Charging pile power distribution module function and contactor reliability verification device and method

Abstract

The invention discloses a charging pile power distribution module function and contactor reliability verification device and method, and belongs to the technical field of charging piles. According to the scheme, a contactor function verification and reliability verification program is installed in the main control unit, the program sends a driving signal to the contactor driving feedback control unit, and the contactor driving feedback control unit controls the coil of the corresponding contactor to be powered on or powered off according to the driving signal. And the main control unit obtains main contact action and auxiliary contact action through the contactor driving feedback control unit and the contactor main contact feedback unit respectively, and performs contactor function and reliability verification according to the consistency of the driving signal, the main contact action and the auxiliary contact action. According to the scheme, automatic function verification and reliability verification can be carried out on a plurality of contactors in the power distribution module of the charging pile through one set of hardware device, the fault position can be quickly positioned, the cost is low, manual operation is not needed, and the verification reliability and efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of charging piles, and particularly to a device and method for verifying the functions of a power distribution module of a charging pile and the reliability of contactors. Background Art

[0002] In the power distribution module of an electric vehicle charging pile, factors such as the main contact state, drive cable connection state, feedback contact state of a contactor, and the mechanical life of the contactor have crucial impacts on the functions and reliability of the entire power distribution module. These factors are directly related to whether the charging pile can stably and efficiently provide charging services for multiple electric vehicles. However, in the prior art, the function verification of the contactor inside the power distribution module usually relies on manual driving tests, which are completed by using a multimeter to measure the on-off states of the main contacts and auxiliary contacts of the contactor. In addition, the reliability test of the contactor is often monitored in a separate environment and cannot comprehensively reflect its performance in actual applications. The above methods have the following deficiencies:

[0003] 1. Low efficiency: The manual test method not only takes a long time but also is difficult to test multiple contactors simultaneously, resulting in low overall test efficiency.

[0004] 2. Poor flexibility: Since each contactor needs to be tested one by one, this method lacks sufficient flexibility and is difficult to adapt to complex application scenarios.

[0005] 3. High defect rate: Manual operation is prone to introducing errors, increasing the uncertainty of test results, and thus raising the defect rate.

[0006] 4. Lack of judgment on action consistency: The existing methods cannot monitor the drive state, feedback contact state, and main contact state of the contactor in real time, which may lead to the problem of inconsistent actions between the main contact and the feedback contact, thus causing abnormal situations during the actual use of the charging pile.

[0007] 5. Difficult fault location: Especially in the case of a large number of contactors, if a fault or incorrect cable connection occurs, it is difficult for the prior art to quickly and accurately locate the specific fault location, increasing the maintenance difficulty and cost.

[0008] Therefore, there is an urgent need for a more efficient and reliable test method and technical means to overcome the above problems and improve the overall performance and stability of the power distribution module. Summary of the Invention

[0009] The technical problem to be solved by the present invention is: in view of the above defects of the prior art, to provide a device and method for verifying the functions of a power distribution module of a charging pile and the reliability of contactors.

[0010] To achieve the above object, in a first aspect, the present invention provides a device for verifying the functions of a charging pile power distribution module and the reliability of contactors. The device includes a contactor drive feedback control unit, a contactor main contact feedback unit, a main control unit, and a display unit;

[0011] The contactor drive feedback control unit is connected to the coils and auxiliary contacts of the plurality of DC contactors through cables, and is also connected to the main control unit; the contactor drive feedback control unit is configured to receive a drive signal sent by the main control unit, and in response to the drive signal, control the coil of the corresponding DC contactor to be energized or de-energized, and feedback the action states of the auxiliary contacts of the plurality of DC contactors to the main control unit;

[0012] The contactor main contact feedback unit is connected to the main contact bases of the plurality of DC contactors one by one through a plurality of metal spring pins; the metal spring pins are used to capture the actions of the main contact bases, and the contactor main contact feedback unit is also configured to feedback the action states of the main contacts of the plurality of DC contactors to the main control unit;

[0013] The main control unit is connected to the contactor drive feedback control unit, the contactor main contact feedback unit, and the display unit. A program for verifying the functions of the power distribution module and the reliability of the contactor is installed in the main control unit. The program sends a drive signal to the contactor drive feedback control unit, receives the action states of the auxiliary contacts and the main contacts, and then makes a determination based on the drive signal and the action states to generate a function and reliability verification result.

