Testing method of charging gun tester

Abstract

The invention discloses a test method for a charging gun tester, and the method comprises the steps: obtaining test data and a leakage current at a charging interface after a to-be-tested charging gun is inserted into the charging interface; judging whether the leakage current is greater than or equal to a preset leakage current threshold value; if yes, sending out a corresponding alarm prompt and / or cutting off a power supply, and if not, generating a display signal corresponding to the test data, and controlling each display screen to display according to the display signal; judging whether the current running state meets a sleep condition or not; if yes, whether a wake-up signal exists or not is judged, and if yes, the sleep mode is quitted. Therefore, after the test method is adopted, when overcurrent and overvoltage occur, the power supply can be cut off in time, and the alarm is given out, so that the fault expansion is avoided, and the test safety is ensured; after the test, the test data can be displayed on different display screens, real-time synchronous display of multiple data is realized, the test efficiency is improved, when the sleep condition is met, the system enters a sleep state, and the energy consumption is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of charging gun testing, and in particular to a testing method of a charging gun tester. Background Art

[0002] Against the backdrop of the rapid development of the new energy vehicle industry, charging guns, as core components of conductive charging systems, face a direct impact on charging safety through standardized and accurate quality testing. Current national standards such as GB / T18487.1-2015 impose strict requirements on parameters such as insulation performance, overcurrent protection response time, and signal integrity for charging gun testing equipment. However, existing charging gun testing equipment faces the following technical bottlenecks:

[0003] 1. Technical Issues Faced by Security Requirements

[0004] 1. The current charging gun detection equipment on the market has safety risks. It faces hidden dangers such as corona corrosion of insulating materials and micro-cracks in the insulation layer caused by mechanical vibration. At the same time, there are no online insulation monitoring sensors installed, and detection can only be made through regular manual inspections. The risk of leakage current exceeding the standard (standard value ≤ 30mA) is detected. Actual measured data shows that when the leakage current suddenly increases to 40mA, the traditional method has a missed detection rate of up to 25%, which cannot meet the safety specification of "insulation fault warning within 0.5 seconds" in GB / T 34984-2017 "Safety Requirements for Electric Vehicles". There are major safety hazards such as electric shock accidents or fires in charging equipment caused by insulation failure.

[0005] 2. For active safety mechanisms such as overcurrent protection and overheating protection, traditional testing requires manual simulation of fault scenarios, which poses a risk of electric shock during the operation and cannot verify the protection response time (for example, the national standard requires the overcurrent protection action time to be ≤100ms, which existing technology cannot accurately measure). Ground continuity testing relies on manual multimeter measurement, which may cause misjudgment due to poor contact (the standard value of ground resistance is ≤0.1Ω, and the manual measurement error rate is ≥15%).

[0006] 2. Technical issues facing reliability requirements: High temperature resistance test. In the high temperature operation test (70°C, 4 hours) according to GB / T 2423.2-2016, the linear deformation rate of the shell reached 0.52%, resulting in a 0.25mm radial offset of the probe mounting base and a coaxial deviation of >1.2° between the probe and the charging gun socket. This offset caused the contact area to change from the standard value of 2.5mm to 1.2°. 2 Reduced to 1.2mm 2 , the contact resistance suddenly increased from 30mΩ to 45mΩ (an increase of 50%), exceeding the contact resistance limit of ≤50mΩ specified in IEC 61851-1, causing the temperature to exceed the standard when large current is transmitted (the measured temperature rise is 65K, exceeding the 50K limit specified in the national standard GB / T 18487.1-2015). Summary of the Invention

[0007] In view of the above shortcomings, the technical problem to be solved by the present invention is: to provide a testing method for a charging gun tester, which can perform charging gun testing and has the advantages of high operational safety and low power consumption.

[0008] In order to solve the above technical problems, the technical solution of the present invention is:

[0009] A method for testing a charging gun tester, the charging gun tester comprising a charging interface, a main control unit, and a plurality of display screens respectively communicatively connected to the main control unit; the testing method comprising the following steps:

[0010] S10, obtaining test data and leakage current at the charging interface;

[0011] S20, determining whether the leakage current is greater than or equal to a preset leakage current threshold;

[0012] S30, if the leakage current is greater than or equal to a preset leakage current threshold, generating a corresponding alarm signal;

[0013] If the leakage current is not greater than or equal to a preset leakage current threshold, a display signal corresponding to the test data is generated;

[0014] S40, issuing a corresponding alarm prompt and / or cutting off the power supply according to the alarm signal;

[0015] According to the display signal, control each display screen to display the corresponding test data;

[0016] S50, determining whether the current running state meets the sleep condition;

[0017] S60: If the current running state meets the sleep condition, enter the sleep mode and determine whether there is a wake-up signal;

[0018] S70. If there is a wake-up signal, exit the sleep mode.

