Direct current charger simulation test system and method

Abstract

The invention discloses a DC charger simulation test system. A BMS simulation module generates a charging power demand according to a preset working condition and sends the charging power demand to a corresponding vehicle controller; the vehicle controller forwards the charging instruction and the demand to a power divider; the power divider is used for generating power regulation parameters for controlling the output characteristics of the power conversion module and contactor state parameters for defining the topological connection state of the power sharing module by integrating the requirements of each channel; the power conversion module generates basic analog power; the power sharing module dynamically distributes power to each physical terminal module according to the state of the contactor; the physical terminal module transmits simulation power data to the BMS simulation module, generates a charging state feedback signal and transmits the charging state feedback signal back to the vehicle controller; and the vehicle controller integrates BMS data and terminal feedback, and dynamically adjusts a charging strategy. The system simulates a real charging scene through modular design, supports multi-channel test, realizes seamless connection between a real controller and a simulation environment, and remarkably improves the development and test efficiency of the charging system.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle charging equipment, and particularly to a DC charger simulation test system and method. Background Art

[0002] With the popularization of electric vehicles, the DC charger, as an energy supply facility for electric vehicles, has become increasingly prominent. The performance of the DC charger directly affects the driving range and charging efficiency of electric vehicles. Therefore, it is of great significance to conduct accurate and efficient simulation tests on DC chargers.

[0003] Existing test schemes include real test scenarios, charging piles combined with programmable loads, vehicle controllers combined with vehicle-end simulators, vehicle controllers combined with simulation test boards and host computer software. Among them, testing through real test scenarios and charging piles combined with programmable loads takes a long time in the implementation process, requires a large amount of resource investment, and has low test efficiency; the test method of vehicle controllers combined with vehicle-end simulators has limited test scope and only supports software function verification, and cannot perform hardware integration tests; the test scheme of vehicle controllers combined with simulation test boards and host computer software has a single test object, is limited to vehicle controller function verification, lacks system-level simulation capabilities, has limited scalability, is difficult to meet complex test requirements, and lacks a flexible software and hardware switching mechanism, resulting in insufficient test flexibility.

[0004] Based on this, a new solution is needed. Summary of the Invention

[0005] The main purpose of the present invention is to provide a DC charger simulation test system and method.

[0006] To achieve the above object, the present invention provides a DC charger simulation test system, including a power distributor, a power conversion simulation module, a power sharing simulation module, a plurality of vehicle controllers, a plurality of communication controllers, a plurality of battery management system simulation modules, and a plurality of physical terminal simulation modules. The battery management system simulation module is used to generate a charging power demand according to the requirements of the simulated working conditions and send the charging power demand to the vehicle controller; the vehicle controller is connected to the communication controller and is used to initiate a charging instruction and forward the charging power demand to the power distributor through the communication controller; the power distributor is used to generate a power adjustment parameter and a contactor status parameter according to the charging power demand, send the power adjustment parameter to the power conversion simulation module, and send the contactor status parameter to the power sharing simulation module; the power conversion simulation module is used to generate a simulated output power according to the power adjustment parameter and send it to the power sharing simulation module; the power sharing simulation module is used to simulate the internal topology state according to the contactor status parameter, determine the simulated output power of different charging channels according to the internal topology state, and send the simulated output power to the physical terminal simulation module of the corresponding charging channel; the physical terminal simulation module sends the received simulated power to the battery management system simulation module according to the control signal from the vehicle controller, and at the same time generates a feedback signal according to the control signal from the vehicle controller and sends it to the vehicle controller; the vehicle controller performs information interaction with the battery management system simulation module according to the feedback signal.

[0007] In the DC charger simulation test system provided by the present invention, the power conversion simulation module includes a simulation parameter setting unit, a power-on setting simulation unit, a power module fault simulation unit, and a power output simulation unit. The simulation parameter setting unit is used for the user to configure the DC voltage and current of the power module and control the power parameters of the simulated output through input settings; the power-on setting simulation unit is used to simulate the power-on and power-off states of the power module; the power module fault simulation unit is used for the user to configure the fault state of the power conversion module to simulate the behavior of the power conversion module when a fault occurs; the power output simulation unit is used to output the corresponding DC voltage and current according to the power adjustment parameter and the simulation state from the power distributor.

[0008] In the DC charger simulation test system provided by the present invention, the power sharing simulation module includes a power distribution scheme analysis unit, a power input simulation unit, a power sharing module fault simulation unit, and a power output simulation unit. The power distribution scheme analysis unit is used to analyze the voltage and current distribution schemes of the DC output channels according to the contactor states from the power distributor; the power input simulation unit is used to simulate the input conditions of the power modules; the power sharing module fault simulation unit is used to simulate the performance when the power sharing module fails; the power output simulation unit is used to output the DC voltage and current corresponding to the simulated power output according to the state of the power sharing simulation module and from the power conversion simulation module.

