All-in-one controller test system and test method
Through the all-in-one controller testing system with low-cost components and software control, the problems of high cost and incomplete simulation of traditional test equipment are solved, and flexible and efficient testing results are achieved, meeting the comprehensive evaluation and optimization of all-in-one controllers.
Patent Information
- Application Number
- CN202510439123.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-09
- Publication Date
- 2025-08-19
AI Technical Summary
The traditional all-in-one controller test equipment is expensive and it is difficult to fully simulate the actual working conditions of the charging and distribution system, resulting in large differences in the test results and insufficient test flexibility and repeatability.
Low-cost components such as 12V DC source, source-load integrated DC source, charging gun, power meter and Zhou Ligong CAN box are used to build a test system, combine software control to realize an automated test process, simulate the actual working conditions of the all-in-one controller, and monitor key parameters in real time through CAN message configuration and real-time monitoring.
Reduce testing costs, improve testing efficiency and accuracy, enhance testing flexibility and scalability, meet different testing needs, and achieve comprehensive evaluation and optimization of all-in-one controllers.
Smart Images
Figure CN120508078A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of electric vehicles, and more particularly to an all-in-one controller testing system and a testing method. Background Art
[0002] In rapidly developing fields such as new energy vehicles, energy storage systems, and smart grids, the performance and stability of charging and distribution systems and their all-in-one controllers are crucial. These systems often incorporate complex power conversion and control logic to ensure stable and efficient operation under various operating conditions. However, testing all-in-one controllers presents numerous challenges. Traditional testing equipment and methods are often costly, requiring not only high-precision measuring instruments but also complex test systems to simulate actual operating conditions. This not only increases R&D and testing costs but also limits test flexibility and repeatability. Furthermore, traditional testing equipment often struggles to fully simulate the actual operating conditions of charging and distribution systems, such as voltage fluctuations and load variations, resulting in significant discrepancies between test results and actual performance. Summary of the Invention
[0003] In view of this, the present invention provides an all-in-one controller testing system and testing method to solve the problems raised in the background technology.
[0004] In order to achieve the above-mentioned objectives, the present invention adopts the following technical solutions: on the one hand, a multi-in-one controller testing system is provided, comprising a multi-in-one controller to be tested, a source-load integrated DC source, a 12V DC source, a slow charging socket, a charging gun, a power meter, and a Zhou Ligong CAN box; wherein, the high-voltage bus input end of the multi-in-one controller to be tested is connected to the output end of the source-load integrated DC source; the power input end of the multi-in-one controller to be tested is connected to the 12V DC source; the Zhou Ligong CAN box is connected to the multi-in-one controller to be tested through a low-voltage signal end CAN line, and the other end of the Zhou Ligong CAN box is connected to the PC end; the AC input end of the multi-in-one controller to be tested is connected to the slow charging socket through a signal line, and the slow charging socket is also connected to the charging gun, and the charging gun is connected to the 220V AC power through the power meter.
[0005] By adopting the above technical solution, the following beneficial technical effects are achieved: the present invention designs a low-cost and efficient testing device that can fully simulate the actual working conditions of the charging and distribution system, realize a comprehensive evaluation of the all-in-one controller charging and distribution system, reduce testing costs while improving testing efficiency and accuracy.
[0006] Preferably, the Zhou Ligong CAN box is configured to simulate the CAN message test conditions required for each test item according to the test requirements of the all-in-one controller under test.
[0007] By adopting the above technical solution, the following beneficial technical effects are achieved: Zhou Liguo CAN box realizes the automatic writing of test processes, monitors key parameters such as current and voltage during the test in real time, and ensures the safety of the test process.
[0008] Preferably, it also includes a discharge gun and a household appliance, the AC input end of the tested all-in-one controller is connected to the slow charging socket through a signal line, and the slow charging socket is also connected to the discharge gun; the discharge gun is connected to the household appliance through the power meter, and is used to construct an AC load test environment for performing a discharge test.
[0009] Preferably, it also includes a resistor, which is connected to the all-in-one controller under test through a power meter. The DCDC test automation process is configured by using the Zhou Ligong CAN box to perform DCDC testing and ensure safety detection of the test process.
[0010] By adopting the above technical solution, the following beneficial technical effects are achieved: expensive electronic loads are replaced by resistors, thereby reducing test costs.
