An offline testing device based on the onboard charger of new energy vehicles

Abstract

The present invention provides an offline testing device for an on-board charger of a new energy vehicle, including a testing component, wherein the testing component includes a shell, a testing module, a moving block, a pushing mechanism, two fixed moving mechanisms, a first electric push rod and a plurality of transmission mechanisms, wherein a movable cavity is opened on the upper surface of the shell; the present invention places the on-board charger on the moving block by relevant personnel, and when the piston rod of the first electric push rod drives the moving block to move downward, the transmission mechanism drives the two fixed moving mechanisms to move similarly, and the two fixed moving mechanisms clamp and fix the on-board charger, and then the on-board charger is pushed to be connected to the testing module by the pushing mechanism. After the test module completes the testing of the on-board charger, the pushing mechanism is started in reverse, and the pushing mechanism separates the on-board charger from the testing module, without the need for manual operation by relevant personnel, thereby reducing the labor intensity of relevant personnel, improving work efficiency and ensuring the personal safety of relevant personnel.

Description

Technical Field

[0001] The present invention relates to the technical field of on-board charger detection for electric vehicles, and in particular to an off-line testing device for an on-board charger for new energy vehicles. Background Art

[0002] Offline testing of onboard chargers for new energy vehicles is necessary to fully verify their core performance, including functionality, safety, and reliability, in an independent environment, separate from the vehicle system. Offline testing can independently verify core functions such as the charger's AC-to-DC power conversion efficiency and compatibility with different charging protocols. It can also manually trigger fault conditions such as overvoltage, overcurrent, and short circuits to verify the effectiveness of protection mechanisms.

[0003] When using existing offline testing equipment, relevant personnel are required to manually connect the on-board charger of the new energy vehicle to the offline testing equipment, and then test the on-board charger of the new energy vehicle. If repeated testing is performed on multiple on-board chargers of new energy vehicles, relevant personnel need to connect and contact the on-board charger of the new energy vehicle with the offline testing equipment multiple times. When relevant personnel work for a long time, the labor intensity of relevant personnel will be increased and the work efficiency will be reduced. If the on-board charger of the new energy vehicle fails or the operation is wrong during manual operation, it is easy to cause the risk of electric shock. Therefore, an offline testing device based on the on-board charger of the new energy vehicle is proposed. Summary of the Invention

[0004] In view of this, the embodiments of the present invention hope to provide an offline testing device based on an on-board charger of a new energy vehicle to solve or alleviate the technical problems existing in the prior art and at least provide a beneficial option.

[0005] The technical solution of an embodiment of the present invention is implemented as follows: An offline testing device based on an on-board charger of a new energy vehicle includes a test component, which includes a shell, a test module, a moving block, a pushing mechanism, two fixed moving mechanisms, a first electric push rod and several transmission mechanisms, wherein an active cavity is opened on the upper surface of the shell, and the moving block is slidably connected to the inner wall of the active cavity; the first electric push rod is arranged on the lower surface of the shell, and the piston rod of the first electric push rod passes through the shell and is arranged on the lower surface of the moving block; the pushing mechanism is arranged on the shell, and several transmission mechanisms are respectively arranged on the moving block and the shell, and a support frame is provided on the lower surface of the shell; the two fixed moving mechanisms are symmetrically arranged on several transmission mechanisms, the test module is arranged on the shell, and the test module passes through the shell and is fixedly connected; a control panel is provided on the front surface of the shell, and the control panel is electrically connected to the test module, the pushing mechanism and the first electric push rod through wires.

[0006] In some embodiments, the pushing mechanism includes a second electric push rod, two L-shaped connecting rods, two L-shaped pushing rods and an I-shaped push plate, wherein the second electric push rod is arranged on one side of the shell, and the piston rod of the second electric push rod passes through the shell and is arranged on one side of the I-shaped push plate; the inner wall of the movable cavity is symmetrically provided with L-shaped movable grooves and movable through holes, and the two L-shaped connecting rods pass through the corresponding movable through holes and are symmetrically arranged on the outer wall of the I-shaped push plate; the outer walls of the two L-shaped pushing rods are fitted with the inner walls of the corresponding L-shaped movable grooves, and the upper surfaces of the two L-shaped pushing rods are arranged on the lower surfaces of the corresponding L-shaped connecting rods; the control panel is electrically connected to the second electric push rod through wires.