[0009] In the DC charger simulation test system provided by the present invention, the battery management system simulation module includes a BMS communication simulation unit, a required voltage and current simulation unit, a battery power simulation unit, a BMS fault simulation unit, and a battery voltage simulation unit. The BMS communication simulation unit is used to simulate the real-time communication between the battery management system and the vehicle controller; the required voltage and current simulation unit simulates the voltage and current requirements of the battery management system and adjusts the output of the charging power according to the actual application requirements; the battery power simulation unit is used to output the simulated battery power according to the charge and discharge states of the battery and the real-time monitoring results; the BMS fault simulation unit is used to simulate various possible fault conditions in the battery management system; the battery voltage simulation unit is used to simulate the voltage state of the battery and dynamically adjust the voltage of the battery.

[0010] In the DC charger simulation test system provided by the present invention, the physical terminal simulation module includes an input voltage simulation unit, an input signal simulation unit, an output signal simulation unit, and a peripheral fault simulation unit. The input voltage simulation unit is used to calculate the voltage according to the simulated power output and provide the simulated voltage value to the BMS; the input signal simulation unit is used to simulate the actions and states of the physical terminal device according to the contactor control signal from the vehicle controller; the output signal simulation unit is used to output the feedback signal of the working state of the simulated terminal device; the peripheral fault simulation unit is used to simulate peripheral faults.

[0011] In the DC charger simulation test system provided by the present invention, there is also an upper computer system, which is used to set different simulation working conditions according to user input and display the data during operation to the user.

[0012] In the DC charger simulation test system provided by the present invention, the upper computer system is also used to diagnose abnormal working conditions according to the data during operation.

[0013] In the DC charger simulation test system provided by the present invention, the physical terminal simulation module communicates with the vehicle controller through a network.

[0014] In the DC charger simulation test system provided by the present invention, the battery management system simulation module interacts with the vehicle controller through the CAN protocol; in the DC charger simulation test system provided by the present invention, the power distributor sets the power regulation parameters and the contactor status parameters through the CAN protocol.

[0015] In addition, to achieve the above object, the present invention also provides a DC charger simulation test method, including the following steps:

[0016] Generate a charging power demand according to the requirements of the simulation working condition through the battery management system simulation module, and send the charging power demand to the vehicle controller;

[0017] Initiate a charging command through the vehicle controller, and forward the charging power demand to the power distributor through the communication controller;

[0018] Generate power regulation parameters and contactor status parameters according to the charging power demand through the power distributor, send the power regulation parameters to the power conversion simulation module, and send the contactor status parameters to the power sharing simulation module;

[0019] Generate a simulated output power according to the power regulation parameters through the power conversion simulation module and send it to the power sharing simulation module;

[0020] Simulate the internal topology state according to the contactor status parameters through the power sharing simulation module, determine the simulated output power of different charging channels according to the internal topology state, and send the simulated output power to the physical terminal simulation module corresponding to the charging channel;

[0021] Send the received simulated power to the battery management system simulation module according to the control signal from the vehicle controller through the physical terminal simulation module, and at the same time generate a feedback signal according to the control signal from the vehicle controller and send it to the vehicle controller;

[0022] Perform information interaction between the vehicle controller and the battery management system simulation module according to the feedback signal.

[0023] The DC charger simulation test system and method provided by the present invention have the following beneficial effects: In the present invention, the BMS simulation module generates a charging power demand according to a preset working condition and sends it to the corresponding vehicle controller; the vehicle controller forwards the charging instruction and demand to the power distributor through the communication controller to start the charging process; the power distributor synthesizes the demands of each channel to generate a power adjustment parameter for controlling the output characteristics of the power conversion module and a contactor state parameter for defining the topological connection state of the power sharing module; the power conversion module generates a basic simulation power; the power sharing module dynamically distributes the power to each physical terminal module according to the contactor state; the physical terminal module performs a dual function, including transmitting the simulated power data to the BMS simulation module to generate a charging status feedback signal (voltage / current / fault code) and sending it back to the vehicle controller; then the vehicle controller integrates the BMS data and the terminal feedback to dynamically adjust the charging strategy to form a test closed-loop; the system simulates a real charging scenario through modular design and supports multi-channel testing; through the hardware-in-the-loop technology, seamless connection between the real controller and the simulation environment is achieved, significantly improving the development and testing efficiency of the charging system. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only the embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained according to the provided drawings:

[0025] Figure 1 The schematic diagram of the DC charger simulation test system provided by an embodiment of the present invention is shown. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] To facilitate the understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. The typical embodiments of the present invention are shown in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thorough and comprehensive.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs. The terms used in the description of the present invention in this specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0028] Figure 1 The schematic diagram of the DC charger simulation test system provided by an embodiment of the present invention is shown. As Figure 1As shown in the figure, the DC charger simulation test system includes a power distributor 100, a power conversion simulation module 200, a power sharing simulation module 300, multiple vehicle controllers 400, multiple communication controllers 500, multiple battery management system simulation modules 600, and multiple physical terminal simulation modules 700. In the present invention, one vehicle controller corresponds to one communication controller, one battery management system simulation module, and one physical terminal simulation module. Users can select the number of battery management system simulation modules and physical terminal simulation modules according to the number of vehicle controllers to be simulated and tested. Thus, the system scale can be flexibly adjusted according to different test requirements and application scenarios, providing strong support for diverse test schemes. The simulator for simulating the power host is composed of the power conversion simulation module 200 and the power sharing simulation module 300, and simulates the operation of the power host under different working conditions under the control of the power distributor 100. Among them, the power distributor 100 is responsible for receiving the charging power requirements of the vehicle controller and adjusting the power output. The power conversion simulation module 200 simulates the power conversion process and generates the simulated output power according to the power adjustment parameters. The power sharing simulation module 300 simulates the topological structure and power distribution of the charging channel according to the output of the power conversion module. The vehicle controller 400 is used to initiate a charging instruction and manage the charging process. The communication controller 500 is responsible for the information transmission between the vehicle controller and the power distributor. The battery management system simulation module 600 simulates the management process of the battery and generates the charging power requirements. The physical terminal simulation module 700 simulates the terminal and processes and feedbacks the charging power according to the control signal. The physical terminal simulation module communicates with the vehicle controller through a network; the battery management system simulation module interacts with the vehicle controller through the CAN protocol; the power distributor sets the power adjustment parameters and the contactor status parameters through the CAN protocol.

