Fault diagnosis method for charging module of four-wheel direct current charging pile

Abstract

The invention discloses a four-wheel direct-current charging pile charging module fault diagnosis method, which comprises the following steps: step 1, self-inspection of a use environment: self-inspection of the use environment of a four-wheel direct-current charging pile and conditions of a vehicle is carried out, and maintenance is directly carried out if problems exist; 2, appearance inspection: inspecting whether the appearance of the charging gun has problems, inspecting whether the appearance of a power line of the charging pile has problems, and inspecting whether a display screen has problems; 3, judging the software; 4, judging the state of the battery; according to the diagnosis method, the faults of the charging pile are classified into environment, appearance, software and charging module problems in sequence, after fault reason classification is completed, the faults exclusive to the charging module are specifically overhauled, and charging module protection is started while overhauled. Particularly, AC input overvoltage and undervoltage protection and over-temperature protection are carried out on the charging module, and the service life of the charging module is prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of four-wheel direct current charging piles, and in particular to a method for diagnosing faults of charging modules of a four-wheel direct current charging pile. Background Art

[0002] The working principle of the four-wheel DC charging pile mainly includes the following steps: In the physical connection stage, the user inserts the charging gun into the charging interface of the electric vehicle and presses the button on the charging gun head. The detection point of the charging pile will detect the voltage change and confirm that the charging gun has been correctly inserted; in the low-voltage auxiliary power-on stage, after the detection point of the charging pile detects the voltage change, the charging pile closes K3 and K4 to make the low-voltage auxiliary power supply circuit conductive and supply power to the control device of the electric vehicle. After the vehicle is powered, it will judge whether the vehicle interface is successfully connected according to the voltage of the monitoring point; in the charging handshake stage, the vehicle control device starts to send communication handshake messages periodically, and the charging pile responds and performs insulation detection to ensure that the insulation performance of the DC line is good and the safety of the charging process; in the charging parameter configuration stage, the charging pile communicates with the electric vehicle and configures the charging parameters, such as voltage and current, to ensure the efficiency and safety of the charging process; in the charging stage, after the configuration is completed, the charging pile starts to charge the electric vehicle battery with the set voltage and current. As the battery voltage rises, the charging current gradually decreases until the battery is full; in the charging end stage, when the battery is full or the user interrupts charging, the charging pile stops charging and enters standby mode.

[0003] As the four-wheel DC charging pile is used for a longer period of time, the charging module installed in the four-wheel DC charging pile may malfunction, requiring maintenance personnel to diagnose and repair the charging module of the four-wheel DC charging pile.

[0004] However, the traditional four-wheel DC charging pile charging module diagnosis has the following disadvantages:

[0005] The failures of traditional four-wheel DC charging piles are not failures of the charging modules themselves. If they are all classified as charging module failures, it will increase the difficulty and complexity of diagnosis. Summary of the invention

[0006] The purpose of the present invention is to provide a method for diagnosing a charging module fault in a four-wheel DC charging pile, so as to solve the problem that the faults of the traditional four-wheel DC charging pile proposed in the above background technology are not faults of the charging module itself, and if all of them are classified as charging module faults, the diagnosis difficulty and tediousness will be increased.

[0007] To achieve the above object, the present invention provides the following technical solution: a method for diagnosing a fault in a charging module of a four-wheel DC charging pile, comprising the following steps:

[0008] Step 1: Self-check the use environment: self-check the use environment of the four-wheel DC charging pile and the vehicle's own conditions. If there are any problems, repair them directly;

[0009] Step 2: Check the appearance: Check whether there are any problems with the appearance of the charging gun, the appearance of the charging pile power cord, and the display screen. If there are any problems, repair them directly;

[0010] Step 3: Check the software: Check whether the charging pile controller, running software and running network are normal. If there is a problem, repair it directly;

[0011] Step 4: Determine the battery status: After eliminating the non-charging module failure, the charging pile cannot charge correctly to determine the battery status;

[0012] Step 5: Module maintenance: According to the battery status determined in step 4, the charging module is repaired.