[0007] In some embodiments, the transmission mechanism includes a forward and reverse bidirectional screw, two connecting blocks, two gears and two racks, wherein the upper surface of the moving block is symmetrically provided with moving through holes, the forward and reverse bidirectional screw passes through the moving block and is rotatably connected by a bearing; the two connecting blocks are slidably connected to the inner walls corresponding to the moving through holes, and the outer walls of the connecting blocks are provided with threaded through holes; the inner walls of the movable cavity are evenly provided with operating grooves, and the two racks are respectively arranged on the inner walls corresponding to the operating grooves; the adjacent sides of the two gears are symmetrically provided at the two ends of the forward and reverse bidirectional screw, and the two gears are respectively engaged with the two racks; the outer wall of the forward and reverse bidirectional screw is threadedly connected to the inner wall of the threaded through hole, and the two fixed moving mechanisms are respectively provided on the upper surfaces of the two connecting blocks.

[0008] In some embodiments, the fixed movable mechanism includes an operating block, a movable block, a clamping plate and several springs, wherein the lower surface of the operating block is arranged on the upper surface of the connecting block, and a movable groove is opened on one side of the operating block; the movable block is slidably connected to the inner wall of the movable groove, and the clamping plate is arranged on the side of the movable block away from the operating block; one end of several of the springs is evenly arranged on the inner wall of the movable groove, and the other ends of several of the springs are evenly arranged on one side of the movable block.

[0009] In some embodiments, the inner wall of the movable cavity is evenly and symmetrically provided with first sliding grooves, the outer wall of the movable block is evenly provided with first sliding blocks, and the outer wall of the first sliding block is slidably connected to the inner wall of the first sliding groove.

[0010] In some embodiments, the outer wall of the shell is symmetrically provided with a second sliding groove, and a second slider is provided on each adjacent side of the two L-shaped connecting rods, and the outer wall of the second slider is slidably connected to the inner wall of the second sliding groove.

[0011] In some embodiments, the inner top wall and the inner bottom wall of the movable groove are respectively provided with a third sliding groove, the upper surface and the lower surface of the movable block are respectively provided with a third slider, and the outer wall of the third slider is slidably connected to the inner wall of the third sliding groove.

[0012] In some embodiments, steel balls are evenly embedded on the upper surface of the moving block.

[0013] In some embodiments, a rubber layer is provided on a side of the clamping plate away from the operating block.

[0014] In some embodiments, the inner wall of the movable through hole is evenly provided with a fourth sliding groove, the outer wall of the connecting block is evenly provided with a fourth sliding block, and the outer wall of the fourth sliding block is slidably connected to the inner wall of the fourth sliding groove.

[0015] The embodiment of the present invention adopts the above technical solution, which has the following advantages:

[0016] 1. The present invention drives the moving block upward by the piston rod of the first electric push rod, and the moving block drives two fixed moving mechanisms to repel each other through a plurality of transmission mechanisms. Thereafter, the relevant personnel place the on-board charger on the moving block. When the piston rod of the first electric push rod drives the moving block downward, the transmission mechanism drives the two fixed moving mechanisms to move close to each other. The two fixed moving mechanisms clamp and fix the on-board charger. Thereafter, the on-board charger is pushed to be connected to the test module through the pushing mechanism. After the test module completes the test of the on-board charger, the pushing mechanism is started in the reverse direction. The pushing mechanism separates the on-board charger from the test module. No manual operation is required by the relevant personnel, thereby reducing the labor intensity of the relevant personnel, improving work efficiency, and ensuring the personal safety of the relevant personnel.

[0017] 2. The present invention drives the "X"-shaped push plate, two L-shaped connecting rods and two L-shaped push rods to move through the piston rod of the second electric push rod, and the "X"-shaped push plate pushes the on-board charger to move, and the on-board charger drives the clamping plates in the two fixed moving mechanisms to move. The clamping plates are assisted by the movable block on the operating block, which can ensure that when the on-board charger is fixed and clamped, the position of the on-board charger can be stabilized, so that the on-board charger is connected to the test module. When the on-board charger needs to be separated from the test module, the relevant personnel reversely start the second electric push rod, and the movable rod of the second electric push rod drives the "X"-shaped push plate, the two L-shaped connecting rods and the two L-shaped push rods to move in the opposite direction. The two L-shaped push rods squeeze the on-board charger to move in the opposite direction, which is used to separate the on-board charger from the test module. The elastic potential energy of the spring drives the movable block and the clamping plate to reset, so that the clamping plate drives the on-board charger to reset. The on-board charger can be moved without manual operation by the relevant personnel, further reducing the workload of the relevant personnel.