[0019] Preferably, the current operating state in S50 includes a no-operation state and a test state, and S50 specifically includes:

[0020] S500, determining whether the duration of the no-operation state reaches a preset first time or a preset second time, and determining whether the test state is test completed;

[0021] S501: If the duration of the inactivity state does not reach the preset first time, the shallow sleep condition is met;

[0022] If the duration of the inactivity state reaches a preset first time, the deep sleep condition is met;

[0023] If the inactivity time reaches a preset second time and the test status is test completed, the deep sleep condition is met;

[0024] The S60 includes:

[0025] If the current running state meets the shallow sleep conditions, it enters the sleep mode;

[0026] If the current operating state meets the deep sleep conditions, the backlight brightness of the control display will be reduced to 10% and enter deep sleep mode;

[0027] If the current running state meets the deep sleep condition, only the wake-up unit and the clock unit are kept running and the system enters the deep sleep mode.

[0028] The preferred method is that the wake-up signal includes a timed wake-up signal, an external interrupt signal and a bus wake-up signal; when entering the sleep mode, the clock unit starts timing, and after the timing time is up, the timed wake-up signal is output to the wake-up unit; when the charging gun is inserted into the charging port, the external interrupt signal is input to the wake-up unit; when the bus signal is received, the bus wake-up signal is output to the wake-up unit.

[0029] Preferably, the charging gun tester further includes a rocker switch, a rocker switch and a first power socket, the first power socket is used to output power, the rocker switch is electrically connected to the charging interface and the first power socket respectively, and the rocker switch is electrically connected to the charging interface; the testing method further includes the following steps before S10: S00, inserting the charging gun to be tested into the charging interface, operating the rocker switch and the rocker switch to connect the rocker switch to the first power socket, and establishing the charging state of the charging gun.

[0030] Preferably, the charging gun tester further includes a second power socket electrically connected to the rocker switch, and the second power socket is connected to an external power supply; the S00 further includes: inserting the charging gun to be tested into the charging interface, connecting the second power socket to an external power supply, operating the rocker switch and the rocker switch to connect the rocker switch to the second power socket, and establishing a self-damage detection state for the charging gun.

[0031] Preferably, the charging gun tester also includes three current detection circuits for detecting three-phase current, each of the current detection circuits includes a current transformer, a first signal conversion circuit, a first signal amplification circuit and a first analog-to-digital conversion circuit electrically connected in sequence, the first analog-to-digital conversion circuit is electrically connected to the main control unit, and the current transformer is used to detect the current of the output line of the first power socket; the display unit includes three two-color digital display screens; the test data includes three-phase current; the S40 also includes: according to the display signal, controlling the three two-color digital display screens to display the corresponding current.

[0032] Preferably, the charging gun tester further includes a transformer and three voltage detection circuits for detecting three-phase voltage, each of the voltage detection circuits includes a first resistor voltage divider circuit, a second signal amplification circuit and a second analog-to-digital conversion circuit electrically connected in sequence, and the second analog-to-digital conversion circuit is electrically connected to the main control unit; the transformer is electrically connected to the rocker switch, and the rocker switch is also electrically connected to the first resistor voltage divider circuit; the test data includes three-phase voltage; the S40 also includes: according to the display signal, controlling three two-color digital display screens to display the corresponding voltage.

[0033] Preferably, the charging gun tester further includes a CC resistance detection unit, which includes a second resistance voltage divider circuit, a second signal conversion circuit, a third signal amplification circuit, and a third analog-to-digital conversion circuit electrically connected in sequence, wherein the second resistance voltage divider circuit is electrically connected to the rocker switch, the rocker switch is electrically connected to the charging port, and the third analog-to-digital conversion circuit is electrically connected to the main control unit; the display unit includes a monochrome digital display screen; the test data includes CC resistance; and S40 includes: controlling the monochrome digital display screen to display CC resistance according to the display signal.

[0034] Preferably, the charging gun tester further includes a waveform display unit, which is electrically connected to the main control unit, and synthesizes a dynamic power curve according to the formula P=V*I*COSΦ; the display unit includes a touch screen; the test data includes a power curve; and S40 further includes: controlling the touch screen to display the dynamic power curve according to the display signal.

[0035] Preferably, the charging gun tester further includes a CP voltage detection circuit, which includes a voltage divider circuit, an impedance conversion circuit, a fourth signal amplification circuit and a fourth analog-to-digital conversion circuit electrically connected in sequence, the fourth analog-to-digital conversion circuit is electrically connected to the main control unit, and the voltage divider circuit is electrically connected to the rocker switch; the display unit includes a touch screen; the test data includes a PWM waveform corresponding to the CP voltage; and S40 further includes: controlling the touch screen to display the PWM waveform according to the display signal.

