New energy vehicle rapid charging diagnosis and test system and method

Abstract

The invention discloses a new energy automobile rapid charging diagnosis and test system and method. The system comprises an industrial personal computer serving as a control unit, an electrical safety detection module, a charging safety detection module, a man-machine interaction module, a power module, a direct current charging module and a channel switching module. The scheme aims at the intelligent diagnosis technology of the new energy automobile, the function and performance detection of key parts such as power electronic equipment of the new energy automobile can be realized, the performance and the safety condition of the automobile are evaluated, and the safety and the reliability of core components of the automobile are ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicle detection, and in particular to a new energy vehicle fast charging diagnosis and testing system and method. Background Art

[0003] In order to ensure the safety of the battery system, protect the safety of the high-voltage system, monitor the safety of the electric drive system, and ensure the safety of charging services, it is necessary to conduct safety inspections and charging function inspections on the vehicle to understand the safety status of the vehicle.

[0004] The safety testing items for new energy vehicles mainly include: potential equalization test, high-voltage component insulation resistance test, vehicle insulation test, voltage withstand test, insulation monitoring function verification, capacitor coupling, charging function test, discharge function test, etc.

[0005] At present, after the production and assembly of new energy vehicles are completed, they will undergo offline testing to ensure the safety performance of the vehicles before leaving the factory. However, due to the limitations of the production inspection process and workstations, the inspection items of a single inspection system are generally relatively simple. For example, only insulation resistance testing or charging function testing can be performed, and one system cannot be used to implement all special inspection items of new energy vehicles compared to traditional vehicles. In addition, there are differences in the focus of the inspection items of the inspection system for vehicles off the production line and the inspection system for vehicles in use: for example, in the potential equalization test, the test points of the production line inspection are the motors and other components inside the vehicle, and the test points of the new energy vehicles in use are easy-to-touch points such as the doors. Therefore, the inspection system on the production line is not applicable to use scenarios such as social inspection lines and 4S stores. Summary of the invention

[0006] In view of the above technical problems, the present invention provides a new energy vehicle fast charging diagnosis and testing system and method.

[0007] The present invention is implemented by adopting the following technical solutions: In the first aspect, a new energy vehicle fast charging diagnosis and testing system comprises: Industrial computer: As a control unit, it coordinates the workflow of the entire system and connects with external upstream systems; Electrical safety detection module: detects the insulation resistance and grounding connectivity safety performance indicators of the vehicle electrical system, and sends the collected and measured data to the control unit; Charging safety detection module: monitors charging parameters in real time and sends the collected and measured data to the control unit; Human-computer interaction module: including display, keyboard, mouse, buttons and alarm lights, showing the test results to the user and facilitating the user to operate the system; Power module: provides stable power for the system and its modules; DC charging module: converts AC power into DC power to provide DC power for the DC charging process of the vehicle under test; Channel switching module: accepts the control of the industrial computer to realize switching between different test channels.

[0008] Specifically, the industrial computer automatically executes the detection process according to the acquired detection task or the preset test program, monitors the test status in real time and records relevant parameters, processes and analyzes the data, and uploads the detection results.

[0009] Specifically, the charging safety detection module contains a communication interface for exchanging data with the electrical system of the vehicle under test; the system is compatible with the electrical systems of new energy vehicles of different brands and models through the communication interface to achieve efficient data transmission.

[0010] On the other hand, a new energy vehicle fast charging diagnosis and testing method is implemented based on the new energy vehicle fast charging diagnosis and testing system, comprising the following steps: Step S1: The new energy vehicle enters the test line, stops and connects to the fast charging diagnosis and test system, opens the test program of the system industrial computer, and automatically obtains the task to be tested from the upstream system; Step S2: The vehicle arrives at the test location and connects all test cables: AC charging gun, DC charging gun and electric platform probe; Step S3: Start the test. The system automatically performs tests through the electrical safety test module and the charging safety test module according to the test task. After the test is completed, the industrial computer automatically determines whether it is qualified and displays the test results on the interactive interface. The data is automatically uploaded to the upstream system. Step S4: Remove all test cables and put them back in place.

[0011] Specifically, step S3 also includes: the electrical safety detection module measures each voltage and resistance value to be tested, charges the vehicle through the DC charging interface, and collects the charging data of the vehicle; the industrial computer control unit analyzes the charging data and electrical data according to a preset algorithm, and evaluates the battery status and charging status indicators of the vehicle.