[0018] The above summary is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments and features described above, further aspects, embodiments and features of the present invention will be readily apparent by reference to the accompanying drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0020] Figure 1 It is a structural diagram of the present invention;

[0021] Figure 2 For the present invention Figure 1 A magnified structural diagram of area A;

[0022] Figure 3 It is a top view of the structure of the present invention;

[0023] Figure 4 For the present invention Figure 3 BB side section structure diagram;

[0024] Figure 5 For the present invention Figure 4 The enlarged structure diagram of the C region;

[0025] Figure 6 For the present invention Figure 4 A magnified structural diagram of the D region;

[0026] Figure 7 For the present invention Figure 3 EE side cross-sectional structure diagram;

[0027] Figure 8 For the present invention Figure 7 A magnified structural diagram of the F region;

[0028] Figure 9 It is a rear structural diagram of the present invention;

[0029] Figure 10 For the present invention Figure 9 GG side cross-sectional structure diagram;

[0030] Figure 11 It is a structural diagram of the driving mechanism of the present invention;

[0031] Figure 12 A structural diagram showing the connection between the transmission mechanism, the moving block and the fixed moving mechanism of the present invention;

[0032] Figure 13 For the present invention Figure 12 HH side cross-sectional structure diagram;

[0033] Figure 14 For the present invention Figure 13 Magnified structural diagram of the J region;

[0034] Figure 15 It is a side structural diagram of the present invention.

[0035] Figure numerals: 1, test assembly; 2, movable cavity; 3, L-shaped movable groove; 4, support frame; 5, control panel; 6, movable through hole; 7, first slide groove; 8, first slider; 9, second slide groove; 10, housing; 11, test module; 12, moving block; 13, pushing mechanism; 14, fixed moving mechanism; 15, first electric push rod; 16, transmission mechanism; 20, second slider; 21, moving groove; 22, rubber layer; 23, steel ball; 24, first Three slide grooves; 25. Third slider; 26. Movable through hole; 27. Threaded through hole; 28. Operating groove; 29. ​​Fourth slide groove; 30. Fourth slider; 130. Second electric push rod; 131. L-shaped connecting rod; 132. L-shaped push rod; 133. X-shaped push plate; 140. Operating block; 141. Movable block; 142. Clamping plate; 143. Spring; 160. Bidirectional screw with positive and negative threads; 161. Connecting block; 162. Gear; 163. Rack. DETAILED DESCRIPTION

[0036] Hereinafter, only certain exemplary embodiments are briefly described. As will be appreciated by those skilled in the art, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and description are to be considered as illustrative in nature and not restrictive.

[0037] It should be noted that the terms "first," "second," "symmetrical," "array," "disposed on," and "provided with" are used only to distinguish descriptions from positional descriptions and should not be understood as indicating or implying relative importance or implicitly indicating the quantity of the technical features indicated. Therefore, limitations on features such as "first" and "symmetrical" may explicitly or implicitly include one or more of these features; similarly, when the quantity of certain features is not limited in the form of words such as "two" or "three," it should be noted that these features also explicitly or implicitly include one or more of the number of features.

[0038] In the present invention, unless otherwise expressly specified or limited, terms such as "installation," "connection," and "fixation" should be understood broadly; for example, they may refer to fixed connection, detachable connection, or integral molding; they may refer to mechanical connection, direct connection, welding, or indirect connection through an intermediate medium; they may refer to internal communication between two components or interaction between two components. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on the specification and drawings in conjunction with specific circumstances.

[0039] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0040] like Figures 1-15 As shown, an embodiment of the present invention provides an off-line test device based on a new energy vehicle on-board charger, including a test component 1, the test component 1 includes a shell 10, a test module 11, a moving block 12, a pushing mechanism 13, two fixed moving mechanisms 14, a first electric push rod 15 and a plurality of transmission mechanisms 16, wherein the upper surface of the shell 10 is provided with an active cavity 2, and the moving block 12 is slidably connected to the inner wall of the active cavity 2, the first electric push rod 15 is arranged on the lower surface of the shell 10, and the piston rod of the first electric push rod 15 passes through the shell 10 and is arranged at On the lower surface of the moving block 12, a pushing mechanism 13 is arranged on the shell 10, and several transmission mechanisms 16 are respectively arranged on the moving block 12 and the shell 10. A support frame 4 is provided on the lower surface of the shell 10, and two fixed moving mechanisms 14 are symmetrically arranged on the several transmission mechanisms 16. A test module 11 is provided on the shell 10, and the test module 11 passes through the shell 10 and is fixedly connected. A control panel 5 is provided on the front surface of the shell 10, and the control panel 5 is electrically connected to the test module 11, the pushing mechanism 13 and the first electric push rod 15 through wires.