[0014] In the device for verifying the functions of the charging pile power distribution module and the reliability of the contactor according to the present invention, the display unit is configured to display the function and reliability verification results.

[0015] In the device for verifying the functions of the charging pile power distribution module and the reliability of the contactor according to the present invention, the device further includes a power supply, and the power supply is configured to supply power to the contactor drive feedback control unit, the contactor main contact feedback unit, and the main control unit.

[0016] In the device for verifying the functions of the charging pile power distribution module and the reliability of the contactor according to the present invention, the device further includes a jig box, the metal spring pins are fixed on the inner surface of the jig box, and the jig box is snap-fitted and fixed to the power distribution module.

[0017] In the device for verifying the functions of the charging pile power distribution module and the reliability of the contactor according to the present invention, the jig box is further provided with a plurality of wire passing holes. One end of the metal spring pin abuts against the main contact bases of the plurality of DC contactors, and the other end is connected to the contactor main contact feedback unit through a wire passing through the wire passing hole.

[0018] In the function distribution module of the charging pile power and the contactor reliability verification device of the present invention, the contactor drive feedback control unit, the contactor main contact feedback unit, and the main control unit all include a controller and multiple IO ports.

[0019] In a second aspect, the present invention further provides a method for verifying the function of the charging pile power distribution module and the reliability of the contactor, which is applied to the above-mentioned charging pile power distribution module function and contactor reliability verification device. The method includes the following steps:

[0020] Step S1: Connect the DC contactor to the circuit of the charging pile power distribution module according to a preset topological structure, and connect the charging pile power distribution module function and contactor reliability verification device to the power distribution module.

[0021] Step S2: Run the contactor function verification program, sequentially poll and control the energization and de-energization of the coils of each contactor, and determine whether the drive signal, main contact action, and auxiliary contact action are consistent. If they are consistent, it is determined that the corresponding contactor passes the verification; otherwise, it is determined that the corresponding contactor fails the verification.

[0022] Step S3: Run the contactor reliability verification program, sequentially control the energization and power-on of the coils of each contactor according to the preset number of on-off times, determine whether the drive signal, main contact action, and auxiliary contact action are consistent, and record the contactor action times, main contact abnormal times, main contact abnormal time serial numbers, auxiliary contact abnormal times, and auxiliary contact abnormal time serial numbers.

[0023] In the method for verifying the function of the charging pile power distribution module and the reliability of the contactor of the present invention, in step S3, if the main contact action is inconsistent with the drive signal, it is determined that the main contact is abnormal; if the auxiliary contact action is inconsistent with the drive signal, it is determined that the auxiliary contact is abnormal.

[0024] The present invention has the following beneficial effects: In the solution of the present invention, a contactor function verification and reliability verification program is installed in the main control unit. The program sends a drive signal to the contactor drive feedback control unit, and the contactor drive feedback control unit controls the energization or de-energization of the coil of the corresponding contactor according to the drive signal. The main control unit obtains the main contact action and the auxiliary contact action through the contactor drive feedback control unit and the contactor main contact feedback unit respectively, and verifies the function and reliability of the contactor according to the consistency of the drive signal, the main contact action, and the auxiliary contact action. This solution can realize the automatic function verification and reliability verification of multiple contactors in the charging pile power distribution module through a set of hardware devices, can quickly locate the fault position, has low cost, does not require manual operation, and improves the reliability and efficiency of verification. Description of the Drawings

[0025] The accompanying drawings described herein are used to provide a further understanding of the present invention and form a part of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0026] Figure 1 It is a block diagram of a device for verifying the functions of a charging pile power distribution module and the reliability of contactors provided by an embodiment of the present invention.