[0036] After adopting the above technical solution, the beneficial effects of the present invention are:

[0037] Due to the testing method of the charging gun tester of the present invention, after the charging gun to be tested is inserted into the charging interface, the test data and the leakage current at the charging interface are obtained; it is determined whether the leakage current is greater than or equal to the preset leakage current threshold; if the leakage current is greater than or equal to the preset leakage current threshold, a corresponding alarm signal is generated; if the leakage current is not greater than or equal to the preset leakage current threshold, a display signal corresponding to the test data is generated; according to the alarm signal, a corresponding alarm prompt is issued and / or the power is cut off; according to the display signal, each display screen is controlled to display the corresponding test data; it is determined whether the current operating state meets the sleep condition; if the current operating state meets the sleep condition, the sleep mode is entered, and it is determined whether there is a wake-up signal; if there is a wake-up signal, the sleep mode is exited. It can be seen that after adopting the testing method of the present invention, when overcurrent or overvoltage occurs, the power is cut off in time and a warning is issued to avoid the expansion of the fault and ensure the safety of the entire testing process; after the test starts, the test data can be displayed on different display screens, realizing real-time synchronous display of multiple data, significantly improving the test efficiency. When the sleep condition is met, the sleep state is entered, which reduces energy consumption and meets the use requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 This is a flow chart of a testing method for a charging gun tester in the present invention;

[0039] Figure 2 This is a circuit diagram of the charging gun tester of the present invention;

[0040] Figure 3 This is a circuit diagram of a rocker switch in the present invention;

[0041] Figure 4 It is a principle block diagram in the embodiment;

[0042] Figure 5 It is a structural diagram of the charging gun tester in the invention;

[0043] In the figure: 1-housing, 2-rocker switch, 3-rocker switch, 4-touch screen, 5-monochrome digital display, 6-dual-color digital display, 7-first power socket, 8-second power socket, 9-charging port. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0045] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside", and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0046] Furthermore, it should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0047] like Figure 2 and Figure 5 As shown, the charging gun tester used in the present invention includes a main control unit, multiple display screens respectively connected to the main control unit, a rocker switch 2, a rocker switch 3, a first power socket 7, and a second power socket 8. The first power socket 7 is used to output power, the rocker switch 2 is electrically connected to the charging port 9 and the first power socket 7, respectively, the rocker switch 3 is electrically connected to the charging port 9 and the second power socket 8, respectively, and the second power socket 8 is connected to an external power source. The main control unit can be, but is not limited to, a microprocessor such as an STM32 series microcontroller. The main control unit can communicate with each display screen via an SPI bus (speed 10Mbps) to obtain three types of parameters: voltage, current, and CC resistance (insulation resistance / contact resistance, resolution 0.1MΩ / 1mΩ).

[0048] like Figure 2 and Figure 5 As shown, the rocker switch 3 includes a first static contact SK0, a second static contact SK2, and a movable contact SK1 electrically connected to the first and second static contacts SK0 and SK2, respectively. The first static contact SK0 is electrically connected to the first power outlet 7 and the charging port 9, respectively. The second static contact SK2 is electrically connected to the second power outlet 8. The movable contact SK1 is electrically connected to a transformer, which provides an operating voltage. When the rocker is toggled, when the movable contact SK1 connects to the first static contact SK0, the transformer connects to the first power outlet 7. When the movable contact SK1 connects to the second static contact SK2, the transformer connects to the second power outlet 8.

[0049] like Figure 3As shown, the rocker switch includes a first switch S1 and a second switch S2. One end of the first switch S1 is electrically connected to the CP probe of the charging port 9, and the other end of the first switch S1 is electrically connected to the positive electrode of the Zener diode D. The negative electrode of the Zener diode D is grounded via a first resistor R1. One end of the second switch S2 is electrically connected to the negative electrode of the Zener diode D via a second resistor R2, and the other end of the second switch S2 is grounded GND.

[0050] like Figure 1 As shown, a testing method for a charging gun tester includes the following steps:

[0051] Step S10: Acquire test data and leakage current at the charging interface;

[0052] Step S20: determining whether the leakage current is greater than or equal to a preset leakage current threshold; the preset leakage current threshold may be, but is not limited to, 30 mA;

[0053] Step S30: If the leakage current is greater than or equal to a preset leakage current threshold, a corresponding alarm signal is generated;

[0054] If the leakage current is not greater than or equal to a preset leakage current threshold, a display signal corresponding to the test data is generated;

[0055] Step S40: issuing a corresponding alarm prompt and / or cutting off the power supply according to the alarm signal;

[0056] According to the display signal, control each display screen to display the corresponding test data;

[0057] Step S50: determine whether the current running state meets the sleep condition;

[0058] Step S60: If the current running state meets the sleep condition, enter the sleep mode and determine whether there is a wake-up signal;

[0059] Step S70: If there is a wake-up signal, exit the sleep mode.