[0011] On the other hand, a method for testing an all-in-one controller is provided, which is performed using the all-in-one controller testing system. The specific steps include the following: Use the Zhou Ligong CAN box and its ZCANPRO software to configure the CAN message test conditions required to simulate each test item according to the test requirements of the all-in-one controller under test; After confirming that all components are connected properly, turn on the 12V DC source to provide low-voltage power to the all-in-one controller under test. Then turn on the source-load integrated DC source and set the bus voltage to 405V to simulate the current voltage of the vehicle battery pack. Then use Zhou Ligong's software ZCANPRO to edit the automated test process, interact with the all-in-one controller under test through the CAN bus, and verify whether the current self-test status is normal. After the verification is passed, the charging test begins, simulating the vehicle message required for the charging test. During the charging process, the verification method is used to monitor the feedback information of the tested all-in-one controller in real time. After the test is completed, a stop charging command is sent, and the self-test of the tested all-in-one controller is checked again to see if it is normal after the charging test. At the same time, the message data of the entire test process is uploaded to the ZCANPRO software for storage and analysis.
[0012] By adopting the above technical solution, the following beneficial technical effects are achieved: the flexibility and scalability of the all-in-one controller test are improved to meet different testing requirements. Not only charging testing but also DCDC testing can be realized, and the actual working environment is fully simulated, making it easier for users to analyze and optimize test results.
[0013] Preferably, the discharge test is performed when the all-in-one controller under test is connected to a discharge gun via a slow charging socket; and the DCDC test is performed when the all-in-one controller under test is connected to a resistor via a power meter.
[0014] Preferably, the feedback information of the tested all-in-one controller includes charging current and voltage.
[0015] It can be seen from the above technical solutions that, compared with the prior art, the present invention has the following beneficial technical effects: (1) The test bench is constructed using low-cost and easily available components such as a 12V DC power supply, an onboard charger, a source-load integrated DC source, a power meter, and a Zhou Ligong CAN box. This solution is not only low-cost and highly flexible, but also can better simulate the actual use scenarios of the charging and distribution system, greatly facilitating the testing needs of the charging and distribution system in the early stages of development. (2) Using a low-power, relatively low-cost integrated source-load DC source as the DC source and load source for the test, combined with a discharge gun, power meter and household appliances, to build an AC load test environment, significantly reducing the cost of test equipment, improving the flexibility and scalability of the test, and meeting different test requirements; (3) Through software control, different charging and distribution scenarios can be simulated to improve the flexibility and accuracy of the test; real-time data acquisition and monitoring functions are provided to facilitate users to analyze and optimize test results.
[0016] (4) Flexible interface and expansion slot design: It is convenient for users to add or replace test modules according to test requirements, improve the scalability of test equipment, and through the connection of multiple device configurations, the solution has the key function testing capabilities required for the development of all-in-one controllers for charging and distribution systems. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In order to more clearly illustrate the embodiments of the present invention 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 merely embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying any creative work.
[0018] Figure 1 It is the overall system structure diagram of the present invention; Figure 2 This is a system structure diagram for performing a charging test in Example 1 of the present invention; Figure 3 This is a system structure diagram for performing a discharge test in Example 2 of the present invention; Figure 4 This is a system structure diagram for performing DCDC testing in Example 3 of the present invention. DETAILED DESCRIPTION
[0019] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.
[0020] The present invention provides a low-cost all-in-one controller test solution with a charging and distribution system. The test bench is constructed using low-cost and easily available components such as a 12V DC power supply, an onboard charger, a resistor, a source-load integrated DC source, a power meter, and a Zhou Ligong CAN box. The overall structure of the system is as follows: Figure 1 As shown, this solution is not only low-cost and highly flexible, but can also better simulate the actual application scenarios of the charging and distribution system, greatly facilitating the testing needs of the charging and distribution system in the early stages of development.
[0021] Example 1 The present invention provides an all-in-one controller testing system, such as Figure 2 As shown, it includes the tested all-in-one controller, the source-load integrated DC source, the 12V DC source, the slow charging socket, the charging gun, the power meter, and the Zhou Ligong CAN box; wherein, the high-voltage bus input end of the tested all-in-one controller is connected to the output end of the source-load integrated DC source; the power input end of the tested all-in-one controller is connected to the 12V DC source; the Zhou Ligong CAN box is connected to the tested all-in-one controller through the low-voltage signal end CAN line, and the other end of the Zhou Ligong CAN box is connected to the PC end; the AC input end of the tested all-in-one controller is connected to the slow charging socket through the signal line, and the slow charging socket is also connected to the charging gun, and the charging gun is connected to the 220V AC power through the power meter.
[0022] Zhou Ligong CAN box configures the CAN message test conditions required to simulate each test item according to the test requirements of the all-in-one controller under test.