[0029] During use, the battery management system simulation module generates a charging power demand according to the requirements of the simulated working conditions, and sends the charging power demand to the vehicle controller; the vehicle controller issues a charging command, and forwards the charging power demand to the power distributor through the communication controller; the power distributor generates a power adjustment parameter and a contactor status parameter according to the charging power demand, sends the power adjustment parameter to the power conversion simulation module, and sends the contactor status parameter to the power sharing simulation module; the power conversion simulation module generates a simulated output power according to the power adjustment parameter and sends it to the power sharing simulation module; the power sharing simulation module simulates the internal topology status according to the contactor status parameter, determines the simulated output power of different charging channels according to the internal topology status, and sends the simulated output power to the physical terminal simulation module of the corresponding charging channel; the physical terminal simulation module sends the received simulated power to the battery management system simulation module according to the control signal from the vehicle controller, and at the same time generates a feedback signal according to the control signal from the vehicle controller and sends it to the vehicle controller; the vehicle controller performs information interaction with the battery management system simulation module according to the feedback signal.

[0030] Specifically, in an embodiment of the present invention, it further includes a host computer system, which is used to set different simulation working conditions according to user input and display the data during operation to the user. The host computer system serves as the central control and monitoring unit, can communicate with each module in real time, set simulation working conditions, and display and diagnose various data during system operation. Specifically, the host computer system includes a user input interface that allows users to set simulation working conditions through a graphical interface, data input boxes, or control buttons; a data display module for real-time display of system operation data such as power, charging current, battery voltage, etc., to help users understand the system working state; an abnormal diagnosis module for automatically identifying abnormal working conditions based on system operation data and issuing alarms or suggestions to help users with maintenance or adjustment. When in use, the user sets different simulation working conditions through the host computer system. Specifically, the user can adjust the parameters of each module through the graphical interface, such as setting the battery charging power requirement, modifying the charging current range or voltage setting; then, the host computer system transmits these settings to the vehicle controller, which in turn affects the power distributor, power conversion simulation module, and other related modules; during system operation, the host computer system real-time displays the operation data of each module, such as charging power, battery voltage, current value, power conversion efficiency, etc.; the user can view the operation status of each charging channel in the host computer system to quickly understand the current working condition; after observing the system operation status, the user can modify the parameters during real-time operation through the host computer system. For example, the user can adjust the battery charging power requirement, charging duration, etc., to simulate different operation scenarios or meet different test requirements; the host computer system automatically diagnoses whether the system has abnormal working conditions (such as overvoltage, overcurrent, uneven power distribution, etc.) by analyzing real-time data; when an abnormality is detected, the system will issue a warning message and display a diagnostic report. According to the type of abnormality, the system will suggest corresponding measures for the user to take, such as adjusting the power output or checking the battery status. Through the host computer system, not only can multiple charging working conditions be simulated, but also the data can be monitored, modified in real time, and abnormal diagnosis can be performed. This makes the system more flexible and can provide accurate feedback and diagnosis for users in practical applications, ensuring the safety and efficiency of the charging process.

[0031] Specifically, in an embodiment of the present invention, the power conversion simulation module is used to simulate the actual power conversion module in the host system. Its core function is to simulate the behavior of the power module in the host and output the corresponding DC voltage and current. In addition, the power conversion simulation module also supports simulating various working conditions such as power-on, power-off states, and fault states, ensuring the testing and verification of the power module under different working scenarios. It includes a simulation parameter setting unit, a power-on setting simulation unit, a power module fault simulation unit, and a power output simulation unit.

[0032] Further, in an embodiment of the present invention, the simulation parameter setting unit is used for the user to configure the DC voltage and current of the power module, and controls the simulated output power parameters through input settings. This function is used to dynamically adjust the behavior of the power conversion module to meet different test requirements. The user can input the voltage and current set values that the power module needs to simulate through this module. The simulation module will output the required DC voltage and current according to these set values.

[0033] Further, in an embodiment of the present invention, the power-on setting simulation unit is used to simulate the power-on and power-off states of the power module. When powering on, the power conversion simulation module starts to output voltage and current; when powering off, the power conversion simulation module stops outputting. This function can be used to test the stability and response of the system under different power supply states. By simulating the power-on and power-off of the power module, the user can verify the startup and shutdown processes of the power conversion module. When powering on, the simulation module will start to output according to the set voltage and current; when powering off, the simulation module will stop outputting power to simulate the shutdown state of the power module.

