards used for fast charging control to the hardware-in-the-loop test cabinet; in the hardware-in-the-loop test cabinet, the BMS master-slave boards are operated and controlled by the model generated by Mat lab, each working condition in the fast charging process is simulated, and the BMS master-slave boards are tested and controlled.
[0006] Configure the BMS test environment on the HIL bench, including connecting the battery simulator, high-voltage simulation power supply, and insulation monitor, and debug and connect them to the BMS master and slave boards according to work requirements to ensure that the basic electrical connections are correct.
[0007] The control system also includes a fast charging parameter configuration module, a fast charging logic processing module and a fast charging interactive message display module; the fast charging parameter configuration module is used to configure the operating parameters corresponding to the test process, and is connected to the fast charging logic processing module. The fast charging logic processing module sends the parameter configuration to the BMC master-slave board to interact with the BMS master-slave board to test the BMS master-slave board and obtain the test results; the fast charging interactive message display module is connected to the fast charging logic processing module to display the interactive message information sent by the fast charging logic processing module.
[0008] A new energy vehicle fast charging test method uses a hardware-in-the-loop test cabinet to build the hardware and bus closed-loop working environment required for the fast charging test for the BMS, controls the operation of the BMS master and slave boards through a model generated by Matlab, simulates each possible working condition during fast charging through the model, configures the content information of the fast charging interaction message corresponding to the working condition, and obtains the test result information through the interaction with the BMS master and slave boards through the configured working condition information.
[0009] The test method also includes determining whether the test type is a positive test or a negative test before the test, then configuring the information sent by the interactive message required for the test and setting the interference message sent by the test and its sending time; then after the test is started, sending the test information and interference message information corresponding to the test type determined before the test to the BMS master and slave boards, interactively obtaining the message information fed back by the BMS, and analyzing the message information fed back by the BMS master and slave boards to obtain the test results.
[0010] The method also includes configuring a BMS test environment on a HIL test bench before testing, including connecting a battery simulator, a high voltage simulation power supply, and an insulation monitor, and debugging and connecting them to the BMS master and slave boards according to work requirements to ensure that basic electrical connections are correct.
[0011] The method also includes building a fast charging test case through software to determine the test steps and test process; in a positive test, the charging parameter configuration module configures the fast charging message to be sent according to the normal fast charging message interaction process, including the message sending cycle, message sending ID, message sending PGN, message sending priority, message data length, and message sending content; in a negative test, the specific test sequence corresponding to the fault disclosure is configured to configure the corresponding message information.
[0012] Before the test, the test environment built by the HIL bench includes: the HIL bench provides the 12V power supply required for the BMS to work, provides the instructions required for the high voltage on the BMS closing relay, the high-voltage loop interlock signal, the PACK voltage simulation voltage source, the single cell voltage simulator, the current, the single cell temperature simulator, etc., and provides the hard-wired CC signal required for BMS fast charging, the fast charging permission signal instruction, the maximum charging current, and the maximum charging voltage.
[0013] After starting the test program, the pre-configured model and its parameters in the HIL test cabinet interact with the BMS master and slave boards, and the fast charging messages are collected and captured through the PCAN-Explorer software. The collected fast charging messages are analyzed, and the overall operation logic of the BMS and the sent messages are observed and analyzed to see whether they meet expectations. A test report is generated based on the test results, recording the test process, test data and test conclusions.
[0014] Observe and analyze whether the overall operation logic of the BMS and the sent messages are in line with expectations, including: in the positive test, the expected conditions include the message ID, message sending cycle, and message content are completely consistent with the fast charging specification; in the negative test, the expected conditions, in addition to the judgment criteria of the positive test, the content, interval time, and sending time of the BMS master control response message are consistent with the preset specifications.