[0012] Specifically, the test tasks include electrical detection of the AC charging port, electrical detection of the DC charging port and detection of charging process parameters, including: insulation resistance test of the AC charging socket, insulation resistance test of the DC charging socket, potential equalization test, maximum temperature of the power battery during charging, maximum voltage of the single battery and extreme difference of voltage of the single battery.

[0013] Specifically, the insulation resistance test includes: the charging gun is connected to the vehicle charging socket, the electrical safety detection module applies a specified DC voltage between the high-voltage terminal of the charging port and the charging port PE, the insulation resistance value of the charging socket is measured and calculated, and it is determined whether the resistance value exceeds the threshold range.

[0014] Specifically, the potential equalization test includes: the charging gun is connected to the vehicle charging socket, the electric platform probe is connected to the conductive part of the vehicle body, the electrical safety detection module outputs an adjustable DC current, and a loop is formed by the charging gun and the electric platform probe to measure the on-resistance between the PE terminals of the AC or DC charging port, and between the PE terminal of the charging port and the conductive part of the vehicle body to determine whether the resistance exceeds the threshold range.

[0015] Specifically, the on-resistance is measured using a four-wire measurement method.

[0016] Specifically, the charging process parameter detection specifically includes: the DC charging module simulates the DC charging pile, and completes data information exchange through CAN bus communication with the DC charging port of the vehicle to be tested through the charging safety detection module, collects the maximum temperature of the power battery, the maximum voltage of the single battery and the voltage extreme difference data of the single battery during the charging process, and determines whether the parameters exceed the threshold range.

[0017] The beneficial effects of the present invention are: the intelligent diagnostic technology for new energy vehicles can realize the function and performance detection of key components such as the power electronic system of new energy vehicles, evaluate the performance and safety of the vehicle, and ensure the safety and reliability of the core components of the vehicle. It is a strong support for the safe operation of new energy vehicles. The system not only improves the operating efficiency of the vehicle, but also significantly improves the safety of the vehicle. By timely discovering potential faults, it prevents accidents from happening. At the same time, it optimizes the maintenance process, reduces unnecessary maintenance costs and time, and brings substantial economic benefits to car owners. It also has the following effects: Improve detection efficiency: The system is very easy to operate and can quickly perform charging diagnosis and testing on new energy vehicles, greatly shortening the detection time and improving detection efficiency. This helps reduce vehicle waiting time and increase the throughput of the detection station.

[0018] Enhanced safety: Through professional fast charging diagnosis and testing, potential safety hazards of new energy vehicles, such as battery overheating and short circuit, can be discovered in time, thus avoiding safety accidents caused by charging failures. This helps to protect the lives of drivers and passengers.

[0019] Optimize maintenance costs: Using the system for regular inspection and maintenance can extend the service life of new energy vehicles, reduce repair costs caused by failures, and reduce overall maintenance costs. This helps reduce the cost of use for car owners.

[0020] Promote industry standardization: As the new energy vehicle market continues to expand, unified testing standards are essential to ensure vehicle quality and safety. The promotion and use of this system will help promote the standardization of the new energy vehicle testing industry and support the implementation of standards.

[0021] Improve user experience: Integrated design, one machine with multiple uses, can detect electrical safety and charging parameters at the same time, user-friendly operation interface, simplified testing process, convenient for testing stations to quickly master the use method. At the same time, fast and accurate charging diagnosis and testing can improve car owners' trust and satisfaction with new energy vehicles, thereby promoting the development of the new energy vehicle market. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0023] Figure 1 This is an architecture diagram of a new energy vehicle fast charging diagnosis and testing system in an embodiment of the present invention; Figure 2 The figure is a flow chart of charging diagnosis and testing in one embodiment of the present invention. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0025] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0026] The following is combined with Figure 1-2 , some embodiments of the present invention are described in detail. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0027] The present invention proposes a new energy vehicle fast charging diagnosis and testing system and method. Figure 1 As shown, including: Industrial computer: As a control unit, it coordinates the workflow of the entire system and connects with external upstream systems; Electrical safety detection module: detects the insulation resistance and grounding connectivity safety performance indicators of the vehicle electrical system, and sends the collected and measured data to the control unit; Charging safety detection module: monitors charging parameters in real time and sends the collected and measured data to the control unit; Human-computer interaction module: including display, keyboard, mouse, buttons and alarm lights, showing the test results to the user and facilitating the user to operate the system; Power module: provides stable power for the system and its modules; DC charging module: converts AC power into DC power to provide DC power for the DC charging process of the vehicle under test; Channel switching module: accepts the control of the industrial computer to realize switching between different test channels.