[0027] Figure 2 It is a topological diagram of the connection of contactors of a charging pile power distribution module according to an embodiment of the present invention.

[0028] Figure 3 It is a schematic diagram of the steps of a method for verifying the functions of a charging pile power distribution module and the reliability of contactors provided by an embodiment of the present invention.

[0029] Figure 4 It is a schematic diagram of the verification result of the functions of a charging pile power distribution module according to an embodiment of the present invention.

[0030] Figure 5 It is a schematic diagram of the verification result of the reliability of contactors of a charging pile power distribution module according to an embodiment of the present invention. Detailed implementation manners

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0032] The embodiments of the present invention will be further described in detail below with reference to the accompanying drawings of the specification. It should be understood that the embodiments described herein are only used to explain and illustrate the present invention and are not used to limit the present invention.

[0033] As Figure 1 shown, an embodiment of the present invention provides a device for verifying the functions of a charging pile power distribution module and the reliability of contactors. The charging pile power distribution module includes a plurality of DC contactors; the plurality of DC contactors are connected between the output ends of a plurality of power modules and the terminal input ends. The device includes a contactor drive feedback control unit, a contactor main contact feedback unit, a main control unit, and a display unit.

[0034] As Figure 2As shown in the figure, it is the contactor topology diagram of the charging pile power distribution module according to an embodiment of the present invention. Among them, there are a total of 18 DC contactors, and the contactors are connected between the power output modules. Those starting with "KM" represent contactors, those starting with "M" represent power output modules, and "gun" represents the charging gun. The connection lines between the contactors are aluminum bars. The function verification device and the contactor reliability verification device of the charging pile power distribution module according to the embodiment of the present invention are integrated devices, which can be used to verify the functions and reliability of the DC contactors in the charging pile power distribution module at the same time. The function verification mainly refers to the positioning and wiring verification of the contactors.

[0035] In the embodiment of the present invention, each of the DC contactors has a main contact and an auxiliary contact, and the main contact and the auxiliary contact act simultaneously.

[0036] The contactor drive feedback control unit is connected to the coils and auxiliary contacts of the multiple DC contactors through cables, and is also connected to the main control unit; the contactor drive feedback control unit is used to receive the drive signal sent by the main control unit, and in response to the drive signal, control the coil of the corresponding DC contactor to be energized or de-energized, and feedback the action state of the auxiliary contacts of the multiple DC contactors to the main control unit.

[0037] The contactor main contact feedback unit is connected to the main contact base columns of the multiple DC contactors in one-to-one correspondence through multiple metal spring pins; the metal spring pins are used to capture the actions of the main contact base columns, and the contactor main contact feedback unit is also used to feedback the action states of the main contacts of the multiple DC contactors to the main control unit.

[0038] The main control unit is connected to the contactor drive feedback control unit, the contactor main contact feedback unit, and the display unit. A power distribution module function verification and contactor reliability verification program is installed in the main control unit. The program sends drive signals to the contactor drive feedback control unit, receives the action states of the auxiliary contacts and the main contacts, and then makes a determination based on the drive signals and the action states to generate function and reliability verification results.

[0039] In the embodiment of the present invention, the display unit is used to display the function and reliability verification results.

[0040] In the embodiment of the present invention, the device further includes a power supply, and the power supply is used to supply power to the contactor drive feedback control unit, the contactor main contact feedback unit, the main control unit, and the display unit.

[0041] In an embodiment of the present invention, the device further includes a jig box, the metal spring pins are fixed on the inner surface of the jig box, and the jig box is snap-fixed to the power distribution module. The jig box is further provided with a plurality of wire passing holes. One end of the metal spring pin abuts against the main contact posts of the plurality of DC contactors, and the other end is connected to the contactor main contact feedback unit through a wire passing through the wire passing holes. In an embodiment of the present invention, in order to facilitate viewing the situation of the power distribution module through the jig box, the jig box is made of a transparent material. The metal spring pins are fixed on the inner surface of the transparent jig box according to the positions of the main contact posts of the contactors, so that metal spring pins are provided at the positions of each main contact post of the contactor. The positioning of the contactor is achieved through the metal spring pins.