[0034] Further, in an embodiment of the present invention, the power module fault simulation unit is used for the user to configure the fault state of the power conversion module to simulate the behavior of the power conversion module when a fault occurs. By simulating the fault state, the test system can check the coping ability of the power module in case of a fault and the fault recovery ability of the system. According to the fault state configured by the user, the power conversion simulation module will simulate the corresponding fault situation. For example, when configured as an overcurrent fault, the module will stop outputting current or output too low current; when configured as an overtemperature fault, the simulation module will simulate abnormal temperature and stop outputting voltage and current.

[0035] Further, in an embodiment of the present invention, the power output simulation unit is used to output the corresponding DC voltage and current according to the power adjustment parameters and simulation status from the power distributor. This output not only depends on conditions such as the power-on state and fault state, but is also affected by the set parameters of the power module (such as voltage and current) to ensure that the output of the simulated power module in different states is true and reliable. The power output simulation unit outputs the corresponding DC voltage and current according to the set voltage, current, power-on state and fault state. Under normal working conditions, the output DC voltage and current conform to the set values; in case of a fault state, the output will reflect the fault phenomenon, such as stopping output or outputting abnormal voltage and current.

[0036] Specifically, in an embodiment of the present invention, the core function of the power sharing simulation module is to determine the distribution of output voltage and current by analyzing the contactor status inside the sharing module based on the voltage and current data received from the power conversion simulation module, ensuring that the current and voltage between each channel meet the set requirements. At the same time, it is also used to detect whether there is an unexpected conduction condition between different charging channels according to the internal topology status, ensuring the safe operation of the power module. It includes a power distribution scheme analysis unit, a power input simulation unit, a power sharing module fault simulation unit, and a power output simulation unit.

[0037] Further, in an embodiment of the present invention, the power distribution scheme analysis unit is used to analyze the voltage and current distribution scheme of the DC output channels according to the contactor status from the power distributor. The contactor status reflects the connection situation between each DC output channel and the power module, thereby determining the actual voltage and current received by each channel. By based on the received contactor status, the voltage and current distribution conditions of each DC output channel are deduced. The opening and closing of the contactor determine how the power module supplies power to each channel, thus ensuring that each channel obtains appropriate power.

[0038] Further, in an embodiment of the present invention, the power input simulation unit is used to simulate the input situation of the power module. According to the received contactor status, the system can simulate how the power module inputs power from the outside and reasonably distributes it to each channel. The power sharing simulation module controls the input and distribution of power according to the contactor status input by the user. The system simulates the power input situation of each channel and ensures that each channel can obtain a stable power input according to the status.

[0039] Further, in an embodiment of the present invention, the power sharing module fault simulation unit is used to simulate the performance when the power sharing module fails, helping to test the response of the system in case of a fault. The fault states include contactor faults, current abnormalities, conduction problems, etc. By simulating the fault scenarios, the safety of the power module and the sharing module is ensured. By configuring the fault states of the power sharing module (such as contactor damage, overcurrent, overheating, etc.), the simulation output of the fault states (such as abnormal current and voltage of each channel) is realized. The user configures the fault states according to needs, and the system simulates the faults according to the configuration. For example, when there is a contactor fault, some channels may not receive power; in case of overcurrent or overheating faults, the system may automatically cut off the power output to prevent equipment damage.

[0040] Further, in an embodiment of the present invention, the power output simulation unit is configured to output the corresponding DC voltage and current according to the state of the power sharing simulation module (such as the contactor state) and the simulated power from the power conversion simulation module. By simulating the output of voltage and current, the system ensures that the power requirements of each channel are met, and issues such as unreasonable conduction or overcurrent do not occur. The system simulates and outputs DC voltage and current to each channel according to the switch state of the contactor and the output of the power conversion simulation module. If the contactor is in the on state, the channel will receive the voltage and current from the power module; if a fault or contactor failure occurs, it may affect the output of current and voltage or cause some channels to lose power.

[0041] During use, the power sharing simulation module first needs to parse the internal contactor state to determine the connection relationship between each DC output channel and the power module, that is, configure the output path and load connection of the power sharing module according to the switch state of the contactor. The power sharing simulation module needs to configure the connection paths of each channel according to the contactor state and judge the current and voltage requirements of each channel. The switch state of the contactor determines which output ports receive power from the power conversion module. For example, when a certain contactor is in the on state, it means that the channel is connected to the power conversion module and will receive the output voltage and current of the power conversion module; when the contactor is in the off state, the channel is not connected to the power supply of the power conversion module. The power sharing simulation module will adjust the output voltage and current in real time according to the internal contactor configuration and the input data of the power module. The voltage and current of each channel are adjusted according to the power sharing strategy and the actual output of the power conversion module to ensure proper power distribution for each channel. In addition, the power sharing simulation module can also implement a fault simulation function, that is, it allows users to configure the state of simulated faults and analyze the power output of each channel in this state. In the fault simulation mode, the power sharing simulation module will simulate the abnormal behavior of power output based on the fault state configured by the user. For example, when an overcurrent fault occurs, the power sharing simulation module will limit the output current, or the output current will suddenly drop; when a short circuit fault occurs, it may cause the output voltage of some channels to be lost, or cut off the output of the faulty channel through a protection mechanism.