[0028] In one embodiment, the industrial computer automatically executes the detection process according to the acquired detection task or the preset test program, monitors the test status in real time and records relevant parameters, processes and analyzes the data, and uploads the detection results.

[0029] The charging safety detection module contains a communication interface for exchanging data with the electrical system of the vehicle under test; through the communication interface, the system is compatible with the electrical systems of new energy vehicles of different brands and models to achieve efficient data transmission.

[0030] The present invention also proposes a new energy vehicle fast charging diagnosis and testing method, which is implemented based on the new energy vehicle fast charging diagnosis and testing system, and includes the following steps: Step S1: The new energy vehicle enters the test line, stops and connects to the fast charging diagnosis and test system, opens the test program of the system industrial computer, and automatically obtains the task to be tested from the upstream system; Step S2: The vehicle arrives at the test location and connects all test cables: AC charging gun, DC charging gun and electric platform probe; Step S3: Start the test. The system automatically performs tests through the electrical safety test module and the charging safety test module according to the test task. After the test is completed, the industrial computer automatically determines whether it is qualified and displays the test results on the interactive interface. The data is automatically uploaded to the upstream system. Step S4: Remove all test cables and put them back in place.

[0031] In a preferred embodiment, step S3 also includes: the electrical safety detection module measures each voltage and resistance value to be tested, charges the vehicle through a DC charging interface, and collects the charging data of the vehicle; the industrial computer control unit analyzes the charging data and electrical data according to a preset algorithm to evaluate the battery status and charging status indicators of the vehicle.

[0032] In this embodiment, the test tasks include electrical detection of the AC charging port, electrical detection of the DC charging port and detection of charging process parameters, specifically including: insulation resistance test of the AC charging socket, insulation resistance test of the DC charging socket, potential equalization test, maximum temperature of the power battery during charging, maximum voltage of a single battery and extreme difference of voltage of a single battery.

[0033] The insulation resistance test specifically includes: the charging gun is connected to the vehicle charging socket, the electrical safety detection module applies a specified DC voltage between the high-voltage terminal of the charging port and the charging port PE, the insulation resistance value of the charging socket is measured and calculated, and it is determined whether the resistance value exceeds the threshold range.

[0034] The potential equalization test specifically includes: the charging gun is connected to the vehicle charging socket, the electric platform probe is connected to the conductive part of the vehicle body, the electrical safety detection module outputs an adjustable DC current, and a loop is formed through the charging gun and the electric platform probe to measure the on-resistance between the PE end of the AC or DC charging port, and between the PE end of the charging port and the conductive part of the vehicle body to determine whether the resistance value exceeds the threshold range. The on-resistance is measured using a four-wire system.

[0035] The charging process parameter detection specifically includes: the DC charging module simulates the DC charging pile, and completes data information exchange through CAN bus communication with the DC charging port of the vehicle to be tested through the charging safety detection module, collects the maximum temperature of the power battery, the maximum voltage of the single battery and the voltage extreme difference data of the single battery during the charging process, and determines whether the parameters exceed the threshold range.

[0036] In another embodiment, the present invention aims to provide a fast charging diagnosis and testing system for new energy vehicles, so as to quickly and accurately perform related tests such as electrical safety and charging parameters on the new energy vehicle testing line.

[0037] To achieve the above object, the present invention adopts the following technical solutions: A new energy vehicle fast charging diagnosis and testing system, such as Figure 1 As shown, the components include: The industrial computer is the control unit of the entire system. It is used to coordinate the workflow of the entire system and connect with external upstream systems. It automatically executes the detection process according to the acquired detection tasks or preset test procedures, monitors the test status in real time, records relevant parameters, processes and analyzes the data, and uploads the detection results.

[0038] The electrical safety detection module is used to detect the insulation resistance, grounding connectivity and other safety performance indicators of the vehicle electrical system, and send the collected and measured data to the control unit; The charging safety detection module is used to monitor the charging voltage, current, power, temperature and other parameters in real time, and send the collected and measured data to the control unit. It contains a communication interface for exchanging data with the electrical system of the vehicle under test. The communication interface ensures that the system is compatible with the electrical systems of new energy vehicles of different brands and models, and realizes efficient data transmission; Human-computer interaction module, including display, keyboard, mouse, buttons, alarm lights, etc., used to display test results to users and facilitate user operation system; The power module is used to provide stable power to the system and its modules.