[0013] As a preferred technical solution of the present invention, the environment in step one specifically refers to whether the external ambient temperature is too low to cause charging to fail; the vehicle's own conditions in step one specifically refer to a false connection or short circuit in the vehicle line or different vehicle models have different communication protocols for on-board charging controllers, which makes the charging pile incompatible with the on-board controller, and the vehicle will not be able to communicate normally with the charging pile.

[0014] As a preferred technical solution of the present invention, whether there is a problem with the appearance of the charging gun in the step 2 is specifically that the metal contacts of the charging gun are dirty, oxidized, damp, overloaded or blocked by foreign objects, resulting in poor or interrupted power transmission; whether there is a problem with the appearance of the charging pile power cord in the step 2 is specifically that the charging pile power cord has poor contact or is damaged, which will cause the power to be unable to be transmitted to the charging pile; whether there is a problem with the display screen in the step 2 is specifically that the device is frozen, the TVI connection cable between the main control board and the display screen is loose, or the button display screen is damaged.

[0015] As a preferred technical solution of the present invention, the software running in the step three is specifically a code bug or a data transmission error, which causes the charging pile to be unable to charge normally; the charging pile controller in the step three is specifically that the charging gun is not plugged in, someone presses the button on the handle during the charging process, and the balance is insufficient, the charging pile will stop charging; the network running in the step three is specifically that the operator network is abnormal, the network is temporarily interrupted, the IoT card has no network or is in arrears, which causes the charging pile to be offline and unable to charge.

[0016] As a preferred technical solution of the present invention, the battery status in the step four is judged specifically as the battery voltage is too low or inconsistent with the sent value, BST insulation failure, BST output connector overtemperature, BST battery pack temperature is too high, BST high-voltage relay failure, BST current is too large, BST voltage is abnormal, pre-charge battery voltage is too high and BRM timeout.

[0017] As a preferred technical solution of the present invention, the phenomenon that the battery voltage is too low or inconsistent with the sent value is that during the pre-charging process, the battery voltage value measured by the charging pile differs from the battery voltage value sent by the BMS by 5%. The maintenance method is to manually output a high voltage to check the charging pile battery voltage calibration. If it is accurate, then the vehicle sent is indeed inconsistent with the actual value. If it is inaccurate, then calibrate the battery voltage.

[0018] As a preferred technical solution of the present invention, the phenomenon of the BST insulation failure is specifically that the vehicle believes that the insulation failure, and the maintenance method is to check the insulation of the charging pile itself. The phenomenon of the BST output connector overheating is specifically that the vehicle believes that the charging gun is overheated, and the maintenance method is to find the cause of the overheating. The phenomenon of the BST battery pack overtemperature is specifically that the vehicle believes that the battery pack temperature is too high, and the maintenance method is to find the vehicle's own reasons. The phenomenon of the BST high-voltage relay failure is specifically that the vehicle believes that the charging pile DC output contactor is faulty, and the maintenance method is that the charging pile disconnects the DC contactor by manual closing and checking the feedback status; if it is indeed broken, the cause needs to be found, such as the setting of the opening and closing number and the damage of the contactor itself; if it is not broken, it is the vehicle's own reason, and the phenomenon of the BST current being too large is Specifically, the vehicle thinks that the current of the charging pile is too large. The maintenance method is to check whether the modules are evenly divided when charging with two guns. Prevent the module wiring or address settings of gun A and gun B from being crossed. Click the battery information on the charging interface to check the BS demand current and the actual output current of the charging pile. If the actual output current is less than the BMS demand current, there is a problem with the vehicle itself. If the actual output current is greater than the BMS demand current, compare the meter current to see if they are consistent. The phenomenon of abnormal BST voltage is that the vehicle thinks that the charging voltage of the charging pile is abnormal. The maintenance method is to click the battery information on the charging interface to check the BMS demand voltage and the actual output voltage of the charging pile. If the actual output voltage is less than the BMS demand voltage, there is a problem with the vehicle itself. If the actual output voltage is greater than the BMS demand voltage, compare the meter voltage.