[0015] The advantages of the present invention are: testing the new energy vehicle fast charging protocol by means of simulation testing, thereby testing and verifying the fast charging protocol before leaving the factory, and improving the stability and reliability of the fast charging system. The test can customize the test items and test content to a large extent, simulate hardware or software failures, and inject failures at various stages of fast charging interaction, which can cover the failures that occur in actual vehicles at work to a large extent. In later work, it is necessary to continue to improve the test cases so that they can automatically determine the test results of each test sequence, without the need for manual intervention to read the message to determine whether the test has passed. In a specific network environment, through multiple groups of test sequences of different types and different test tendencies,
[0016] The fast charging protocol in the BCU (Battery-Control-Unit) of the BMS (Battery-Management-System) is tested, and the actual output in the test is compared with the expected output to determine to what extent the actual output is consistent with the standard output. This test system can reduce the risk of errors in actual field operation of the product to a certain extent. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The following is a brief description of the contents expressed in the drawings of the present invention and the symbols in the drawings:
[0018] Figure 1 This is a schematic diagram of the parameter configuration interface of the present invention;
[0019] Figure 2 It is a schematic diagram of the logic interaction between the fast charging parameter configuration module, the fast charging logic processing module, the BMS main control module BCU and the fast charging interactive message display module of the present invention;
[0020] Figure 3The figure is a flow chart of the testing method of the present invention. DETAILED DESCRIPTION
[0021] The specific implementation of the present invention will be further explained in detail below by describing the optimal embodiment with reference to the accompanying drawings.
[0022] This solution uses the Hardware-in-the-Loop (HIL) test cabinet to build the hardware and bus closed-loop working environment required for fast charging testing for the BMS. The model generated by Matlab is used to control the operation of the BMS master and slave boards, and the test system is used to simulate the special working conditions that may occur during fast charging, and the content information of the fast charging interaction message is configured to achieve the purpose of BMS fast charging logic testing.
[0023] A new energy vehicle fast charging test method uses a hardware-in-the-loop test cabinet to build the hardware and bus closed-loop working environment required for the fast charging test for the BMS. The model generated by Matlab is a logical system for the operation of each hardware in the hardware-in-the-loop test cabinet. The hardware-in-the-loop test cabinet is used to simulate the working conditions of the whole vehicle, and then the operation of the BMS master and slave boards is controlled. The model can simulate the following working conditions: controlling the DC power supply in the hardware-in-the-loop test cabinet to power the BMS master and slave boards, simulating the whole vehicle battery to power the BMS master and slave boards; controlling the CAN board in the hardware-in-the-loop test cabinet to send messages, simulating other ECUs (Electron ic Control Units) in the whole vehicle it) Send vehicle messages to BMS, such as high-voltage instructions on the vehicle and slow-charging gun connection confirmation signals; control the voltage of the single-cell voltage simulator in the hardware-in-the-loop test cabinet to simulate the rise and fall of the single-cell voltage in the vehicle battery pack; control the temperature simulation board of the hardware-in-the-loop test cabinet to simulate the temperature acquisition value sent to BMS by the temperature sensor on the vehicle; control the signal on and off of the signal input and output board in the hardware-in-the-loop test cabinet to simulate the disconnection fault and connection status of various detection signals on the vehicle, etc. Use the model to simulate each possible working condition during fast charging, configure the content information of the fast charging interaction message corresponding to the working condition, and interact with the BMS master and slave boards through the configured working condition information to obtain the test result information.
[0024] The BMS master-slave board includes the main control board BCU and the slave control board. The hardware-in-the-loop test cabinet HIL can build the hardware and its working environment required for the test, simulate the BMS working environment to test the BMS master-slave board, and build the hardware and working environment required for the BMS master-slave board through HIL to achieve the electrical basis for the BMS master-slave board to work. In the HIL platform, software is used to develop corresponding test cases, and the software is used to simulate the working status and feedback information of the BMS master-slave board under different working conditions. The feedback status information of the BMS is analyzed to determine whether the BMS fast charging protocol is correct or meets the preset requirements and regulations. On the HIL bench, the hardware and software construction must be realized respectively. The hardware construction is to ensure that the BMS master-slave board can work normally; the software construction is to interact with the BMS master-slave board to realize the software-level simulation of the BMS working interaction, and realize the interaction with the BMS to realize the work of the BMS. The hardware construction includes configuring the BMS test environment on the HIL bench before testing, including connecting the battery simulator, high-voltage simulation power supply, insulation monitor, and debugging and connecting them to the BMS master and slave boards according to work requirements to ensure that the basic electrical connections are correct. Correct electrical connection is the basis for the operation of the BMS master and slave boards, which is also the basis for fast charging testing. Only by correctly building and connecting the electrical equipment can the working data of the BMS master and slave boards be tested through different software programs and different test cases in the subsequent testing process, and then the test results can be analyzed. Before the test, the test environment built by the HIL bench includes: the HIL bench provides the 12V power supply required for the BMS to work, provides the instructions required for the high voltage on the BMS closing relay, the high-voltage loop interlock signal, the PACK voltage simulation voltage source, the single cell voltage simulator, the current, the single cell temperature simulator, etc., and provides the hard-wired CC signal required for BMS fast charging, the fast charging permission signal instruction, the maximum charging current, and the maximum charging voltage.