[0039] The DC charging module is used to convert AC power into DC power and provide DC power for the DC charging process of the vehicle under test.

[0040] The channel switching module accepts the control of the industrial computer to switch between different test channels In one embodiment, the system can be integrated into a cabinet or box, and the area occupied in the field can be small. The control unit can use a high-performance microprocessor, and the electrical safety detection and charging parameter detection can be configured by software to adapt to different detection standards. The display and operation interface can be designed with a touch screen to simplify the user operation process.

[0041] The detection system is responsible for executing various test procedures, such as insulation resistance test of AC charging socket, insulation resistance test of DC charging socket, potential equalization test, maximum temperature of power battery during charging, maximum voltage of single battery, extreme voltage of single battery, etc., to check the charging performance and safety of new energy vehicles.

[0042] Working principle: When the new energy vehicle enters the testing line, the staff stops the vehicle and connects it to the fast charging diagnostic and testing system.

[0043] The system automatically starts the detection program, measures the voltage and resistance values ​​to be tested through the electrical safety detection module, charges the vehicle through the DC charging interface, and collects the vehicle's charging data through the charging safety detection module.

[0044] The industrial computer control unit analyzes charging data and electrical data according to preset algorithms to evaluate the vehicle's battery status, charging status and other indicators.

[0045] Potential equalization test: The charging gun is connected to the vehicle charging socket, and the electric platform probe is connected to the conductive part of the vehicle body. The vehicle charging port potential equalization test uses the electrical safety detection module to output an adjustable DC current, and the charging gun and the electric platform probe form a loop to measure the on-resistance between the PE terminals of the AC / DC charging port and between the PE terminal of the charging port and the conductive part of the vehicle body to determine whether the resistance exceeds the threshold range. The four-wire measurement method is used to reduce measurement errors.

[0046] Insulation resistance test: The charging gun is connected to the vehicle charging socket. The vehicle charging port insulation resistance test is performed by the electrical safety detection module applying a specified DC voltage between the high-voltage terminal of the charging port and the charging port PE. The insulation resistance value of the charging socket is obtained by measurement and calculation to determine whether the resistance value exceeds the threshold range.

[0047] Charging parameter detection: The DC charging pile is simulated through the DC charging module, and the CAN bus communication with the DC charging port of the vehicle to be tested is completed through the charging safety detection module to complete data information exchange, collect various data such as the maximum temperature of the power battery, the maximum voltage of the single battery, and the extreme difference of the single battery voltage during the charging process, and determine whether the parameters exceed the threshold range, and predict whether the power battery may have safety accidents such as charging overheating and fire.

[0048] In one embodiment, a new energy vehicle fast charging diagnosis and testing system detection operation steps are as follows: Figure 2 As shown: Step 1: Open the detection system program of the industrial computer and automatically obtain the tasks to be detected from the upstream system; Step 2: The vehicle arrives at the test location and connects all test cables, including AC charging gun, DC charging gun, electric platform probe, etc.); Step 3: The operator starts the test, and the system automatically performs electrical tests on the AC charging port, DC charging port, and charging process parameter tests. After the test is completed, it automatically determines whether it is qualified and displays the test results on the interactive interface. The data is automatically uploaded to the upstream system; Step 4: Remove all test cables and put them back in place.

[0049] In order to solve the problem that the existing detection equipment has a single function and cannot complete the detection of vehicle charging function and electrical safety at one equipment station, and the operation process is relatively cumbersome, the present invention provides a detection system for new energy vehicles in use, which can realize electrical safety detection and charging function detection of the insulation resistance, potential equalization, battery temperature and voltage during the charging process, etc. of the charging socket of the new energy vehicle on a set of equipment, with accurate measurement, simple and fast operation, and automatic digital recording of the whole process.

[0050] For the aforementioned embodiments, for the sake of simplicity, they are all described as a series of action combinations, but those skilled in the art should be aware that the present application is not limited by the order of the actions described, because according to the present application, some steps can be performed in other orders or simultaneously. Secondly, those skilled in the art should also be aware that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily required by the present application.

[0051] The above embodiments describe the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited by the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the modifications and changes made by those skilled in the art shall be within the scope of protection of the appended claims of the present invention without departing from the spirit and scope of the present invention.