[0023] The test was performed using an all-in-one controller test system. The specific steps include the following: S1. Configure test conditions: Use the Zhou Ligong CAN box and its ZCANPRO software to configure the CAN message test conditions required to simulate each test item according to the test requirements of the all-in-one controller under test; S2. Perform OBC charging test: After confirming that all components are connected normally, turn on the 12V DC source to provide low-voltage power to the all-in-one controller under test, then turn on the source-load integrated DC source and set the bus voltage to 405V to simulate the current voltage of the vehicle battery pack. Then use Zhou Ligong's software ZCANPRO to edit the automated test process, interact with the all-in-one controller under test through the CAN bus, and verify whether the current self-test status is normal; S3. After the verification is passed, the charging test begins, simulating the vehicle message required for the charging test. During the charging process, the feedback information of the tested all-in-one controller is monitored in real time through the verification method; S4. After the test is completed, a stop charging instruction is sent, and the self-test of the tested all-in-one controller is checked again to see if it is normal after the charging test. At the same time, the message data of the entire test process is uploaded to the ZCANPRO software for storage and analysis.
[0024] Example 2 like Figure 3 As shown, this embodiment includes a discharge gun and a household appliance. This is the only difference from Example 1; the remaining connections are the same. This solution can be used when a discharge test is required. The AC input of the all-in-one controller under test is connected to a slow-charging socket via a signal line, which is also connected to the discharge gun. The discharge gun is connected to the household appliance via a power meter to create an AC load test environment for the discharge test. The operating principle is the same as in Example 1.
[0025] Example 3 like Figure 4 As shown, in this embodiment, a resistor is also included. The resistor is connected to the all-in-one controller under test through a power meter. By using the Zhou Ligong CAN box to configure the DCDC test automation process, the DCDC test is performed and the safety detection of the test process is ensured. When the DCDC test is required, it can be implemented according to this solution, and the working principle is the same as that of Example 1.
[0026] It can be seen that the present invention has the key function testing capabilities required for the development of an all-in-one controller for a charging and distribution system, and the test is flexible and scalable to meet different testing requirements.
[0027] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.
[0028] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. An all-in-one controller testing system, characterized in that: It includes an all-in-one controller under test, a source-load integrated DC source, a 12V DC source, a slow charging socket, a charging gun, a power meter, and a Zhou Ligong CAN box; wherein, the high-voltage bus input end of the all-in-one controller under test is connected to the output end of the source-load integrated DC source; the power input end of the all-in-one controller under test is connected to the 12V DC source; the Zhou Ligong CAN box is connected to the all-in-one controller under test through a low-voltage signal end CAN line, and the other end of the Zhou Ligong CAN box is connected to the PC end; the AC input end of the all-in-one controller under test is connected to the slow charging socket through a signal line, and the slow charging socket is also connected to the charging gun, and the charging gun is connected to the 220V AC power through the power meter.
2. The all-in-one controller testing system according to claim 1, characterized in that: The Zhou Ligong CAN box is configured to simulate the CAN message test conditions required for each test item according to the test requirements of the all-in-one controller under test.
3. The all-in-one controller testing system according to claim 1, characterized in that: It also includes a discharge gun and a household appliance. The AC input end of the tested all-in-one controller is connected to the slow charging socket through a signal line, and the slow charging socket is also connected to the discharge gun; the discharge gun is connected to the household appliance through the power meter, and is used to construct an AC load test environment for performing a discharge test.
4. The all-in-one controller testing system according to claim 1, characterized in that: It also includes a resistor, which is connected to the all-in-one controller under test through a power meter. The DCDC test automation process is configured by using the Zhou Ligong CAN box to perform DCDC testing and ensure safety detection during the testing process.
5. A method for testing an all-in-one controller, characterized in that: Testing is performed using the all-in-one controller testing system according to any one of claims 1 to 4, the specific steps comprising: Use the Zhou Ligong CAN box and its ZCANPRO software to configure the CAN message test conditions required to simulate each test item according to the test requirements of the all-in-one controller under test; After confirming that all components are connected properly, turn on the 12V DC source to provide low-voltage power to the all-in-one controller under test. Then turn on the source-load integrated DC source and set the bus voltage to 405V to simulate the current voltage of the vehicle battery pack. Then use Zhou Ligong's software ZCANPRO to edit the automated test process, interact with the all-in-one controller under test through the CAN bus, and verify whether the current self-test status is normal. After the verification is passed, the charging test begins, simulating the vehicle message required for the charging test. During the charging process, the verification method is used to monitor the feedback information of the tested all-in-one controller in real time. After the test is completed, a stop charging command is sent, and the self-test of the tested all-in-one controller is checked again to see if it is normal after the charging test. At the same time, the message data of the entire test process is uploaded to the ZCANPRO software for storage and analysis.
6. The all-in-one controller testing method according to claim 5, characterized in that: The discharge test is performed when the all-in-one controller under test is connected to a discharge gun through a slow charging socket; the DCDC test is performed when the all-in-one controller under test is connected to a resistor through a power meter.
7. The all-in-one controller testing method according to claim 5, characterized in that: The feedback information of the tested all-in-one controller includes charging current and voltage.