[0042] In this embodiment, by simulating the entire process of power distribution, the power sharing simulation module can accurately control the voltage and current output of each channel and support the simulation and detection of fault states. It determines the power connection relationship of each channel by parsing the contactor state and adjusts the power output of each channel according to the output of the power conversion simulation module. The fault simulation function can help the system simulate different fault scenarios and ensure the reliability and stability of the system. These functions ensure the high flexibility and efficiency of the power sharing simulation module and can accurately simulate the power distribution and power management process.

[0043] Specifically, in an embodiment of the present invention, the battery management system simulation module 600 (hereinafter referred to as the BMS simulation module) is used to simulate the entire management process of the battery management system (BMS), especially the interaction between the vehicle controller (CCU) and the BMS, the charging power requirements, and the generation of data such as battery charge and voltage. It includes a BMS communication simulation unit, a required voltage and current simulation unit, a battery charge simulation unit, a BMS fault simulation unit, and a battery voltage simulation unit.

[0044] Further, in an embodiment of the present invention, the BMS communication simulation unit is used to simulate the real-time communication between the battery management system (BMS) and the vehicle controller (CCU) to ensure that these two systems can exchange information such as battery status and charging requirements. Through simulating communication protocols (such as CAN, UART, etc.), the BMS simulation module interacts with the vehicle controller. By receiving control commands from the vehicle controller (CCU) and the charging strategy or battery status required by the battery management system, the BMS communication simulation unit simulates the response of the battery management system according to the received vehicle controller commands and feeds back battery-related status data such as battery charge and battery voltage to the CCU. During the simulated communication process, the BMS communication simulation unit will generate different messages, such as battery status reports, charging status requests, etc., which reflect the working status of the battery management system and the required battery management operations.

[0045] Further, in an embodiment of the present invention, the required voltage and current simulation unit simulates the voltage and current requirements required by the battery management system (BMS) to adjust the output of the charging power according to the actual application requirements. Through real-time monitoring and calculation of the battery, the required voltage and current simulation unit can dynamically generate the voltage and current requirements of the battery within a specific time period. According to the state of the battery (such as charge, voltage, current) and the current charging strategy, the required voltage and current simulation unit calculates the voltage and current values required by the battery. For example, when the battery charge is low, the required voltage and current simulation unit may request a higher charging current to increase the charging speed; while when the battery charge is high, the required current will gradually decrease to ensure safe charging.

[0046] Further, in an embodiment of the present invention, the battery charge simulation unit outputs the simulated battery charge according to the charge and discharge state of the battery and the real-time monitoring results. The battery charge reflects the remaining energy of the battery at present and affects the charging requirements of the battery. By simulating the charging process of the battery, the battery charge simulation unit calculates the real-time charge of the battery according to the set charging curve (such as constant current, constant voltage charging). During the charging process, the battery charge will gradually increase, and the module will update the charge value of the battery in real time according to the charging current and voltage.

[0047] Further, in an embodiment of the present invention, the BMS fault simulation unit is used to simulate various fault conditions that may occur in the battery management system (BMS), such as battery overvoltage, overcurrent, overheating, etc., to detect the system's response and fault handling capabilities under abnormal conditions. According to the set fault type, the BMS fault simulation unit will generate a corresponding fault message and send it to the vehicle controller (CCU). For example, when the battery voltage exceeds the safe range, the BMS fault simulation unit will simulate the battery overvoltage fault and generate a relevant alarm message; when the battery temperature is too high, it will also trigger an alarm for abnormal temperature. Fault simulation helps to test the system's response capabilities and safety measures under different fault conditions.

[0048] Further, in an embodiment of the present invention, the battery voltage simulation unit is used to simulate the voltage state of the battery and dynamically adjust the battery voltage according to factors such as the battery's charge and discharge process and environmental conditions. According to the battery's charge and discharge process and the working mode of the battery management system, the battery voltage simulation unit will generate a battery voltage value. The battery voltage will change during the charging process. In the initial stage of charging, the voltage gradually rises, and after reaching the set charging voltage, the battery voltage stabilizes. During the battery discharge process, the battery voltage will gradually decrease. The battery voltage simulation unit provides accurate battery state information for the system by calculating the battery voltage in real time.

[0049] In this embodiment, the battery management system simulation module can effectively simulate the working process of the battery management system, including the battery's charging requirements, communication interaction, dynamic changes in battery power and voltage, fault simulation, etc. In this way, the entire system can be verified and tested under different working states and environments to ensure the performance and reliability of the battery management system, and then optimize the battery's charge and discharge strategy and extend the battery's service life.

[0050] Specifically, in an embodiment of the present invention, the physical terminal simulation module is responsible for simulating the feedback signals of physical terminal devices (such as access control, emergency stop contactors), generating corresponding electrical signals, and transmitting them as input signals to the battery management system (BMS). The functions of this module include outputting virtual power according to the state of physical peripherals, receiving and simulating contactor control signals, outputting feedback signals, and simulating peripheral faults. It includes an input voltage simulation unit, an input signal simulation unit, an output signal simulation unit, and a peripheral fault simulation unit.