[0042] In an embodiment of the present invention, the contactor drive feedback control unit, the contactor main contact feedback unit, and the main control unit are independent single boards. The contactor drive feedback control unit and the contactor main contact feedback unit are connected to the main control unit through a CAN bus and communicate through CAN messages. In practical applications, the main control unit and the display unit can be integrated together.

[0043] The contactor drive feedback control unit, the contactor main contact feedback unit, and the main control unit all include a controller and a plurality of IO ports. The contactor drive feedback control unit includes a plurality of IO ports for outputting contactor drive signals and a plurality of IO ports for inputting the action states of the auxiliary contacts of the contactor. The contactor main contact feedback unit includes a plurality of IO ports for inputting the action states of the main contacts of the contactor. The main control unit includes IO ports for inputting the action states of the main contacts and the auxiliary contacts of the contactor. The corresponding relationship between each pin of the wiring terminal and the contactor number, and the corresponding relationship between the wiring terminal and the IO port are predefined in the contactor drive feedback control unit and the contactor main contact feedback unit, so as to correspond the received main contact action signal and auxiliary contact action signal to the contactor number.

[0044] The IO ports of the contactor drive feedback control unit and the main contact feedback unit of the contactor are connected to the contactor through a terminal block. The controller on the contactor drive feedback control unit is used to receive the drive signal from the main control unit, control the corresponding contactor coil to be energized or de-energized through the IO port, then collect the action signal of the auxiliary contact of the contactor through the IO port, judge whether the action state of the auxiliary contact is closed or open through the internal circuit, and transmit the judgment result to the main control unit. The controller of the main contact feedback unit collects the action signal of the main contact of the contactor through the IO port, judges whether the action state of the main contact is closed or open through the internal circuit, and transmits the judgment result to the main control unit. The main control unit makes a consistency judgment on the drive state, the main contact action state, and the auxiliary contact action state. For example, if the drive state is to energize the coil of a certain contactor, the actions of the main contact and the auxiliary contact should both be closed, indicating that the contactor functions normally. If the drive state, the main contact action state, and the auxiliary contact action state of a certain contactor are inconsistent, it indicates that the corresponding contactor is faulty or the wiring is incorrect, so that the corresponding contactor can be quickly located according to the contactor network topology diagram for targeted troubleshooting.

[0045] In the embodiment of the present invention, two independent programs, namely, the contactor function verification program and the reliability verification program, are configured inside the main control unit. According to the user settings, the corresponding program is run to automatically perform function verification or reliability verification on all contactors in the power distribution module without manual operation, improving the reliability and efficiency of the verification, enhancing the overall performance and stability of the power distribution module, and the function of the charging pile power distribution module and the contactor reliability verification device in the embodiment of the present invention realize two verifications through a set of hardware devices, with low hardware and labor costs. At the same time, the verification results can be stored for convenient subsequent traceability.

[0046] As Figure 3 shown, the embodiment of the present invention also provides a method for verifying the function of the charging pile power distribution module and the reliability of the contactor. The function of the charging pile power distribution module and the reliability of the contactor are verified by using the above-mentioned charging pile power distribution module function and contactor reliability verification device. The method includes the following steps:

[0047] Step S1, connect the DC contactor to the circuit of the charging pile power distribution module according to a preset topology structure, and connect the charging pile power distribution module function and contactor reliability verification device to the power distribution module.

[0048] Specifically, after connecting the circuits of the power distribution module, fasten the fixture box with metal spring pins onto the power distribution module, making the metal spring pins contact the main contact posts of each contactor in the power distribution module one by one. Connect the cables of the function verification device for the power distribution module of the charging pile and the reliability verification device for the contactor. Turn on the power supply, start the function verification program or the reliability verification program in the main control unit, and perform an automated test.

[0049] Step S2: Run the contactor function verification program, sequentially poll and control the coil of each contactor to be energized and de-energized, and determine whether the drive signal, main contact action, and auxiliary contact action are consistent. If they are consistent, it is determined that the corresponding contactor passes the verification; otherwise, it is determined that the corresponding contactor fails the verification.