[0019] As a preferred technical solution of the present invention, the phenomenon of the pre-charging battery voltage being too high is specifically that the charging pile master controller believes that the battery voltage is too high during the pre-charging process, and the phenomenon of the BRM timeout is specifically that during the communication between the charging pile and the BMS, the vehicle fails to reply to the BRI message within the standard specified time.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows: the diagnostic method classifies the faults of the charging pile into problems of the environment, appearance, software and the charging module itself in turn. After the fault causes are classified, specific maintenance is performed on the faults specific to the charging module, and the charging module protection is started during the maintenance, specifically, the charging module is protected against AC input overvoltage, undervoltage and overtemperature, thereby extending the service life of the charging module. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0022] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0023] See also Figure 1 The present invention provides a method for diagnosing a fault in a charging module of a four-wheel DC charging pile, comprising the following steps:

[0024] Step 1: Self-check the use environment: self-check the use environment of the four-wheel DC charging pile and the vehicle's own conditions. If there are any problems, repair them directly;

[0025] Step 2: Check the appearance: Check whether there are any problems with the appearance of the charging gun, the appearance of the charging pile power cord, and the display screen. If there are any problems, repair them directly;

[0026] Step 3: Check the software: Check whether the charging pile controller, running software and running network are normal. If there is a problem, repair it directly;

[0027] Step 4: Determine the battery status: After eliminating the non-charging module failure, the charging pile cannot charge correctly to determine the battery status;

[0028] Step 5: Module maintenance: According to the battery status determined in step 4, the charging module is repaired.

[0029] The environment in step one specifically refers to whether the external ambient temperature is too low to cause charging to fail; the vehicle's own conditions in step one specifically refer to a false connection or short circuit in the vehicle line or different vehicle models have different communication protocols for on-board charging controllers, which makes the charging pile incompatible with the on-board controller, and the vehicle will not be able to communicate normally with the charging pile.

[0030] In step 2, check whether there are any problems with the appearance of the charging gun, specifically if the metal contacts of the charging gun are dirty, oxidized, damp, overloaded, or blocked by foreign objects, resulting in poor or interrupted power transmission; in step 2, check whether there are any problems with the appearance of the charging pile power cord, specifically if the charging pile power cord has poor contact or is damaged, which will result in the inability to transmit power to the charging pile; in step 2, check whether there are any problems with the display screen, specifically if the device is frozen, the TVI connection cable between the main control board and the display screen is loose, or the button display screen is damaged.

[0031] The software running in step three is specifically determined to be a code bug or data transmission error, which causes the charging pile to be unable to charge normally; the charging pile controller in step three is specifically that the charging gun is not fully inserted, someone presses the button on the handle during the charging process, or the balance is insufficient, the charging pile will stop charging; the network running in step three is specifically that the operator network is abnormal, the network is temporarily interrupted, the IoT card has no network or is in arrears, which causes the charging pile to be offline and unable to charge.

[0032] In step 4, the battery status is judged as follows: the battery voltage is too low or inconsistent with the sent value, BST insulation failure, BST output connector overtemperature, BST battery pack temperature is too high, BST high-voltage relay failure, BST current is too large, BST voltage is abnormal, pre-charge battery voltage is too high, and BRM timeout.

[0033] The phenomenon that the battery voltage is too low or inconsistent with the sent value is that during the pre-charging process, the battery voltage value measured by the charging pile differs by 5% from the battery voltage value sent by the BMS. The maintenance method is to manually output a high voltage to check the battery voltage calibration of the charging pile. If it is accurate, then the value sent by the vehicle is indeed inconsistent with the actual value. If it is inaccurate, calibrate the battery voltage.