[0051] Further, in an embodiment of the present invention, the input voltage simulation unit is configured to calculate a voltage based on the simulated power output and provide an analog voltage value to the BMS. By simulating the voltage conditions of the battery management system in different operating states, the physical terminal simulation module can provide a real voltage signal to the BMS for testing and verifying the response and stability of the system. According to the simulated power, the physical terminal simulation module calculates the simulated voltage using known current and voltage relationships (such as Ohm's law or battery charging characteristics) and outputs it. This voltage value will match the actual battery state to help test the BMS system's response ability to different voltage levels.

[0052] Further, in an embodiment of the present invention, the input signal simulation unit is configured to receive contactor control signals from a vehicle controller (CCU), such as an access control contactor, an emergency stop contactor, etc., and simulate the actions and states of physical terminal devices through these signals. According to the received contactor control signals, the physical terminal simulation module simulates the switching actions of the contactors. If an open signal is received, the simulation module will output an open signal feedback; if a close signal is received, it will output a close signal feedback. This can simulate the operation process of the access control contactor or the emergency stop contactor in actual applications.

[0053] Further, in an embodiment of the present invention, the output signal simulation unit is configured to output feedback signals of devices such as an access control contactor, an emergency stop contactor, etc., to simulate the working states of terminal devices. These signals are used to inform the battery management system (BMS) of the current states of external peripherals, such as whether the access control system is open or the emergency stop button has been triggered. The physical terminal simulation module outputs corresponding feedback signals according to the actual states of physical peripherals (such as the access control contactor is open or the emergency stop button is pressed). These signals are used to simulate the feedback of the access control or emergency stop system and report the working states of external peripherals to the BMS or the vehicle control system.

[0054] Further, in an embodiment of the present invention, the peripheral fault simulation unit is configured to simulate peripheral faults, such as the failure of an access control contactor or the malfunction of an emergency stop button, etc., to test the system's response ability and fault handling mechanism under abnormal conditions. Through the input peripheral fault conditions (such as contactor failure, signal loss, etc.), it outputs simulated fault signals (such as the switch fails to respond, signal loss, etc.). By simulating peripheral faults, the physical terminal simulation module generates abnormal signals. These signals simulate the situation of device failure, such as the access control contactor cannot be closed or the emergency stop button cannot be triggered, to test the system's reaction when a fault occurs and ensure that the fault handling mechanism can be activated in time and ensure safety.

[0055] In this embodiment, the physical terminal simulation module, through various functions, simulates the states, input and output signals, and fault conditions of terminal devices to ensure that the battery management system (BMS) can operate normally under various working states and fault conditions.

[0056] In the present invention, the BMS simulation module generates a charging power demand according to a preset operating condition and sends it to the corresponding vehicle controller; the vehicle controller forwards the charging instruction and demand to the power distributor through the communication controller to start the charging process; the power distributor synthesizes the demands of each channel to generate a power adjustment parameter for controlling the output characteristics of the power conversion module and a contactor state parameter for defining the topological connection state of the power sharing module; the power conversion module generates a basic simulated power; the power sharing module dynamically distributes the power to each physical terminal module according to the contactor state; the physical terminal module performs a dual function, including transmitting the simulated power data to the BMS simulation module to generate a charging status feedback signal (voltage / current / fault code) and sending it back to the vehicle controller; and then the vehicle controller integrates the BMS data and the terminal feedback to dynamically adjust the charging strategy to form a test closed loop. This system simulates a real charging scenario through modular design and supports multi-channel testing; through the hardware-in-the-loop technology, it realizes the seamless connection between the real controller and the simulated environment, significantly improving the development and testing efficiency of the charging system.

[0057] Implementing the DC charger simulation test system provided by the present invention has the following advantages:

[0058] 1. Flexible component configuration

[0059] By flexibly selecting the number of vehicle controllers, users can customize and adjust the scale of the system according to actual test requirements and application scenarios. This enables the system to handle different test scenarios, providing strong support for both single-device testing and more complex multi-channel parallel testing. Such a design can not only meet the needs of standardized testing but also be extended and customized according to special scenarios, thus enhancing the flexibility and adaptability of the testing.

[0060] 2. Efficient human-machine interaction and data display

[0061] Through the interface display module and the data setting module, the system simplifies the operation process, enabling users to interact with the test system more conveniently. Traditional testing often requires manual use of equipment such as multimeters for data acquisition, which is inefficient and error-prone. Now, through the system's automated data acquisition method, testers can view and analyze data such as voltage and messages in real time, greatly improving the testing efficiency and accuracy. This design not only enhances the intelligence of the testing process but also reduces the risk of human errors.

[0062] 3. Advantages of pure software simulation

[0063] Adopting a pure software simulation mode, the interaction between all components depends only on the network rather than physical connections. Compared with the traditional semi-physical simulation mode, this method avoids signal interference and errors that may be caused by physical connections, making the simulation process more stable and reliable. At the same time, due to the lack of dependence on physical devices, the hardware cost is greatly reduced, and the maintenance difficulty is also reduced accordingly. This enables the system to achieve an efficient virtual test environment, reducing the loss and maintenance of physical devices.