[0050] Step S3: Run the contactor reliability verification program, sequentially control the coil of each contactor to be energized and powered on according to the preset number of on-off cycles, and determine whether the drive signal, main contact action, and auxiliary contact action are consistent. Record the contactor action times, main contact abnormal times, main contact abnormal times serial number, auxiliary contact abnormal times, and auxiliary contact abnormal times serial number. Specifically, if the main contact action is inconsistent with the drive signal, it is determined that the main contact is abnormal; if the auxiliary contact action is inconsistent with the drive signal, it is determined that the auxiliary contact is abnormal.

[0051] Among them, Step S2 and Step S3 can be interchanged, and the corresponding program is run according to the settings in the main control unit.

[0052] In Step S2, the main control unit sends a drive signal to the drive feedback control unit, and the drive feedback control unit controls the corresponding contactor to be energized or de-energized according to the drive signal. If the drive signal, main contact action, and auxiliary contact action are inconsistent, it can be determined that the wiring of the corresponding contactor is abnormal or the contactor is faulty. In Step S2, the main control unit performs the function verification on only one contactor at a time, and then proceeds with the function verification of the next contactor after completion, so as to facilitate the positioning of wiring errors.

[0053] In the embodiment of the present invention, the main control unit stores the data of the contactor function verification and reliability verification in the memory and displays it through the display unit. As Figure 4 shown in the schematic diagram of the function verification result of the embodiment of the present invention, among them, the test result of contactor 7 is "failed", and the test results of the remaining contactors are all "passed". According to this result, it is possible to quickly conduct a targeted investigation on contactor 7, which effectively improves the efficiency compared with the method of manually locating and investigating one by one with a multimeter. As Figure 5 shown in the schematic diagram of the reliability verification result of the embodiment of the present invention, in the figure, for each contactor, information such as the main contact abnormal times, main contact abnormal times serial number, auxiliary contact abnormal times, and auxiliary contact abnormal times serial number is displayed.

[0054] In the embodiments of the present invention, filtering processing is also performed on the main contact action and auxiliary contact action of the contactor to filter out the transient interference signals caused by the bounce of the elastic piece. In addition, the bounce time of the elastic piece of the contactor contact can be monitored. When the bounce time exceeds the preset threshold, for function verification, it is determined that the verification fails, and for reliability verification, it is determined to be abnormal. Specifically, the above filtering processing can be performed in the contactor drive feedback control unit and the contactor main contact feedback unit, and the bounce time is fed back to the main control unit, and the main control unit determines the function verification and reliability verification results according to the bounce time. In addition, the parameters of the function verification program and the reliability verification program can be adjusted in combination with the performance parameters of contactors of various brands to enhance the applicability of the solution of this embodiment.

[0055] The present invention has the following beneficial effects: In the solution of the present invention, a power module function verification and contactor reliability verification program is installed in the main control unit. The program sends a drive signal to the contactor drive feedback control unit, and the contactor drive feedback control unit controls the coil of the corresponding contactor to be energized or de-energized according to the drive signal. The main control unit obtains the main contact action and auxiliary contact action through the contactor drive feedback control unit and the contactor main contact feedback unit respectively, and verifies the function and reliability of the contactor according to the consistency of the drive signal, the main contact action and the auxiliary contact action. This solution can realize the automatic function verification and reliability verification of multiple contactors in the power distribution module of the charging pile through a set of hardware devices, can quickly locate the fault location, has low cost, does not require manual operation, improves the reliability and efficiency of verification, and the test records are displayed and archived in real time, which is convenient for subsequent traceability, improves the overall performance and stability of the power distribution module, ensures that the charging pile can operate stably under various working conditions and provide high-quality services, thereby significantly improving the reliability and maintenance efficiency of the charging pile.

[0056] The above is only the specific implementation manner of the present invention, and the scope of the present invention cannot be limited thereby. Equivalent changes made by those of ordinary skill in the art according to this creation, as well as changes well-known to those skilled in the art, should still fall within the scope covered by the present invention.