[0034] The phenomenon of BST insulation failure is that the vehicle thinks it is an insulation failure, and the maintenance method is to check the insulation of the charging pile itself. The phenomenon of BST output connector overtemperature is that the vehicle thinks the charging gun is overtemperature, and the maintenance method is to find the cause of the overtemperature. The phenomenon of BST battery pack overtemperature is that the vehicle thinks the battery pack temperature is too high, and the maintenance method is to find the vehicle's own reasons. The phenomenon of BST high-voltage relay failure is that the vehicle thinks the charging pile DC output contactor is faulty, and the maintenance method is to manually close and disconnect the DC contactor of the charging pile and check the feedback status; if it is indeed broken, you need to find the cause, such as the setting of the opening and closing number and the damage of the contactor itself; if it is not broken, it is the vehicle's own problem. The phenomenon of BST current overlargeness is that the vehicle thinks The current of the charging pile is too large. The maintenance method is to charge both guns at the same time. Check whether the modules are evenly divided to prevent the module wiring or address settings of gun A and gun B from being crossed. Click the battery information on the charging interface to check the BS demand current and the actual output current of the charging pile. If the actual output current is less than the BMS demand current, there is a problem with the vehicle itself. If the actual output current is greater than the BMS demand current, compare the meter current to see if they are consistent. The phenomenon of abnormal BST voltage is that the vehicle thinks that the charging voltage of the charging pile is abnormal. The maintenance method is to click the battery information on the charging interface to check the BMS demand voltage and the actual output voltage of the charging pile. If the actual output voltage is less than the BMS demand voltage, there is a problem with the vehicle itself. If the actual output voltage is greater than the BMS demand voltage, compare the meter voltage.

[0035] The phenomenon of the pre-charge battery voltage being too high is that the charging pile master controller believes that the battery voltage is too high during the pre-charging process. The phenomenon of BRM timeout is that during the communication between the charging pile and the BMS, the vehicle does not reply to the BRI message within the standard specified time.