[0064] 4. Comprehensive multi-condition verification ability

[0065] The system has powerful programming functions and can simulate various complex working scenarios to comprehensively verify the performance of the system under different working conditions. Whether it is different loads, temperatures, humidities, or other special working conditions, the system can effectively simulate and evaluate. This ability allows testers to accurately analyze the stability and performance bottlenecks of the system, ensuring reliability and stability under various working conditions. In addition, the system can judge and analyze the simulated working conditions, providing important data support for further optimizing and improving the system.

[0066] 5. Components with fast reconfigurability

[0067] The components based on software implementation can quickly build and modify different components, facilitating the comparison and evaluation of different solutions and accelerating the design iteration; predicting and analyzing the system performance and functions in advance, discovering potential problems, and reducing late-stage design changes and rework; using this simulation system to verify and optimize the solutions at the initial stage of product R & D, avoiding the high costs brought by a large number of tests on the actual physical system; at the same time, in high-risk scenarios, it can simulate dangerous situations in a virtual environment to avoid personnel and equipment facing actual risks.

[0068] Correspondingly, the present invention also provides a method for simulating and testing a DC charger, including the following steps:

[0069] Generate a charging power demand according to the requirements of the simulated working condition through the battery management system simulation module, and send the charging power demand to the vehicle controller;

[0070] Initiate a charging instruction through the vehicle controller, and forward the charging power demand to the power distributor through the communication controller;

[0071] Generate a power adjustment parameter and a contactor status parameter according to the charging power demand through the power distributor, send the power adjustment parameter to the power conversion simulation module, and send the contactor status parameter to the power sharing simulation module;

[0072] Generate a simulated output power according to the power adjustment parameter through the power conversion simulation module and send it to the power sharing simulation module;

[0073] The power sharing simulation module simulates the internal topology state according to the contactor state parameter, determines the simulated output power of different charging channels according to the internal topology state, and sends the simulated output power to the physical terminal simulation module of the corresponding charging channel;

[0074] The physical terminal simulation module sends the received simulated power to the battery management system simulation module according to the control signal from the vehicle controller, and simultaneously generates a feedback signal according to the control signal from the vehicle controller and sends it to the vehicle controller;

[0075] The vehicle controller performs information interaction with the battery management system simulation module according to the feedback signal.

[0076] In the specification provided here, a large number of specific details are described. However, it can be understood that the embodiments of the present invention can be practiced without these specific details. In some instances, well-known methods, structures, and technologies are not shown in detail so as not to obscure the understanding of this specification.

[0077] Similarly, it should be understood that, in order to streamline this disclosure and assist in understanding one or more of the various inventive aspects, in the foregoing description of the exemplary embodiments of the present invention, the various features of the present invention are sometimes grouped together in a single embodiment, figure, or description thereof. However, the disclosed method should not be construed as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as reflected in the following claims, the inventive aspects lie in less than all the features of the single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of the present invention.

[0078] Those skilled in the art can understand that the modules in the devices in the embodiments can be adaptively changed and disposed in one or more devices different from this embodiment. The modules or units or components in the embodiments can be combined into one module or unit or component, and in addition, they can be divided into multiple sub-modules or sub-units or sub-components. Except that at least some of such features and / or processes or units are mutually exclusive, any combination can be adopted to combine all the features disclosed in this specification (including the accompanying claims, abstract, and drawings) and all the processes or units of any method or device so disclosed. Unless otherwise expressly stated, each feature disclosed in this specification (including the accompanying claims, abstract, and drawings) can be replaced by an alternative feature that provides the same, equivalent, or similar purpose.

[0079] In addition, those skilled in the art can understand that although some embodiments herein include certain features included in other embodiments rather than other features, the combination of features of different embodiments means that it is within the scope of the present invention and forms different embodiments. For example, in the following claims, any one of the claimed embodiments can be used in any combination.

[0080] Each component embodiment of the present invention can be implemented in hardware, or in software modules running on one or more processors, or in a combination thereof. Those skilled in the art should understand that a microprocessor or a digital signal processor (DSP) can be used in practice to implement some or all of the functions of some or all of the components according to the embodiments of the present invention. The present invention can also be implemented as a device or apparatus program (such as a computer program and a computer program product) for executing part or all of the methods described herein. Such a program for implementing the present invention can be stored on a computer-readable medium, or can be in the form of one or more signals. Such signals can be downloaded from an Internet website, or provided on a carrier signal, or provided in any other form.

[0081] It should be noted that the above embodiments illustrate the present invention rather than limit the present invention, and those skilled in the art can design alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word "comprising" does not exclude the presence of elements or steps not listed in the claim. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The present invention can be implemented by means of hardware including several different elements and by means of a suitably programmed computer. In the unit claims listing several devices, several of these devices can be embodied by the same item of hardware. The use of the words first, second, and third, etc. does not denote any order. These words can be interpreted as names.