[0041] The two L-shaped push rods 132 are symmetrically arranged on the inner wall of the movable chamber 2, and the two L-shaped push rods 132 are symmetrically arranged on the outer wall of the movable chamber 2. The outer walls of the two L-shaped push rods 132 are fitted with the inner walls of the corresponding L-shaped movable grooves 3, and the upper surfaces of the two L-shaped push rods 132 are arranged on the lower surfaces of the corresponding L-shaped connecting rods 131. The control panel 5 is electrically connected to the second electric push rod 130 through wires. The piston rod of the second electric push rod 130 drives the ""-shaped push plate 133, the two L-shaped connecting rods 131 and the two L-shaped push rods 1 32 moves, the "X"-shaped push plate 133 pushes the on-board charger to move, and the on-board charger drives the clamping plates 142 in the two fixed moving mechanisms 14 to move. The clamping plates 142 are assisted by the movable block 141 on the operating block 140, which can ensure that the on-board charger can be fixedly clamped while stabilizing the position of the on-board charger so that the on-board charger is connected to the test module 11. After the on-board charger test is completed, the relevant personnel use the control panel 5 to control the second electric push rod 130 in the reverse direction. The movable rod of the second electric push rod 130 drives the "X"-shaped push plate 133, the two L-shaped connecting rods 131 and the two L-shaped pushing rods 132 to move in the reverse direction. The two L-shaped pushing rods 132 squeeze the on-board charger to move in the reverse direction, which is used to separate the on-board charger from the test module 11. The elastic potential energy of the spring 143 drives the movable block 141 and the clamping plate 142 to reset, so that the clamping plate 142 drives the on-board charger to reset.

[0042] In this embodiment, specifically, the transmission mechanism 16 includes a forward and reverse bidirectional screw 160, two connecting blocks 161, two gears 162 and two racks 163, wherein the upper surface of the moving block 12 is symmetrically provided with moving through holes 26, the forward and reverse bidirectional screw 160 passes through the moving block 12 and is rotatably connected by a bearing, the two connecting blocks 161 are slidably connected to the inner wall of the corresponding moving through hole 26, and the outer wall of the connecting block 161 is provided with a threaded through hole 27, the inner wall of the movable chamber 2 is evenly provided with an operating groove 28, and the two racks 163 are respectively arranged on the inner wall of the corresponding operating groove 28, the adjacent side of the two gears 162 is symmetrically provided at both ends of the forward and reverse bidirectional screw 160, and the two gears 162 are respectively meshed with the two racks 163, the outer wall of the forward and reverse bidirectional screw 160 is threadedly connected to the inner wall of the threaded through hole 27, The two fixed moving mechanisms 14 are respectively arranged on the upper surfaces of the two connecting blocks 161. When the piston rod of the first electric push rod 15 is used to drive the moving block 12 to move up and down, the moving block 12 drives the gears 162 on the several transmission mechanisms 16 to rotate on the corresponding racks 163, thereby causing the racks 163 to rotate in the corresponding threaded through holes 27, thereby causing the connecting blocks 161 on the several transmission mechanisms 16 to move relative to or repel each other, and the two connecting blocks 161 in the several transmission mechanisms 16 continue to move relative to or repel each other. The two connecting blocks 161 in the several transmission mechanisms 16 respectively drive the two operating blocks 140 to move relative to or repel each other, and the two operating blocks 140 respectively drive the two clamping plates 142 to move relative to or repel each other through the two movable blocks 141, so that the clamping plates 142 clamp or release the on-board charger.

[0043] In this embodiment, specifically, the fixed moving mechanism 14 includes an operating block 140, a movable block 141, a clamping plate 142 and a plurality of springs 143, wherein the lower surface of the operating block 140 is arranged on the upper surface of the connecting block 161, and a movable groove 21 is opened on one side of the operating block 140, the movable block 141 is slidably connected to the inner wall of the movable groove 21, and the clamping plate 142 is arranged on the side of the movable block 141 away from the operating block 140, one end of the plurality of springs 143 is evenly arranged on the inner wall of the movable groove 21, and the other end of the plurality of springs 143 is evenly arranged on one side of the movable block 141, and the elastic potential energy of the springs 143 arranged above drives the movable block 141 and the clamping plate 142 to be reset.

[0044] In this embodiment, specifically, the inner wall of the active cavity 2 is evenly and symmetrically provided with a first sliding groove 7, the outer wall of the movable block 12 is evenly provided with a first slider 8, and the outer wall of the first slider 8 is slidably connected to the inner wall of the first sliding groove 7. Through the above setting, the first slider 8 is slid in the first sliding groove 7, which can both assist the movable block 12 to move and stabilize the position of the movable block 12.

[0045] In this embodiment, specifically, the outer wall of the shell 10 is symmetrically provided with a second sliding groove 9, and a second slider 20 is provided on the adjacent side of the two L-shaped connecting rods 131. The outer wall of the second slider 20 is slidably connected to the inner wall of the second sliding groove 9. Through the above setting, the second slider 20 is slid in the second sliding groove 9, which can not only assist the L-shaped connecting rod 131 to move, but also stabilize the moving position of the L-shaped connecting rod 131.