Claims

1. A new energy vehicle fast charging diagnosis and testing system, characterized in that: include: Industrial computer: As a control unit, it coordinates the workflow of the entire system and connects with external upstream systems; Electrical safety detection module: detects the insulation resistance and grounding connectivity safety performance indicators of the vehicle electrical system, and sends the collected and measured data to the control unit; Charging safety detection module: monitors charging parameters in real time and sends the collected and measured data to the control unit; Human-computer interaction module: including display, keyboard, mouse, buttons and alarm lights, showing the test results to the user and facilitating the user to operate the system; Power module: provides stable power for the system and its modules; DC charging module: converts AC power into DC power to provide DC power for the DC charging process of the vehicle under test; Channel switching module: accepts the control of the industrial computer to realize switching between different test channels.

2. A new energy vehicle fast charging diagnosis and testing system as claimed in claim 1, characterized in that: The industrial computer automatically executes the detection process according to the acquired detection task or the preset test program, monitors the test status in real time and records relevant parameters, processes and analyzes the data, and uploads the detection results.

3. A new energy vehicle fast charging diagnosis and testing system as claimed in claim 1, characterized in that: The charging safety detection module contains a communication interface for exchanging data with the electrical system of the vehicle under test; the system is compatible with the electrical systems of new energy vehicles of different brands and models through the communication interface to achieve efficient data transmission.

4. A new energy vehicle fast charging diagnosis and testing method, based on a new energy vehicle fast charging diagnosis and testing system according to any one of claims 1 to 3, characterized in that: The following steps are involved: Step S1: The new energy vehicle enters the test line, stops and connects to the fast charging diagnosis and test system, opens the test program of the system industrial computer, and automatically obtains the task to be tested from the upstream system; Step S2: The vehicle arrives at the test location and connects all test cables: AC charging gun, DC charging gun and electric platform probe; Step S3: Start the test. The system automatically performs tests through the electrical safety test module and the charging safety test module according to the test task. After the test is completed, the industrial computer automatically determines whether it is qualified and displays the test results on the interactive interface. The data is automatically uploaded to the upstream system. Step S4: Remove all test cables and put them back in place.

5. A new energy vehicle fast charging diagnosis and testing method as claimed in claim 4, characterized in that: The step S3 also includes: the electrical safety detection module measures each voltage and resistance value to be tested, charges the vehicle through the DC charging interface, and collects the charging data of the vehicle; the industrial computer control unit analyzes the charging data and electrical data according to a preset algorithm to evaluate the battery status and charging status indicators of the vehicle.

6. A new energy vehicle fast charging diagnosis and testing method as claimed in claim 5, characterized in that: The test tasks include electrical testing of the AC charging port, electrical testing of the DC charging port and testing of charging process parameters, specifically including: insulation resistance test of the AC charging socket, insulation resistance test of the DC charging socket, potential equalization test, maximum temperature of the power battery during charging, maximum voltage of a single battery and extreme voltage difference of a single battery.

7. A new energy vehicle fast charging diagnosis and testing method as claimed in claim 6, characterized in that: The insulation resistance test specifically includes: the charging gun is connected to the vehicle charging socket, the electrical safety detection module applies a specified DC voltage between the high-voltage terminal of the charging port and the charging port PE, the insulation resistance value of the charging socket is measured and calculated, and it is determined whether the resistance value exceeds the threshold range.

8. A new energy vehicle fast charging diagnosis and testing method as claimed in claim 6, characterized in that: The potential equalization test specifically includes: the charging gun is connected to the vehicle charging socket, the electric platform probe is connected to the conductive part of the vehicle body, the electrical safety detection module outputs an adjustable DC current, a loop is formed by the charging gun and the electric platform probe, and the on-resistance between the PE terminals of the AC or DC charging port and between the PE terminals of the charging port and the conductive part of the vehicle body is measured to determine whether the resistance exceeds the threshold range.

9. A new energy vehicle fast charging diagnosis and testing method as claimed in claim 8, characterized in that: The on-resistance is measured using a four-wire system.

10. A new energy vehicle fast charging diagnosis and testing method as claimed in claim 6, characterized in that: The charging process parameter detection specifically includes: a DC charging module simulates a DC charging pile, and completes data information exchange through CAN bus communication with the DC charging port of the vehicle to be tested through the charging safety detection module, collects the maximum temperature of the power battery, the maximum voltage of the single battery and the voltage extreme difference data of the single battery during the charging process, and determines whether the parameters exceed the threshold range.

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