[0036] In the present invention, the four-wheel DC charging pile performs self-inspection on the use environment and the vehicle's own conditions to check whether the external environment temperature is too low to cause charging failure; the vehicle line has a false connection or short circuit or the communication protocols of the on-board charging controllers of different models are different, making the charging pile incompatible with the on-board controller, and the vehicle will not be able to communicate with the charging pile normally. If there is a problem, it should be directly repaired; check whether there is a problem with the appearance of the charging gun, check whether there is a problem with the appearance of the charging pile power cord, and check whether there is a problem with the display screen. The problem with the appearance of the charging gun is specifically that the metal contacts of the charging gun are dirty, oxidized, damp, overloaded, or blocked by foreign objects, resulting in poor or interrupted power transmission; check whether there is a problem with the appearance of the charging pile power cord, specifically that the charging pile power cord contacts Defective or damaged equipment will result in the inability to transmit electricity to the charging pile; whether there is a problem with the display screen, specifically the device is frozen, the TVI connection line between the main control board and the display screen is loose, or the button display screen is damaged. If there is a problem, repair it directly; determine whether the charging pile controller and the running software and the running network are normal, and determine whether the running software is a code bug or a data transmission error, which causes the charging pile to fail to charge normally; the charging pile controller, specifically the charging gun is not fully inserted, someone presses the button on the handle during charging, and the balance is insufficient, the charging pile will stop charging; the running network, specifically the operator network is abnormal, the network is temporarily interrupted, the IoT card has no network or is in arrears, resulting in the charging pile being offline and unable to charge , if there is a problem, directly perform maintenance; after eliminating the non-charging module fault, the charging pile cannot charge correctly to judge the battery status; according to the battery status judged in step 4, the charging module is repaired. The phenomenon that the battery voltage is too low or inconsistent with the sent value is that during the pre-charging process, the battery voltage value measured by the charging pile differs from the battery voltage value sent by the BMS by 5%. The maintenance method is to manually output a high voltage to check the charging pile battery voltage calibration. If it is accurate, it is true that the vehicle sends inconsistent with the actual value. If it is inaccurate, calibrate the battery voltage. The phenomenon of BST insulation failure is specifically that the vehicle thinks it is an insulation failure. The maintenance method is to check the insulation of the charging pile itself. The phenomenon of BST output connector overheating is specifically that the vehicle thinks it is an insulation failure. The charging gun is overheated. The maintenance method is to find the cause of the overheating. The phenomenon of BST battery pack overtemperature is that the vehicle thinks the battery pack temperature is too high. The maintenance method is to find the vehicle's own reasons. The phenomenon of BST high-voltage relay failure is that the vehicle thinks the charging pile DC output contactor is faulty. The maintenance method is to manually close the charging pile to disconnect the DC contactor and check the feedback status. If it is indeed broken, the cause needs to be found, such as the setting of the opening and closing number and the damage of the contactor itself. If it is not broken, it is the vehicle's own reason. The phenomenon of BST current being too large is that the vehicle thinks the charging pile current is too large. The maintenance method is to check whether the modules are evenly distributed when charging with two guns, to prevent the module wiring or address settings of gun A and gun B from being crossed.Click on the battery information on the charging interface to check the BS demand current and the actual output current of the charging pile. If the actual output current is less than the BMS demand current, there is a problem with the vehicle itself; if the actual output current is greater than the BMS demand current, compare the meter current to see if they are consistent. The phenomenon of abnormal BST voltage is that the vehicle thinks the charging voltage of the charging pile is abnormal. The maintenance method is to click on the battery information on the charging interface to check the BMS demand voltage and the actual output voltage of the charging pile. If the actual output voltage is less than the BMS demand voltage, there is a problem with the vehicle itself. If the actual output voltage is greater than the BMS demand voltage, compare the meter voltage. The phenomenon of excessive pre-charge battery voltage is that the charging pile master controller thinks the battery voltage is too high during pre-charging. The phenomenon of BRM timeout is that the charging pile master controller thinks the battery voltage is too high during pre-charging. During the communication between the charging pile and the BMS, the vehicle does not reply to the BRI message within the standard time, the output voltage is too high or the IGBT is overcurrent, the output voltage or current is abnormal, causing damage to the internal components of the module. It is usually necessary to disconnect the AC power supply and then restart it to try to restore to normal; improper voltage adjustment, unreasonable voltage adjustment causes module output overvoltage. At this time, after power failure, adjust the voltage adjustment potentiometer counterclockwise to the minimum, and then re-adjust the output voltage of the module; real-time charging module protection, AC input overvoltage, undervoltage, when the AC input voltage of the charging pile exceeds the normal working range, the charging template will automatically protect and stop working; overtemperature protection, if the heat dissipation is poor or the ambient temperature is too high, the charging template will automatically shut down due to overheating. In addition, the cabinet is equipped with a glass door or is airtight, resulting in overheating protection. ;

[0037] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for diagnosing a fault in a charging module of a four-wheel DC charging pile, characterized in that: The following steps are involved: Step 1: Self-check the use environment: self-check the use environment of the four-wheel DC charging pile and the vehicle's own conditions. If there are any problems, repair them directly; Step 2: Check the appearance: Check whether there are any problems with the appearance of the charging gun, the appearance of the charging pile power cord, and the display screen. If there are any problems, repair them directly; Step 3: Check the software: Check whether the charging pile controller, running software and running network are normal. If there is a problem, repair it directly; Step 4: Determine the battery status: After eliminating the non-charging module failure, the charging pile cannot charge correctly to determine the battery status; Step 5: Module maintenance: According to the battery status determined in step 4, the charging module is repaired.

2. A four-wheel DC charging pile charging module fault diagnosis method according to claim 1, characterized in that: The environment in step one specifically refers to whether the external ambient temperature is too low to cause charging to fail; the vehicle's own conditions in step one specifically refer to a false connection or short circuit in the vehicle line or different vehicle models have different communication protocols for on-board charging controllers, which makes the charging pile incompatible with the on-board controller, and the vehicle will not be able to communicate normally with the charging pile.