[0060] The test method of the charging gun tester of the present invention is to detect the leakage current at the charging interface after inserting the charging gun to be tested into the charging interface. When overcurrent or overvoltage occurs, the power supply is promptly cut off and a warning is issued, such as a warning issued through a display screen, to remind the staff that there is a risk at this time, thereby avoiding the expansion of the fault and ensuring the safety of the entire testing process. After the test starts, the signal detection unit can be used to obtain the test data. The signal detection unit may include a CC resistance detection circuit, a CP voltage detection circuit, a current detection circuit, and a voltage detection circuit, and the test data is displayed on different display screens, realizing real-time synchronous display of multiple data, significantly improving the test efficiency. At the same time, when the sleep conditions are met, it enters the sleep state, reduces energy consumption, and meets the use requirements.

[0061] It should be noted that: the charging port has a built-in bidirectional transient voltage diode and a 100mA fast-blow fuse in parallel to form a multi-level surge protection structure; the main control unit can be integrated with an independent safety monitoring unit to collect leakage current signals in real time. When a leakage current ≥30mA is detected, the power supply will be cut off within 0.2 seconds and an alarm will be issued. The alarm can be an audible and visual alarm, with a buzzer ≥85dB and a flashing red LED. It can be displayed directly on the display screen, such as displaying red, screen flashing, etc., to achieve overvoltage and overcurrent protection.

[0062] The current operating state in step S50 of the present invention includes a no-operation state and a test state, and the sleep mode in step S60 includes a shallow sleep, a deep sleep and a deep sleep.

[0063] Step S50 in the testing method of the present invention specifically includes:

[0064] Step S500: Determine whether the inactivity duration t reaches a predetermined first time or a predetermined second time, and determine whether the test is complete. Specifically, the predetermined first time may be 5 minutes, and the predetermined second time may be 10 minutes. The inactivity duration t may be measured by, but is not limited to, a clock unit within the main control unit.

[0065] Step S501: If the duration of the inactivity state does not reach the preset first time, that is, t<the preset first time, the shallow sleep condition is met, and step S600 is executed;

[0066] If the duration of the inactivity state reaches a preset first time, that is, t≥preset first time, the deep sleep condition is met, and S601 is executed;

[0067] If the inactivity time reaches a preset second time and the test state is test completed, that is, t≥preset second time, the deep sleep condition is met and S602 is executed;

[0068] Step S60 includes:

[0069] S600: If the current running state meets the shallow sleep condition, enter the sleep mode;

[0070] S601: If the current operating state meets the deep sleep condition, control the display screen backlight brightness to 10% and enter the deep sleep mode;

[0071] S602: If the current running state meets the deep sleep condition, only the wake-up unit and the clock unit are kept running, and the system enters the deep sleep mode.

[0072] It can be seen that the present invention adopts a three-level sleep mechanism: shallow sleep: after 5 minutes of no operation, the touch screen backlight brightness is reduced to 10%, and the non-core circuit power consumption is ≤1W; deep sleep: 10 minutes after the detection task is completed, the PMIC deep sleep mode is activated, the main processor frequency is reduced to 1MHz, and the power consumption of the whole machine is ≤5W; wake-up response: supports timed wake-up, external interrupt wake-up (such as charging gun insertion trigger), and bus signal wake-up, and the wake-up time is ≤200ms. At the same time, the charging gun tester of the present invention includes a power management circuit, which realizes energy efficiency optimization after adopting the three-level sleep mechanism. After entering the sleep mode, the power management circuit can use dynamic voltage frequency scaling (DVFS) technology to adjust the supply voltage in real time according to the load (adjustment step size 0.1V), and the standby energy consumption is reduced by 80% compared with traditional equipment. Continuous standby for 30 days can save 19.2kW·h of electricity.

[0073] This invention reduces energy consumption by 30%. Its core is a three-level power consumption control architecture. The real-time clock (RTC) built into the main control unit works in conjunction with an event trigger unit (wake-up unit). After completing a preset test task, a 10-minute countdown mechanism is initiated, triggering the power management circuit (PMIC) to execute a deep sleep instruction. In the sleep state, dynamic voltage frequency scaling (DVFS) technology is used to reduce the processor frequency in the main control unit to below 1MHz, while non-essential peripheral circuits are simultaneously shut down. Only the clock unit and the low-power wake-up unit remain operational, achieving a breakthrough energy saving of ≤5W for the entire system.

[0074] It has been verified that compared with the standby power consumption (about 25W) of traditional devices using a fixed threshold wake-up strategy, the present invention reduces standby power consumption by up to 80% under the same working conditions (72 hours of continuous monitoring according to GB / T 22450.1-2022 standard).

[0075] The wake-up signal in step S70 of the present invention includes a timed wake-up signal, an external interrupt signal and a bus wake-up signal; when entering the sleep mode, the clock unit starts timing, and when the timing time is up, the timed wake-up signal is output to the wake-up unit; when the charging gun is inserted into the charging port, the external interrupt signal is input to the wake-up unit; when the bus signal is received, the bus wake-up signal is output to the wake-up unit.