Claims

1. A charging pile power distribution module function and contactor reliability verification device, the charging pile power distribution module includes a plurality of DC contactors; the plurality of DC contactors are connected between the output ends and terminal input ends of a plurality of power modules, characterized in that: The device comprises a contactor drive feedback control unit, a contactor main contact feedback unit, a main control unit, and a display unit; The contactor drive feedback control unit is connected to the coils and auxiliary contacts of the plurality of DC contactors through cables, and is also connected to the main control unit; the contactor drive feedback control unit is used to receive a drive signal from the main control unit, and in response to the drive signal, control the corresponding coil of the DC contactor to be energized or de-energized, and feed back the action status of the auxiliary contacts of the plurality of DC contactors to the main control unit; The contactor main contact feedback unit is connected to the main contact base columns of the multiple DC contactors in a one-to-one correspondence through a plurality of metal spring pins; the metal spring pins are used to capture the movement of the main contact base columns, and the contactor main contact feedback unit is also used to feed back the movement status of the main contacts of the multiple DC contactors to the main control unit; The main control unit is connected to the contactor drive feedback control unit, the contactor main contact feedback unit, and the display unit. The main control unit is installed with a power distribution module function verification and a contactor reliability verification program. The program sends a drive signal to the contactor drive feedback control unit, receives the action status of the auxiliary contacts and the action status of the main contacts, and then makes a judgment based on the drive signal and the action status to generate a function and reliability verification result.

2. The charging pile power distribution module function and contactor reliability verification device according to claim 1, characterized in that: The display unit is used to display the function and reliability verification results.

3. The charging pile power distribution module function and contactor reliability verification device according to claim 1, characterized in that: The device also includes a power supply, which is used to supply power to the contactor drive feedback control unit, the contactor main contact feedback unit, and the main control unit.

4. The charging pile power distribution module function and contactor reliability verification device according to claim 1, characterized in that: The device also includes a fixture box, the metal spring pins are fixed on the inner surface of the fixture box, and the fixture box is fixedly engaged with the power distribution module.

5. The charging pile power distribution module function and contactor reliability verification device according to claim 4, characterized in that: The jig box is also provided with a plurality of wire holes, one end of the metal spring pin abuts against the main contact base columns of the plurality of DC contactors, and the other end is connected to the contactor main contact feedback unit through a wire passing through the wire hole.

6. The charging pile power distribution module function and contactor reliability verification device according to claim 1, characterized in that: The contactor drive feedback control unit, the contactor main contact feedback unit and the main control unit all include a controller and a plurality of IO ports.

7. A method for verifying the function of a charging pile power distribution module and the reliability of a contactor, applied to the device for verifying the function of a charging pile power distribution module and the reliability of a contactor as claimed in any one of claims 1 to 6, characterized in that: The method comprises the following steps: Step S1, connecting the DC contactor to the circuit of the charging pile power distribution module according to a preset topological structure, and connecting the charging pile power distribution module function and contactor reliability verification device to the power distribution module; Step S2, running the contactor function verification program, polling and controlling the power on and off of the coils of each contactor in turn, judging whether the drive signal, the main contact action, and the auxiliary contact action are consistent, if they are consistent, judging that the corresponding contactor has passed the verification, otherwise, judging that the corresponding contactor has not passed the verification; Step S3, run the contactor reliability verification program, control the coils of each contactor to be energized and powered on in turn according to the preset number of on and off times, determine whether the drive signal, main contact action, and auxiliary contact action are consistent, and record the number of contactor actions, the number of main contact abnormalities, the main contact abnormality number, the auxiliary contact abnormality number, and the auxiliary contact abnormality number.

8. A method for verifying the function of a charging pile power distribution module and the reliability of a contactor according to claim 7, characterized in that: In step S3, if the main contact action is inconsistent with the drive signal, it is determined that the main contact is abnormal, and if the auxiliary contact action is inconsistent with the drive signal, it is determined that the auxiliary contact is abnormal.

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