[0025] At the software program level, before testing, it is necessary to determine whether the test type is a positive test or a negative test, and then configure the information sent by the interactive message required for the test and set the interference message sent by the test and its sending time; then after the test is started, the test information and interference message information corresponding to the test type determined before the test are sent to the BMS master and slave boards, and the message information fed back by the BMS is obtained interactively, and the message information fed back by the BMS master and slave boards is analyzed to obtain the test results.
[0026] In setting up the test cases corresponding to the software program, it is necessary to determine the test steps and test process; in the positive test, the charging parameter configuration module configures the fast charging message to be sent according to the normal fast charging message interaction process, including the message sending cycle, message sending ID, message sending PGN, message sending priority, message data length, and message sending content; in the negative test, the specific test sequence corresponding to the fault disclosure is configured to configure the corresponding message information.
[0027] The software platform corresponding to the HIL system builds test cases to perform fast charging interaction tests on the BMS, simulates environmental parameters under different working conditions to detect the BMS and analyzes the BMS output message information to obtain the corresponding test report results, where the software part includes a parameter configuration module and a fast charging logic processing module. The fast charging parameter configuration module is used to configure the corresponding parameter information under the test conditions, and its output end is connected to the fast charging logic processing module; the specific configuration content of the configuration module includes: configuring the message ID and content of the fast charging handshake phase, the message ID and content of the charging parameter configuration phase, the message ID and content of the fast charging phase, the message ID and content of the fast charging end phase, the charging error message ID and content, etc. The configured information is sent to the fast charging logic processing module, which interacts with the BMS main control module BCU and reads the message data in the fast charging CAN information, and displays it through the fast charging interaction message display module; such as Figure 2 As shown in the figure, the specific work flow of the fast charging logic processing module includes: simulating the messages that the fast charging pile needs to send to the BMS during the fast charging process, such as CHM (charger handshake message), CRM (charger identification message), CML (charger maximum output capacity message), CRO (charger output status ready state message) and other messages; simulating the fast charging pile to receive messages sent by the BMS during the fast charging process, such as BHM (vehicle handshake message), BRM (BMS and vehicle identification message), BCP (power battery charging parameter message), BRO (battery charging ready state message) and other messages; the messages of the fast charging logic processing module and the BMS main control module interact through the CAN communication line with a baud rate of 250Kb / s; the overall interaction mode is responsive, that is, the fast charging logic processing module sends CHM (charger handshake message), and after receiving the BHM (vehicle handshake message) sent by the BMS main control module, it sends CRM (charging identification message), etc. The message interaction sequence and logic meet the national standard GB / T 27930-2015; During the entire interaction process, the message logic, priority, data length, message cycle, etc. sent by the fast charging logic processing module meet the description in the national standard GB / T 27930-2015. When receiving the message sent by the BMS main control module, the logic, priority, content, etc. of the message will be parsed according to the description in the national standard GB / T 27930-2015. If it does not meet the standard, the fault will be reported to let the operator know.
[0028] After starting the test program, the pre-configured model and its parameters in the HIL test cabinet interact with the BMS master and slave boards, and the fast charging messages are collected and captured through the PCAN-Explorer software. The collected fast charging messages are analyzed, and the overall operation logic of the BMS and the sent messages are observed and analyzed to see whether they meet expectations. A test report is generated based on the test results, and the test process, test data, and test conclusions are recorded. The observation and analysis of whether the overall operation logic of the BMS and the sent messages meet expectations include: in the positive test, the expected conditions include the message ID, message sending cycle, and message content are completely consistent with the fast charging specifications; in the negative test, the expected conditions are met, in addition to the judgment criteria of the positive test, the content, interval time, and sending time of the BMS master control response message are consistent with the preset specifications.