[0046] In this embodiment, specifically, the inner top wall and the inner bottom wall of the movable groove 21 are respectively provided with a third sliding groove 24, and the upper surface and the lower surface of the movable block 141 are respectively provided with a third slider 25, and the outer wall of the third slider 25 is slidably connected to the inner wall of the third sliding groove 24. Through the above setting, the third slider 25 is slid in the third sliding groove 24, which can not only assist the movable block 141 to move, but also stabilize the moving position of the movable block 141.

[0047] In this embodiment, specifically, steel balls 23 are evenly embedded on the upper surface of the moving block 12 . The steel balls 23 are arranged as above to assist the on-board charger in sliding on the moving block 12 , thereby reducing the friction between the on-board charger and the moving block 12 .

[0048] In this embodiment, specifically, a rubber layer 22 is provided on the side of the clamping plate 142 away from the operating block 140. The rubber layer 22 is provided to increase the friction between the clamping plate 142 and the on-board charger, thereby further fixing the position of the on-board charger.

[0049] In this embodiment, specifically, the inner wall of the movable through hole 26 is evenly provided with a fourth sliding groove 29, and the outer wall of the connecting block 161 is evenly provided with a fourth slider 30. The outer wall of the fourth slider 30 is slidably connected to the inner wall of the fourth sliding groove 29. Through the above setting, the fourth slider 30 is slid in the fourth sliding groove 29, which can not only assist the connecting block 161 to move, but also stabilize the moving position of the connecting block 161.

[0050] When the present invention is working: the relevant personnel lay an insulating pad under the support frame 4, and the relevant personnel place the on-board charger on the moving block 12, wherein the steel ball 23 is used to assist the on-board charger to slide on the moving block 12, reducing the friction between the on-board charger and the moving block 12. Thereafter, the relevant personnel control the first electric push rod 15 to start through the control panel 5. When the piston rod of the first electric push rod 15 drives the moving block 12 to move downward, the moving block 12 drives the gears 162 on the transmission mechanism 16 to rotate on the corresponding rack 163. As a result, the rack 163 rotates in the corresponding threaded through hole 27, thereby causing the connecting blocks 161 on the several transmission mechanisms 16 to move relative to each other. When the movable block 12 moves to the inner bottom wall of the movable cavity 2, the two connecting blocks 161 in the several transmission mechanisms 16 continue to move relative to each other. The two connecting blocks 161 in the several transmission mechanisms 16 respectively drive the two operating blocks 140 to move relative to each other. The two operating blocks 140 respectively drive the two clamping plates 142 to move relative to each other through the two movable blocks 141, so that the clamping plates 142 clamp and fix the on-board charger.

[0051] After that, the relevant personnel start the second electric push rod 130 through the control panel 5. The piston rod of the second electric push rod 130 drives the I-shaped push plate 133, two L-shaped connecting rods 131 and two L-shaped push rods 132 to move. The I-shaped push plate 133 pushes the on-board charger to move, and the on-board charger drives the clamping plates 142 in the two fixed moving mechanisms 14 to move. The clamping plates 142 are assisted on the operating block 140 by the movable block 141, which can ensure that when the on-board charger is fixed and clamped, the moving position of the on-board charger can be stabilized, so that the on-board charger is connected to the test module 11.

[0052] Test module 11 consists of test equipment and auxiliary tools. The test equipment includes a DC power supply (simulating a battery pack, with a voltage range that matches the rated input of the on-board charger, such as 300-500V), an electronic load (simulating a charging load, supporting constant current / constant voltage modes), an oscilloscope (monitoring waveforms), a power analyzer (measuring efficiency and power factor), an insulation resistance tester, a withstand voltage tester, and a CAN bus device.

[0053] Auxiliary tools include wiring harness adapters (adapting to vehicle charger interfaces, such as charging gun interfaces, high-voltage DC interfaces, and low-voltage control interfaces) and adapter boards (simulating vehicle CAN bus signals).

[0054] The positive and negative terminals of the DC power supply are connected to the high-voltage DC input interface of the on-board charger (usually the battery pack interface) through a high-voltage wiring harness. The simulated battery pack provides a DC input voltage (e.g., 300-500V) for the on-board charger. The voltage is adjustable and is used to test the operating status of the on-board charger under different input voltages. Some DC power supplies can simulate the dynamic characteristics of the battery pack (e.g., voltage fluctuations) to verify the adaptability of the on-board charger.

[0055] The input of the electronic load is connected to the high-voltage DC output interface (charging output) of the on-board charger through a high-voltage wiring harness. As the on-board charger's load, it absorbs charging power and supports constant current (CC) and constant voltage (CV) mode adjustment. This is used to test the output power, efficiency, and dynamic response of the on-board charger. By setting a sudden load change (such as a sudden increase from 25% to 100% of the rated power), the current / voltage stabilization time of the on-board charger is detected.