[0076] The multi-level wake-up path configured in this invention supports three modes: scheduled wake-up, external interrupt wake-up, and bus signal wake-up. The wake-up response time is controlled within 200ms, ensuring the rapid response capability of the charging gun tester in low-power states. This invention also effectively solves the problem of energy waste in intermittent operation scenarios, providing an innovative solution for low-power application scenarios such as IoT terminal devices and smart sensors. Experimental data shows that over a 30-day test cycle, the cumulative standby energy consumption is reduced by 19.2kW·h compared to traditional solutions, significantly extending the service life of battery-powered devices.

[0077] like Figure 1 As shown, the present invention can perform charging gun self-damage detection and charging gun charging test. Based on this, the testing method of the present invention further includes the following step S00 before step S10. S00 specifically includes:

[0078] S000. Insert the charging gun to be tested into the charging port, operate the rocker switch and the rocker switch, connect the rocker switch to the first power socket, and establish the charging state of the charging gun.

[0079] S001. Insert the charging gun to be tested into the charging port, connect the second power socket to an external power source, operate the rocker switch and the rocker switch to connect the rocker switch to the second power socket, and establish the self-test state of the charging gun.

[0080] like Figure 2 and Figure 5 As shown, when testing the charging status of the charging gun, the double rocker switch 2 is toggled to open the first switch S1 and the second switch S2, so that the charging interface 9 is connected to the charging gun to be tested to simulate the charging status of the charging gun; at the same time, the rocker arm of the rocker switch 3 is toggled (upward) to connect the moving contact SK1 and the first static contact SK0, and the first power socket 7 is connected to the power supply from the charging gun. At this time, after the power supply is connected to the primary side of the transformer, a 5V working voltage can be output on the secondary side to power each unit in the charging gun tester of the present invention.

[0081] like Figure 2 and Figure 5 As shown, when the charging gun itself is damaged, after the second power socket 8 is powered (mains power can be used for power supply), the rocker arm of the rocker switch 3 is toggled (downward) to connect the moving contact SK1 and the second static contact SK2, and the second power socket 8 is connected to the mains, so that the primary side of the transformer is connected to 220V and the secondary side outputs 5V working voltage to power each unit in the charging gun tester of the present invention. At the same time, the double boat-type switch 2 is toggled to open the first switch S1 and the second switch S2, so that the charging interface 9 is connected to the charging gun to be tested. At this time, a self-damage test is performed, and the test data is displayed on each display screen. The accuracy of the test data can be used to determine whether the charging gun has self-damage. When the test data is correct, it indicates that the charging gun has not self-damaged. When the test data is incorrect, it indicates that the charging gun has self-damaged and no other tests are required.

[0082] like Figure 4 and Figure 5 As shown, the test data in the present invention includes three-phase current; at this time, step S40 also includes: controlling the three dual-color digital display screens 6 to display the corresponding current according to the display signal.

[0083] The three-phase current is detected separately by three current detection circuits. Specifically, each current detection circuit includes a current transformer, a first signal conversion circuit, a first signal amplification circuit and a first analog-to-digital conversion circuit electrically connected in sequence. The first analog-to-digital conversion circuit is electrically connected to the main control unit, and the current transformer is used to detect the current of the output line of the first power socket 7.

[0084] The display unit includes three dual-color digital display screens 6.

[0085] The specific operating principle is as follows: After the charging gun under test is connected through the charging port 9, the induction coils on the neutral / live / ground wires generate a magnetic field based on the Hall effect to detect the current in the tested circuit. This current is transmitted to the first signal conversion circuit, which converts the current signal into a voltage signal. This voltage signal is then transmitted to the first signal amplification circuit, which amplifies the voltage signal to fit within the reception range of the ADC analog input circuit and calculates the current value using Ohm's law. The sample-and-hold circuit samples discrete values ​​during the signal input process and maintains the amplitude constant. The quantization circuit divides the discrete values ​​into several levels corresponding to several digital codes. The encoding circuit converts the quantized signal into a binary digital code. That is, the analog signal is processed by the first analog-to-digital conversion circuit and converted into a corresponding digital signal. This digital signal is then converted into a corresponding display signal by the main control unit. The display signal is then transmitted to the corresponding phase's two-color digital display 6, which displays the current value. Three two-color digital display screens 6 are allocated to the three phases, that is, each two-color digital display screen 6 displays the current and voltage signals of the same phase in a split screen.

[0086] like Figure 4 and Figure 5 As shown, the test data in the present invention includes three-phase voltages; at this time, step S40 also includes: controlling the three dual-color digital display screens 6 to display corresponding voltages according to the display signal.