[0029] In this embodiment, the main process of testing the BMS is as follows:
[0030] 1. First, determine whether the test type is a positive test (a positive test means that the BMS performs fast charging normally according to the interaction process under normal conditions) or a negative test (a negative test means that the fast charging interaction is interrupted by interference under abnormal conditions), configure the content, message ID, priority and other important information required for the interaction message sent by the test, and set in advance the time at which the interference message sent by the test is sent in the fast charging interaction stage (charging handshake, charging parameter configuration, charging stage, charging end stage). The specific parameter configuration is shown as follows Figure 1 As shown, the logic between the fast charging parameter configuration module, the fast charging logic processing module, the BMS main control module BCU and the fast charging interactive message display module is as follows Figure 2 shown.
[0031] 2. Configure the BMS test environment on the HIL bench, including connecting the battery simulator, high-voltage simulation power supply, insulation monitor, etc., debug and connect the BMS, and ensure that the basic electrical connections are correct.
[0032] 3. Through the software platform, build BMS fast charging test cases and determine the test steps and test process. In the positive test, the charging parameter configuration module needs to configure the fast charging message to be sent according to the normal fast charging message interaction process, including the message sending cycle, message sending ID, message sending PGN, message sending priority, message data length, message sending content, etc.; in the negative test, it is necessary to configure according to a specific test sequence. For example, when the test requires the system not to send a message, the fast charging parameter configuration module should turn off the sending switch of all messages; when it is necessary to send a message that does not conform to the specification, the fast charging parameter module should modify the ID of the message sending, and it should be different from all message IDs in the specification; when it is necessary to send a message whose content does not conform to the specification, the fast charging parameter configuration module should modify the content part of the fast charging message to make it different from the message content during normal interaction to achieve the test effect.
[0033] 4. Build the environment before BMS testing. The HIL bench provides the 12V power supply required for BMS operation, the instructions required for high voltage on the BMS closed relay, the high voltage loop interlock signal, the PACK voltage simulation voltage source, the single cell voltage simulator, the current, the single cell temperature simulator, etc.; it provides the hard-wired CC signal required for BMS fast charging, the fast charging permission signal instruction, the maximum charging current, the maximum charging voltage, etc.; the above signals can enable the BMS system to start working normally, and the BMS slave is responsible for collecting information such as single cell voltage and single cell temperature, and the collected information is transmitted to the BMS host for analysis and processing; in addition to processing the information collected by the slave, the BMS host also needs to control the entire system, such as normal driving discharge, sleep, fast charging, slow charging, etc.
[0034] 5. Start the test program, observe the messages transmitted by the BMS host through the fast charging CAN (Controller-Area-Network) network, and collect and capture the fast charging messages through the PCAN-Expeller software.
[0035] 6. Analyze the collected fast-charge messages and observe whether the overall operation logic of the BMS and the messages sent are in line with expectations. In the positive test, the expected conditions include message ID, message sending cycle, message content, etc., which are completely consistent with the fast-charge specification; in the negative test, in addition to the judgment criteria of the positive test, the expected conditions should also pay attention to the content, interval time, and sending time of the BMS master control response message. The messages of the positive test and the negative test should fully comply with the description in GB / T27930-2015.
[0036] 7. Generate test report: Generate a test report based on the test results, record the test process, test data and test conclusions, and provide a reference for subsequent optimization and improvement. The complete test process is as follows: Figure 3 shown.
[0037] Obviously, the specific implementation of the present invention is not limited to the above-mentioned methods. As long as various non-substantial improvements are made using the method concept and technical solution of the present invention, they are all within the protection scope of the present invention.
Claims
1. A new energy vehicle fast charging test system, characterized in that: It includes using a hardware-in-the-loop test cabinet to build the hardware and bus closed-loop working environment required for fast charging testing for the BMS, and then connecting the BMS master-slave boards used for fast charging control to the hardware-in-the-loop test cabinet; in the hardware-in-the-loop test cabinet, the BMS master-slave boards are operated and controlled through the model generated by Matlab, simulating each working condition in the fast charging process and testing and controlling the BMS master-slave boards.