[0056] The input end of the power analyzer is connected in parallel to the high-voltage input circuit of the DC power supply and the on-board charger to monitor the input voltage, current and power. The output end of the power analyzer is connected in parallel to the high-voltage output circuit of the on-board charger and the electronic load to monitor the output voltage, current and power, calculate the energy conversion efficiency of the on-board charger (output power / input power), and analyze power quality parameters such as power factor and harmonics.

[0057] The CAN bus device is connected to the vehicle charger's low-voltage control interface (CAN communication terminal) via a CAN wiring harness. It simulates the vehicle's BMS (Battery Management System) sending CAN messages (such as battery voltage, SOC, and charge enable signals) to control the on-board charger's start / stop and power regulation. It also receives status messages from the on-board charger (such as charging current, temperature, and fault codes) to verify the compatibility of communication protocols (such as the GB / T27930 national standard).

[0058] Connect the oscilloscope probe to the key signal nodes of the on-board charger (such as the high-voltage input / output terminals, PWM control signals, and both ends of the sampling resistor), and connect its ground terminal to the on-board charger casing. This is used to monitor voltage / current waveforms, ripple amplitude, switching frequency, and other parameters, and analyze the hardware stability of the on-board charger (for example, whether the filter capacitor has failed).

[0059] Connect the high-voltage terminal of the insulation resistance tester to the high-voltage terminal of the on-board charger (short-circuit the input / output terminals), and the ground terminal of the insulation resistance tester to the on-board charger casing. Test the insulation resistance between the two (≥100MΩ).

[0060] The output end of the withstand voltage tester is connected to the high voltage terminal and the casing, and the rated voltage (such as 1500VDC) is applied to detect whether there is breakdown or leakage current exceeds the standard (≤10mA).

[0061] The specific test steps are as follows:

[0062] 1. Static parameter test

[0063] Insulation and voltage withstand test:

[0064] Use an insulation resistance tester to apply 500VDC between the high-voltage terminal (input + output short-circuited) and the outer casing of the on-board charger. The insulation resistance reading should be ≥ 100MΩ (GB / T18384.3 standard).

[0065] The withstand voltage tester is set to 1500VDC / 1min and applied to the high voltage terminal and the casing. The leakage current is ≤10mA, and there is no breakdown or flashover phenomenon.

[0066] Standby power consumption test:

[0067] Connect the on-board charger to a 12V low-voltage power supply. When the CAN bus is not communicating, use a power meter to measure the standby power consumption to be ≤10W (typical value ≤5W).

[0068] 2. Dynamic loading test

[0069] Input voltage range verification:

[0070] The DC power supply is set to 300 VDC (lower limit), the electronic load is set to 50% rated power (constant current mode), and CANoe sends a charging enable signal. The onboard charger should start normally, and the output voltage should be stable within ±2% of the target value.

[0071] Gradually increase the input voltage to 500V (rated value) and 600V (upper limit), repeat the test, and record the output power fluctuation at different voltages to ensure it remains ≤5%.

[0072] Efficiency curve test:

[0073] The input voltage is fixed at 400 VDC, and the electronic load is gradually increased from 20% of the rated power (for example, 2.5 kW) to 100% (12.5 kW), with a 2-minute pause at each 10% power point.

[0074] The power analyzer simultaneously collects input / output power, calculates efficiency, and the typical value should be ≥95% (rated power point). The efficiency-load rate curve is drawn (e.g., ≥93% at 20% load, ≥95% at 50% load).

[0075] Dynamic response test:

[0076] When the load suddenly increases from 25% to 75% (50% step amplitude), the output voltage drop monitored by an oscilloscope is ≤5%, and the recovery time is ≤50ms.

[0077] Reverse test: When the load drops from 75% to 25%, the voltage overshoot is ≤5% and the recovery time is ≤100ms (refer to GB / T34657.2 standard).

[0078] 3. CAN communication protocol verification

[0079] BMS analog communication:

[0080] CANoe loads the GB / T27930-2015 protocol database and simulates the BMS sending the following message:

[0081] Battery status message (ID=0x292): Contains battery voltage (e.g., 380V), SOC (50%), and charging permission signal (TRUE).

[0082] Charging control message (ID=0x293): Set the target charging current (e.g. 30A).

[0083] Monitor the on-board charger feedback message (ID=0x282): Contains actual charging current, voltage, temperature, etc. The data should be consistent with the command, and the communication cycle is ≤100ms.

[0084] Fault response testing:

[0085] When a fault command (such as "battery overvoltage" or "overtemperature") is sent via CANoe, the on-board charger should stop output within 50ms and the status message should update the fault code (such as 0x01 for overvoltage).

[0086] After clearing the fault, send a reset command and the on-board charger should be able to restart.