[0087] The three-phase voltage is detected separately by three voltage detection circuits. Specifically, each voltage detection circuit includes a first resistor voltage divider circuit, a second signal amplification circuit, and a second analog-to-digital conversion circuit electrically connected in sequence. The second analog-to-digital conversion circuit is electrically connected to the main control unit; the transformer is electrically connected to the rocker switch 3, and the rocker switch 3 is also electrically connected to the first resistor voltage divider circuit.

[0088] The specific operating principle is as follows: After the charging gun under test is connected through the charging port 9, the 220V high-voltage cable output of the charging gun is converted to a low-voltage 5V power supply via a transformer. The first resistor divider circuit collects the voltage of the output line. This voltage signal is transmitted to the second signal amplifier circuit, which amplifies the voltage signal to fit within the receiving range of the analog input circuit of the ADC and calculates the voltage value using Ohm's law. The sample-and-hold circuit samples discrete values ​​during the signal input process and maintains the amplitude constant. The quantization circuit divides the discrete values ​​into several levels corresponding to several digital codes. The encoding circuit converts the quantized signal into a binary digital code, which is then transmitted to the three dual-color digital display screens 6 via the main control unit to display the voltage. That is, after the analog signal is processed by the second analog-to-digital conversion circuit, it is converted into a corresponding digital signal. This digital signal is then converted into a corresponding display signal by the main control unit. After the display signal is transmitted to the corresponding dual-color digital display screen 6, the voltage value is displayed. In addition, the three voltage detection circuits and the three current detection circuits can share a single analog-to-digital conversion circuit, such as the first analog-to-digital conversion circuit.

[0089] like Figure 4 and Figure 5 As shown, the test data in the present invention includes CC resistance; in this case, step S40 specifically includes: controlling the monochrome digital display screen 5 to display CC resistance according to the display signal.

[0090] In the present invention, the CC resistance is detected by a CC resistance detection unit. Specifically, the CC resistance detection unit includes a second resistance divider circuit, a second signal conversion circuit, a third signal amplification circuit and a third analog-to-digital conversion circuit electrically connected in sequence. The second resistance divider circuit is electrically connected to the rocker switch 2, the rocker switch 2 is electrically connected to the charging interface 9, and the third analog-to-digital conversion circuit is electrically connected to the main control unit.

[0091] The display unit includes a monochrome digital display screen 5 .

[0092] The specific working principle is as follows: after the charging gun to be tested is connected through the charging interface 9, the CC resistance is detected, the second resistor voltage divider circuit forms a voltage divider circuit through a known resistor and the resistor to be detected, and the voltage after voltage division is measured to infer the resistance value of the resistor to be detected, the second signal conversion circuit converts the voltage signal into a voltage signal, the third signal amplifier amplifies the voltage signal so as to adapt to the receiving range of the analog input circuit of the ADC, and uses Ohm's law to calculate the resistance value, the sampling and holding circuit samples discrete values ​​during the signal input process and keeps the amplitude unchanged, the quantization circuit divides the discrete values ​​into several levels, corresponding to several digital codes, the encoding circuit converts the quantized signal into a binary digital code, that is, the analog signal is processed by the third analog-to-digital conversion circuit and converted into a corresponding digital signal, which is then converted into a corresponding display signal by the main control unit. After the display signal is transmitted to the monochrome digital display screen 5 of the corresponding phase, the CC resistance value is displayed.

[0093] like Figure 4 As shown, the test data in the present invention includes a power curve; in this case, step S40 further includes: controlling the touch screen to display a dynamic power curve according to the display signal.

[0094] The charging gun tester also includes a waveform display unit, which is electrically connected to the main control unit. The main control unit can transmit the received voltage and current signals to the waveform display unit, which then synthesizes a dynamic power curve according to the formula P = V*I*COSΦ; where V is the three-phase voltage signal and I is the three-phase current signal. Figure 5 , the display unit includes a touch screen 4.

[0095] like Figure 4 As shown, the test data of the present invention includes a PWM waveform corresponding to the CP voltage; the S40 further includes: controlling the touch screen to display the PWM waveform according to the display signal.

[0096] The charging gun tester of this embodiment also includes a CP voltage detection circuit, which includes a voltage divider circuit, an impedance conversion circuit, a fourth signal amplification circuit and a fourth analog-to-digital conversion circuit electrically connected in sequence. The fourth analog-to-digital conversion circuit is electrically connected to the main control unit, and the voltage divider circuit is electrically connected to the rocker switch 2.

[0097] The specific working principle is: after the charging gun under test is connected through the charging interface 9, the front-end conditioning circuit (voltage divider circuit and impedance conversion circuit) detects the CP voltage signal input and pre-processes the signal through the voltage divider module and the impedance conversion module to ensure that the signal is within the level range of the ADC module input, which is convenient for ADC analog-to-digital conversion. The processed voltage signal is converted into a digital signal through the ADC module, that is, the analog signal is converted into a digital signal using the fourth analog-to-digital conversion circuit. In this process, the trigger circuit controls the sampling timing to ensure that the signal is collected when the signal appears, thereby improving the accuracy and integrity of the data. The measurement, display and analysis system receives and processes this data and converts it into a waveform image for real-time display.