Claims

1. A DC charger simulation test system, characterized in that: It includes a power distributor, a power conversion simulation module, a power sharing simulation module, multiple vehicle controllers, multiple communication controllers, multiple battery management system simulation modules, and multiple physical terminal simulation modules. The battery management system simulation module is used to generate a charging power requirement according to the requirements of the simulated working conditions, and send the charging power requirement to the vehicle controller; the vehicle controller is connected to the communication controller to initiate a charging instruction, and forward the charging power requirement to the power distributor through the communication controller; the power distributor is used to generate a power adjustment parameter and a contactor state parameter according to the charging power requirement, and send the power adjustment parameter to the power conversion simulation module, and send the contactor state parameter to the power sharing simulation module ; The power conversion simulation module is used to generate simulated output power according to the power regulation parameters and send it to the power sharing simulation module; the power sharing simulation module is used to simulate the internal topology state according to the contactor state parameters, and determine the simulated output power of different charging channels according to the internal topology state, and send the simulated output power to the physical terminal simulation module of the corresponding charging channel; the physical terminal simulation module sends the received simulated power to the battery management system simulation module according to the control signal from the vehicle controller, and generates a feedback signal according to the control signal from the vehicle controller and sends it to the vehicle controller; the vehicle controller exchanges information with the battery management system simulation module according to the feedback signal.

2. The DC charger simulation test system according to claim 1, characterized in that: The power conversion simulation module includes a simulation parameter setting unit, a power-on setting simulation unit, a power module fault simulation unit, and a power output simulation unit. The simulation parameter setting unit is used for the user to configure the DC voltage and current of the power module, and control the power parameters of the simulated output through input settings; the power-on setting simulation unit is used to simulate the power-on and power-off states of the power module; the power module fault simulation unit is used for the user to configure the fault state of the power conversion module to simulate the behavior of the power conversion module when a fault occurs; the power output simulation unit is used to output the corresponding DC voltage and current according to the power adjustment parameters and simulation state from the power distributor.

3. The DC charger simulation test system according to claim 1, characterized in that: The power sharing simulation module includes a power distribution scheme analysis unit, a power input simulation unit, a power sharing module fault simulation unit, and a power output simulation unit. The power distribution scheme analysis unit is used to analyze the voltage and current distribution scheme of the DC output channel according to the contactor status from the power distributor; the power input simulation unit is used to simulate the input condition of the power module; the power sharing module fault simulation unit is used to simulate the performance of the power sharing module when a fault occurs; and the power output simulation unit is used to output the DC voltage and current corresponding to the simulated power according to the status of the power sharing simulation module and the simulated power from the power conversion simulation module.

4. The DC charger simulation test system according to claim 1, characterized in that: The battery management system simulation module includes a BMS communication simulation unit, a demand voltage and current simulation unit, a battery power simulation unit, a BMS fault simulation unit and a battery voltage simulation unit. The BMS communication simulation unit is used to simulate the real-time communication between the battery management system and the vehicle controller; the demand voltage and current simulation unit simulates the voltage and current requirements required by the battery management system, and adjusts the output of the charging power according to actual application requirements; the battery power simulation unit is used to output the simulated battery power according to the battery charging and discharging status and real-time monitoring results; the BMS fault simulation unit is used to simulate various fault conditions that may occur in the battery management system; the battery voltage simulation unit is used to simulate the voltage state of the battery and dynamically adjust the battery voltage.

5. The DC charger simulation test system according to claim 1, characterized in that: The physical terminal simulation module includes an input voltage simulation unit, an input signal simulation unit, an output signal simulation unit, and a peripheral fault simulation unit. The input voltage simulation unit is used to calculate the voltage according to the simulated power output and provide the simulated voltage value to the BMS; the input signal simulation unit is used to simulate the action and state of the physical terminal device according to the contactor control signal from the vehicle controller; the output signal simulation unit is used to output a feedback signal of the working state of the simulated terminal device; and the peripheral fault simulation unit is used to simulate peripheral faults.

6. The DC charger simulation test system according to claim 1, characterized in that: It also includes a host computer system for setting different simulation conditions according to user input and displaying the running data to the user.

7. The DC charger simulation test system according to claim 6, characterized in that: The host computer system is also used to diagnose abnormal operating conditions based on the running data.

8. The DC charger simulation test system according to claim 1, characterized in that: The physical terminal simulation module communicates with the vehicle controller via a network.

9. The DC charger simulation test system according to claim 1, characterized in that: The battery management system simulation module interacts with the vehicle controller via the CAN protocol, and the power distributor sets the power regulation parameters and the contactor state parameters via the CAN protocol.

10. A DC charger simulation test method, characterized in that: The following steps are involved: Generate a charging power requirement according to the requirements of the simulated working condition through a battery management system simulation module, and send the charging power requirement to a vehicle controller; Initiating a charging instruction through the vehicle controller, and forwarding the charging power demand to the power distributor through the communication controller; Generate a power adjustment parameter and a contactor state parameter according to the charging power demand by the power distributor, send the power adjustment parameter to the power conversion simulation module, and send the contactor state parameter to the power sharing simulation module; Generate simulated output power according to the power adjustment parameter by the power conversion simulation module and send it to the power sharing simulation module; The power sharing simulation module simulates the internal topology state according to the contactor state parameters, determines the simulated output power of different charging channels according to the internal topology state, and sends the simulated output power to the physical terminal simulation module of the corresponding charging channel; The received simulated power is sent to the battery management system simulation module according to the control signal from the vehicle controller through the physical terminal simulation module, and a feedback signal is generated according to the control signal from the vehicle controller and sent to the vehicle controller; The vehicle controller exchanges information with the battery management system simulation module according to the feedback signal.

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