[0087] 4. Charging process simulation

[0088] Wake up and start:

[0089] Connect to a 12V power supply and simulate the vehicle charging wake-up signal (CC / CP signal) through the adapter board. The low-voltage side relay of the on-board charger should be closed, and the CAN bus enters the communication state.

[0090] Charging process control:

[0091] Simulate the process of “pre-charge → constant current charge → constant voltage charge → end”:

[0092] Pre-charging stage: The on-board charger outputs a small current (10-20A) to charge the dummy battery, and enters constant current mode when the voltage rises to 300V.

[0093] Constant current stage: maintain the current at 30A until the voltage reaches 400V and then switch to constant voltage mode.

[0094] Constant voltage stage: When the voltage remains at 400V and the current gradually decreases to 5A, the on-board charger sends a charging end signal.

[0095] 5. Overvoltage / overcurrent protection

[0096] Overvoltage trigger:

[0097] When the DC power input voltage rises to 650V (overvoltage threshold, usually 130% of the rated value), the on-board charger should cut off the high-voltage output within 10ms and the fault light will light up.

[0098] Overcurrent trigger:

[0099] The electronic load is set to 120% of the rated current (e.g. 36A). The onboard charger should limit the current to 110% (33A) within 50ms and shut down the output after 5s.

[0100] 6. Key points of data collection

[0101] For each test item, record 3 sets of data (e.g., efficiency is averaged), and abnormal data must be marked (e.g., overcurrent protection response time is measured to be 45ms, while the standard is ≤50ms).

[0102] Save waveform files (such as oscilloscope PWM waveforms, CAN bus message logs), and efficiency curve screenshots of power analyzers.

[0103] 7. Report Content Framework

[0104] Test overview: on-board charger model, test standard (such as GB / T34657.2-2017), and equipment list.

[0105] Electrical performance: efficiency curve, input / output range, dynamic response parameters.

[0106] Communication protocol: CAN message interaction timing diagram, fault code response time.

[0107] Safety protection: each protection threshold and action time.

[0108] After the on-board charger test is completed, the relevant personnel reversely start the second electric push rod 130 through the control panel 5 controller, and the movable rod of the second electric push rod 130 drives the "X"-shaped push plate 133, the two L-shaped connecting rods 131 and the two L-shaped push rods 132 to move in the opposite direction. The two L-shaped push rods 132 squeeze the on-board charger to move in the opposite direction, which is used to separate the on-board charger from the test module 11. The elastic potential energy of the spring 143 drives the movable block 141 and the clamping plate 142 to reset, so that the clamping plate 142 drives the on-board charger to reset. The on-board charger can be moved without manual operation by the relevant personnel.

[0109] After that, the relevant personnel control the first electric push rod 15 to start in the reverse direction through the control panel 5. The piston rod of the first electric push rod 15 drives the moving block 12 to move upward, and the moving block 12 drives the gears 162 on the corresponding racks 163 to rotate in the opposite direction, so that the racks 163 rotate in the opposite direction in the corresponding threaded through holes 27, so that the connecting blocks 161 on the several transmission mechanisms 16 move in opposite directions. When the moving block 12 moves to be flush with the upper surface of the shell 10, the two connecting blocks 161 in the several transmission mechanisms 16 continue to move in opposite directions, and the two connecting blocks 161 in the several transmission mechanisms 16 respectively drive the two operating blocks 140 to move in opposite directions. The two operating blocks 140 respectively drive the two clamping plates 142 to move in opposite directions through the two movable blocks 141, so that the clamping plate 142 releases the on-board charger, making it convenient for relevant personnel to take out the on-board charger after testing.

[0110] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various modifications and substitutions within the technical scope disclosed in the present invention, and such modifications and substitutions are intended to be within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the scope of protection of the claims.