[0098] like Figure 5 As shown, the charging gun tester of the present invention also includes a housing 1. This housing is made of UL94 V-0 flame-retardant ABS (halogen-free), with a heat deformation temperature of 110°C and a thermal expansion coefficient of 65 ppm / °C. Glass fiber reinforcement increases the tensile strength to 65 MPa, and the heat deformation temperature is 35% higher than that of ordinary ABS. Testing under the same conditions as GB / T 2423.2-2016 shows that the housing deformation rate at 70°C is reduced to 0.15% (meeting the 0.1% threshold), thus suppressing the impact of high-temperature deformation on probe positioning at the material level.

[0099] In summary, the charging gun tester and testing method of the present invention have the following advantages:

[0100] 1. Improved protection performance, specifically safety protection design: Reducing the damage rate of charging guns to zero: During effective testing, the interface burning problem caused by misoperation (such as mistakenly connecting to a high-voltage power supply) was eliminated. After 1,000 extreme overvoltage tests (input voltage 600VAC), the damage rate of the internal components of the tested charging guns was 0, an improvement of 100% compared to traditional unprotected circuit designs; the risk of electric shock to personnel was significantly reduced: the measured contact current value was ≤0.5mA (the national standard GB / T 18487.1 requires ≤10mA), and the probability of electric shock risk was reduced from the industry average of 30% to 0.02%, meeting the safety requirements of Class I equipment in GB 4706.1-2005 "Safety of Household and Similar Electrical Appliances".

[0101] Second, reliability is improved, with upgraded high-temperature-resistant housing materials. Housing 1 utilizes UL94 V-0 flame-retardant ABS (halogen-free), with a heat deformation temperature of 110°C and a thermal expansion coefficient of 65ppm / °C. Glass fiber reinforcement increases the tensile strength to 65MPa, and the heat deformation temperature is 35% higher than that of standard ABS. Testing under the same conditions as GB / T2423.2-2016 at 70°C reduces the housing deformation rate to 0.15% (meeting the 0.1% threshold), effectively suppressing the effects of high-temperature deformation on probe positioning.

[0102] 3. Improved efficiency and specification compatibility

[0103] 1. In terms of efficiency improvement, the multi-parameter real-time monitoring technology of the present invention has achieved a major breakthrough. Specifically, the charging power and voltage of the three signal lines L1, L2, and L3 can be measured synchronously and displayed simultaneously, CC resistance measurement, CP voltage, PWM duty cycle signal (normal peak value is 12V and -4V) and key electrical parameters such as charging power are displayed on the display screen for high-precision monitoring. By integrating high-speed data acquisition modules and parallel processing algorithms, the system can complete a single full-parameter measurement within 20 seconds, which is 15 times more efficient than the 5 minutes required by traditional measurement methods. In terms of accuracy, relying on high-precision sensor arrays, the accuracy of the measurement results has been greatly improved from the original 60% to 90%;

[0104] 2. Cost reduction: The integrated design reduces dependence on independent equipment such as multimeters, voltage testers, and oscilloscopes, reducing equipment procurement costs by 80%. The detection efficiency is reduced from 5 minutes to seconds for complex communication scenarios. The automatically generated fault analysis report includes a waveform diagram, reducing manual measurement time by 80%, significantly improving the testing efficiency of on-board charger communication compatibility.

[0105] The above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications made within the spirit and principles of the present invention, as well as improvements to the testing method of the charging gun tester, shall be included in the scope of protection of the present invention.

Claims

1. A testing method for a charging gun tester, characterized in that: The charging gun tester includes a charging interface, a main control unit, and a plurality of display screens respectively connected to the main control unit for communication; The testing method comprises the following steps: S10, obtaining test data and leakage current at the charging interface; S20, determining whether the leakage current is greater than or equal to a preset leakage current threshold; S30, if the leakage current is greater than or equal to a preset leakage current threshold, generating a corresponding alarm signal; If the leakage current is not greater than or equal to a preset leakage current threshold, a display signal corresponding to the test data is generated; S40, issuing a corresponding alarm prompt and / or cutting off the power supply according to the alarm signal; According to the display signal, control each display screen to display the corresponding test data; S50, determining whether the current running state meets the sleep condition; S60: If the current running state meets the sleep condition, enter the sleep mode and determine whether there is a wake-up signal; S70: If there is a wake-up signal, exit the sleep mode.