2. A new energy vehicle fast charging test system as claimed in claim 1, characterized in that: Configure the BMS test environment on the HIL bench, including connecting the battery simulator, high-voltage simulation power supply, and insulation monitor, and debug and connect them to the BMS master and slave boards according to work requirements to ensure that the basic electrical connections are correct.
3. A new energy vehicle fast charging test system as described in claim 1 or 2, characterized in that: The control system also includes a fast charging parameter configuration module, a fast charging logic processing module and a fast charging interactive message display module; the fast charging parameter configuration module is used to configure the operating parameters corresponding to the test process, and is connected to the fast charging logic processing module. The fast charging logic processing module sends the parameter configuration to the BMC master-slave board to interact with the BMS master-slave board to test the BMS master-slave board and obtain the test results; the fast charging interactive message display module is connected to the fast charging logic processing module to display the interactive message information sent by the fast charging logic processing module.
4. A new energy vehicle fast charging test method, characterized in that: The hardware-in-the-loop test cabinet is used to build the hardware and bus closed-loop working environment required for fast charging testing for the BMS. The BMS master and slave boards are controlled through the model generated by Matlab. The model simulates every possible working condition during fast charging, configures the content information of the fast charging interaction message corresponding to the working condition, and interacts with the BMS master and slave boards through the configured working condition information to obtain the test result information.
5. A new energy vehicle fast charging test method as claimed in claim 4, characterized in that: The test method also includes determining whether the test type is a positive test or a negative test before the test, then configuring the information sent by the interactive message required for the test and setting the interference message sent by the test and its sending time; then after the test is started, sending the test information and interference message information corresponding to the test type determined before the test to the BMS master and slave boards, interactively obtaining the message information fed back by the BMS, and analyzing the message information fed back by the BMS master and slave boards to obtain the test results.
6. A new energy vehicle fast charging test method as claimed in claim 5, characterized in that: The method also includes configuring a BMS test environment on the HIL bench before testing, including connecting a battery simulator, a high-voltage simulation power supply, and an insulation monitor, and debugging and connecting them to the BMS master and slave boards according to work requirements to ensure that basic electrical connections are correct.
7. A new energy vehicle fast charging test method as claimed in claim 5, characterized in that: The method also includes building a fast charging test case through software to determine the test steps and test process; in the affirmative test, the charging parameter configuration module configures the fast charging message sent according to the normal fast charging message interaction process, including the message sending cycle, message sending ID, message sending PGN, message sending priority, message data length, and message sending content; In the negative test, the configuration is performed according to the specific test sequence corresponding to the fault disclosure to configure the corresponding message information.
8. A new energy vehicle fast charging test method as described in any one of claims 4-7, characterized in that: Before the test, the test environment built by the HIL bench includes: the HIL bench provides the 12V power supply required for the BMS to work, provides the instructions required for the high voltage on the BMS closing relay, the high-voltage loop interlock signal, the PACK voltage simulation voltage source, the single cell voltage simulator, the current, the single cell temperature simulator, etc., and provides the hard-wired CC signal required for BMS fast charging, the fast charging permission signal instruction, the maximum charging current, and the maximum charging voltage.
9. A new energy vehicle fast charging test method as described in any one of claims 4-7, characterized in that: After starting the test program, the pre-configured model and its parameters in the HIL test cabinet interact with the BMS master and slave boards, and the fast charging messages are collected and captured through the PCAN-Explorer software. The collected fast charging messages are analyzed, and the overall operation logic of the BMS and the sent messages are observed and analyzed to see whether they meet expectations. A test report is generated based on the test results, recording the test process, test data, and test conclusions.
10. A new energy vehicle fast charging test method as claimed in claim 9, characterized in that: Observe and analyze whether the overall operation logic of the BMS and the messages sent are in line with expectations, including: In the positive test, the expected conditions include the message ID, message sending cycle, and message content being completely consistent with the fast charging specifications; in the negative test, the expected conditions are met, in addition to the judgment criteria of the positive test, the content, interval time, and sending time of the BMS master control response message are consistent with the preset specifications.