Claims

1. An off-line testing device for a new energy vehicle onboard charger, comprising a testing component (1), characterized in that: The test assembly (1) comprises a housing (10), a test module (11), a moving block (12), a pushing mechanism (13), two fixed moving mechanisms (14), a first electric push rod (15) and a plurality of transmission mechanisms (16), wherein: An active cavity (2) is provided on the upper surface of the housing (10), and the moving block (12) is slidably connected to the inner wall of the active cavity (2); The first electric push rod (15) is arranged on the lower surface of the housing (10), and the piston rod of the first electric push rod (15) passes through the housing (10) and is arranged on the lower surface of the moving block (12); The pushing mechanism (13) is arranged on the housing (10), and a plurality of the transmission mechanisms (16) are respectively arranged on the moving block (12) and the housing (10), and a support frame (4) is provided on the lower surface of the housing (10); The two fixed moving mechanisms (14) are symmetrically arranged on a plurality of the transmission mechanisms (16); the test module (11) is arranged on the housing (10); the test module (11) passes through the housing (10) and is fixedly connected; A control panel (5) is provided on the front surface of the housing (10), and the control panel (5) is electrically connected to the test module (11), the pushing mechanism (13) and the first electric push rod (15) through electric wires; The transmission mechanism (16) includes a forward and reverse bidirectional screw (160), two connecting blocks (161), two gears (162) and two racks (163), wherein: The upper surface of the moving block (12) is symmetrically provided with moving through holes (26), and the forward and reverse bidirectional screw (160) passes through the moving block (12) and is rotatably connected via a bearing; The two connecting blocks (161) are slidably connected to the inner walls of the corresponding movable through holes (26), and the outer walls of the connecting blocks (161) are provided with threaded through holes (27); The inner wall of the movable cavity (2) is evenly provided with operating grooves (28), and the two racks (163) are respectively arranged on the inner walls corresponding to the operating grooves (28); The two gears (162) are symmetrically arranged on adjacent sides at both ends of the forward and reverse bidirectional screw (160), and the two gears (162) are respectively meshed with the two racks (163); The outer wall of the forward and reverse bidirectional screw (160) is threadedly connected to the inner wall of the threaded through hole (27), and the two fixed moving mechanisms (14) are respectively arranged on the upper surfaces of the two connecting blocks (161); The fixed moving mechanism (14) includes an operating block (140), a movable block (141), a clamping plate (142) and a plurality of springs (143), wherein: The lower surface of the operating block (140) is arranged on the upper surface of the connecting block (161), and a moving groove (21) is provided on one side of the operating block (140); The movable block (141) is slidably connected to the inner wall of the movable groove (21), and the clamping plate (142) is arranged on a side of the movable block (141) away from the operating block (140); One end of a plurality of the springs (143) is evenly arranged on the inner wall of the movable groove (21), and the other end of a plurality of the springs (143) is evenly arranged on one side of the movable block (141).

2. The off-line testing device for a new energy vehicle onboard charger according to claim 1 is characterized in that: The pushing mechanism (13) comprises a second electric push rod (130), two L-shaped connecting rods (131), two L-shaped pushing rods (132) and an X-shaped pushing plate (133), wherein: The second electric push rod (130) is arranged on one side of the housing (10), and the piston rod of the second electric push rod (130) passes through the housing (10) and is arranged on one side of the X-shaped push plate (133); The inner wall of the movable cavity (2) is symmetrically provided with an L-shaped movable through groove (3) and a movable through hole (6), and the two L-shaped connecting rods (131) pass through the corresponding movable through holes (6) and are symmetrically arranged on the outer wall of the "X"-shaped push plate (133); The outer walls of the two L-shaped push rods (132) are fitted to the inner walls of the corresponding L-shaped movable through grooves (3), and the upper surfaces of the two L-shaped push rods (132) are arranged on the lower surfaces of the corresponding L-shaped connecting rods (131); The control panel (5) is electrically connected to the second electric push rod (130) via an electric wire.

3. The off-line testing device for a new energy vehicle onboard charger according to claim 1 is characterized in that: The inner wall of the movable cavity (2) is evenly and symmetrically provided with a first sliding groove (7), the outer wall of the movable block (12) is evenly provided with a first sliding block (8), and the outer wall of the first sliding block (8) is slidably connected to the inner wall of the first sliding groove (7).

4. The off-line testing device for a new energy vehicle onboard charger according to claim 2 is characterized in that: The outer wall of the housing (10) is symmetrically provided with a second sliding groove (9), and a second slider (20) is provided on the adjacent side of the two L-shaped connecting rods (131), and the outer wall of the second slider (20) is slidably connected to the inner wall of the second sliding groove (9).

5. The off-line testing device for a new energy vehicle onboard charger according to claim 1 is characterized in that: The inner top wall and the inner bottom wall of the movable groove (21) are respectively provided with a third sliding groove (24), and the upper surface and the lower surface of the movable block (141) are respectively provided with a third sliding block (25), and the outer wall of the third sliding block (25) is slidably connected to the inner wall of the third sliding groove (24).

6. The off-line testing device for a new energy vehicle onboard charger according to claim 1 is characterized in that: Steel balls (23) are evenly embedded on the upper surface of the moving block (12).

7. The off-line testing device for a new energy vehicle onboard charger according to claim 1 is characterized in that: A rubber layer (22) is provided on a side of the clamping plate (142) away from the operating block (140).

8. The off-line testing device for a new energy vehicle onboard charger according to claim 1 is characterized in that: The inner wall of the movable through hole (26) is evenly provided with a fourth sliding groove (29), the outer wall of the connecting block (161) is evenly provided with a fourth sliding block (30), and the outer wall of the fourth sliding block (30) is slidably connected to the inner wall of the fourth sliding groove (29).

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