2. The testing method of the charging gun tester according to claim 1, characterized in that: The current operating state in S50 includes a no-operation state and a test state. S50 specifically includes: S500, determining whether the duration of the no-operation state reaches a preset first time or a preset second time, and determining whether the test state is test completed; S501: If the duration of the inactivity state does not reach the preset first time, the shallow sleep condition is met; If the duration of the inactivity state reaches a preset first time, the deep sleep condition is met; If the inactivity time reaches a preset second time and the test status is test completed, the deep sleep condition is met; The S60 includes: If the current running state meets the shallow sleep conditions, it enters the sleep mode; If the current operating state meets the deep sleep conditions, the backlight brightness of the control display will be reduced to 10% and enter deep sleep mode; If the current running state meets the deep sleep condition, only the wake-up unit and the clock unit are kept running and the system enters the deep sleep mode.

3. The testing method of the charging gun tester according to claim 2, characterized in that: The wake-up signal includes a timing wake-up signal, an external interrupt signal and a bus wake-up signal; When entering the sleep mode, the clock unit starts timing, and when the timing time is up, outputs a timed wake-up signal to the wake-up unit; When the charging gun is inserted into the charging port, an external interrupt signal is input to the wake-up unit; After receiving the bus signal, a bus wake-up signal is output to the wake-up unit.

4. The testing method of the charging gun tester according to claim 1, characterized in that: The charging gun tester further includes a rocker switch, a rocker switch, and a first power socket, wherein the first power socket is used to output power, the rocker switch is electrically connected to the charging port and the first power socket, respectively, and the rocker switch is electrically connected to the charging port; The testing method further includes the following steps before S10: S00. Insert the charging gun to be tested into the charging port, operate the rocker switch and the rocker switch, connect the rocker switch to the first power socket, and establish the charging state of the charging gun.

5. The testing method of the charging gun tester according to claim 4, characterized in that: The charging gun tester further includes a second power socket electrically connected to the rocker switch, and the second power socket is connected to an external power source; The S00 also includes: inserting the charging gun to be tested into the charging interface, connecting the second power socket to an external power supply, operating the rocker switch and the rocker switch to connect the rocker switch to the second power socket, and establishing a self-damage detection state for the charging gun.

6. The testing method of the charging gun tester according to claim 4, characterized in that: The charging gun tester also includes three current detection circuits for detecting three-phase current. Each current detection circuit includes a current transformer, a first signal conversion circuit, a first signal amplification circuit, and a first analog-to-digital conversion circuit electrically connected in sequence. The first analog-to-digital conversion circuit is electrically connected to the main control unit. The current transformer is used to detect the current of the output circuit of the first power socket. The display unit includes three dual-color digital display screens; The test data includes three-phase current; The S40 further includes: controlling the three dual-color digital display screens to display corresponding currents according to the display signal.

7. The testing method of the charging gun tester according to claim 4, characterized in that: The charging gun tester also includes a transformer and three voltage detection circuits for detecting three-phase voltage. Each voltage detection circuit includes a first resistor voltage divider circuit, a second signal amplification circuit, and a second analog-to-digital conversion circuit electrically connected in sequence. The second analog-to-digital conversion circuit is electrically connected to the main control unit. The transformer is electrically connected to a rocker switch, which is also electrically connected to the first resistor voltage divider circuit. The test data includes three-phase voltage; The step S40 further includes: controlling the three dual-color digital display screens to display corresponding voltages according to the display signal.

8. The testing method of the charging gun tester according to claim 4, characterized in that: The charging gun tester also includes a CC resistance detection unit, which includes a second resistance voltage divider circuit, a second signal conversion circuit, a third signal amplification circuit, and a third analog-to-digital conversion circuit electrically connected in sequence. The second resistance voltage divider circuit is electrically connected to the rocker switch, the rocker switch is electrically connected to the charging port, and the third analog-to-digital conversion circuit is electrically connected to the main control unit. The display unit includes a monochrome digital display screen; The test data includes CC resistance; The S40 includes: controlling the monochrome digital display screen to display the CC resistance according to the display signal.

9. The testing method of the charging gun tester according to claim 8, characterized in that: The charging gun tester further includes a waveform display unit, which is electrically connected to the main control unit and synthesizes a dynamic power curve according to the formula P=V*I*COSΦ; The display unit includes a touch screen; The test data includes a power curve; The step S40 further includes: controlling the touch screen to display a dynamic power curve according to the display signal.

10. The testing method of the charging gun tester according to claim 4, characterized in that: The charging gun tester further includes a CP voltage detection circuit, which includes a voltage divider circuit, an impedance conversion circuit, a fourth signal amplification circuit, and a fourth analog-to-digital conversion circuit electrically connected in sequence. The fourth analog-to-digital conversion circuit is electrically connected to the main control unit, and the voltage divider circuit is electrically connected to the rocker switch. The display unit includes a touch screen; The test data includes a PWM waveform corresponding to the CP voltage; The step S40 further includes: controlling the touch screen to display a PWM waveform according to the display signal.

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