3. A four-wheel DC charging pile charging module fault diagnosis method according to claim 1, characterized in that: Whether there is a problem with the appearance of the charging gun in the step 2 is specifically that the metal contacts of the charging gun are dirty, oxidized, damp, overloaded or blocked by foreign objects, resulting in poor or interrupted power transmission; whether there is a problem with the appearance of the charging pile power cord in the step 2 is specifically that the charging pile power cord has poor contact or is damaged, which will result in the inability to transmit power to the charging pile; whether there is a problem with the display screen in the step 2 is specifically that the device is frozen, the TVI connection cable between the main control board and the display screen is loose, or the button display screen is damaged.

4. A four-wheel DC charging pile charging module fault diagnosis method according to claim 1, characterized in that: The software running in the step three is specifically judged to be a code bug or a data transmission error, which causes the charging pile to be unable to charge normally; the charging pile controller in the step three is specifically that the charging gun is not fully inserted, someone presses the button on the handle during the charging process, and the balance is insufficient, and the charging pile will stop charging; the network running in the step three is specifically that the operator network is abnormal, the network is temporarily interrupted, the IoT card has no network or is in arrears, which causes the charging pile to be offline and unable to charge.

5. A four-wheel DC charging pile charging module fault diagnosis method according to claim 1, characterized in that: The battery status in step 4 is judged specifically as follows: the battery voltage is too low or inconsistent with the sent value, BST insulation failure, BST output connector overtemperature, BST battery pack temperature is too high, BST high-voltage relay failure, BST current is too large, BST voltage is abnormal, pre-charge battery voltage is too high, and BRM timeout.

6. A four-wheel DC charging pile charging module fault diagnosis method according to claim 5, characterized in that: The phenomenon that the battery voltage is too low or inconsistent with the sent value is that during the pre-charging process, the battery voltage value measured by the charging pile differs by 5% from the battery voltage value sent by the BMS. The maintenance method is to manually output a high voltage to check the charging pile battery voltage calibration. If it is accurate, then the vehicle sent value is indeed inconsistent with the actual value. If it is inaccurate, then calibrate the battery voltage.

7. A four-wheel DC charging pile charging module fault diagnosis method according to claim 5, characterized in that: The phenomenon of BST insulation failure is that the vehicle thinks it is an insulation failure, and the maintenance method is to check the insulation of the charging pile itself. The phenomenon of BST output connector overtemperature is that the vehicle thinks the charging gun is overtemperature, and the maintenance method is to find the cause of overtemperature. The phenomenon of BST battery pack overtemperature is that the vehicle thinks the battery pack temperature is too high, and the maintenance method is to find the vehicle's own reasons. The phenomenon of BST high-voltage relay failure is that the vehicle thinks the charging pile DC output contactor is faulty, and the maintenance method is to manually close and disconnect the DC contactor of the charging pile and check the feedback status; if it is indeed broken, the cause needs to be found, such as the setting of the opening and closing number and the damage of the contactor itself; if it is not broken, it is the vehicle's own problem. The phenomenon of BST current overlargeness is that the vehicle thinks The current of the charging pile is too large. The maintenance method is to charge both guns at the same time. Check whether the modules are evenly divided to prevent the module wiring or address settings of gun A and gun B from being crossed. Click the battery information on the charging interface to check the BS demand current and the actual output current of the charging pile. If the actual output current is less than the BMS demand current, there is a problem with the vehicle itself. If the actual output current is greater than the BMS demand current, compare the meter current to see if they are consistent. The phenomenon of abnormal BST voltage is that the vehicle thinks that the charging voltage of the charging pile is abnormal. The maintenance method is to click the battery information on the charging interface to check the BMS demand voltage and the actual output voltage of the charging pile. If the actual output voltage is less than the BMS demand voltage, there is a problem with the vehicle itself. If the actual output voltage is greater than the BMS demand voltage, compare the meter voltage.

8. A four-wheel DC charging pile charging module fault diagnosis method according to claim 5, characterized in that: The phenomenon of the pre-charge battery voltage being too high is specifically that the charging pile master controller believes that the battery voltage is too high during the pre-charging process, and the phenomenon of the BRM timeout is specifically that during the communication between the charging pile and the BMS, the vehicle does not reply to the BRI message within the standard specified time.

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