High-voltage component off-line testing device

Abstract

The invention discloses an off-line testing device for a high-voltage component. The off-line testing device is characterized in that a high-voltage simulation unit outputs direct-current voltage of more than 330V; the discharge load resistor is connected with a high-voltage output interface of the high-voltage component; the protocol playback unit is connected and communicated with the upper computer software and the CAN analyzer; the signal simulation unit is used for simulating CP signals and CC signals; the safety monitoring unit is provided with a pointer type voltmeter and a digital display type voltmeter in parallel; a 12V switching power supply is connected with a low-voltage power supply interface of the high-voltage component; and the temperature sensing unit is used for simulating and feeding back a temperature signal by a 10-kilohm resistor element.

Description

Technical Field

[0001] The present invention relates to the technical field of high-voltage component testing for new energy vehicles, and in particular to an off-line testing device for high-voltage components. Background Art

[0002] The high-voltage components of new energy vehicles (including on-board chargers (OBCs), air-conditioning compressors, power battery packs, and motor controllers) are the core systems for the safe operation of the entire vehicle. During maintenance or production testing, the high-voltage components need to be functionally verified to ensure that their performance meets standards. During testing and verification, the high-voltage components need to be installed back on the vehicle for verification, which is complicated to operate and occupies production line resources. Large test platforms are difficult to move and cannot support rapid deployment in remote maintenance points or teaching scenarios. Current offline testing technology has the following defects: traditional test equipment cannot accurately simulate real-world operating signals; there is a lack of reliable discharge circuit design, which can easily lead to no-load high voltage accumulation and pose a risk of electric shock; multi-level voltage monitoring is not integrated, and overvoltage / overcurrent faults cannot be responded to in real time; the test process cannot reproduce the dynamic charging logic of the entire vehicle. Summary of the Invention

[0003] The present invention is provided to solve the above-mentioned technical problems.

[0004] An off-line testing device for high-voltage components, including on-board chargers, air-conditioning compressors, power battery packs, and motor controllers, includes:

[0005] High-voltage simulation unit: high-voltage power supply, outputting DC voltage above 330V, connected to the high-voltage input interface of high-voltage components;

[0006] Discharge load resistor: a high-power wirewound resistor connected to the high-voltage output interface of the high-voltage component;

[0007] Protocol playback unit: host computer software and CAN analyzer, connected to the communication interface of high-voltage components;

[0008] Test box and unit modules arranged in the test box:

[0009] Signal simulation unit: includes a CP signal module composed of a PWM signal generator and a CC signal module composed of a 680Ω resistor element, and is only connected to the signal terminal of the on-board charger;

[0010] Safety monitoring unit: pointer voltmeter and digital voltmeter installed in parallel on the high-voltage DC line, low-voltage DC line and AC mains line;

[0011] Low voltage conversion unit: 12V switching power supply, connecting the low voltage power interface of high voltage components;

[0012] Temperature sensing unit: 10kΩ resistor, connected only to the onboard charger.

[0013] Furthermore, when testing the air conditioning compressor, the signal simulation unit and the temperature sensing unit are disabled;

[0014] When testing the power battery pack, disable the signal simulation unit, temperature sensor unit, and high-voltage simulation unit;

[0015] When testing the motor controller, disable the signal simulation unit and the temperature sensing unit, and enable three discharge load resistors connected across the three-phase output terminals of the motor controller.

[0016] Furthermore, the discharge load resistor is a wire-wound resistor with a rated power of 5000W and a resistance of 200Ω.

[0017] Furthermore, the PWM signal generator can support independent adjustment of duty cycle, frequency, and output voltage, with a duty cycle adjustment range of 0%-97% and a frequency adjustment range of 1kHz-8kHz.

[0018] Furthermore, the protocol playback unit collects standard CAN messages through the original vehicle communication diagnostic interface and stores them in the host computer software, supporting offline playback to trigger the high-voltage component working program.

[0019] Furthermore, the safety monitoring unit also includes a circuit breaker provided on the high-voltage DC line, the low-voltage DC line and the AC mains line.

[0020] Furthermore, the model of the high-voltage power supply is DQ-4000S-1000, the model of the discharge load resistor is RX20T-5000W / 200RJ, the model of the CAN analyzer is CANalyst-II, the model of the 12V switching power supply is S-200-12, and the model of the PWM signal generator is STM_OSC.

[0021] This invention uses a protocol playback unit (host computer software + CAN analyzer) to pre-store and replay standard CAN messages for multiple vehicle models, breaking through the closed communication protocol barriers of automobile manufacturers. Combined with a dynamically adjustable CP signal (duty cycle 0%-97%, frequency 1kHz-8kHz), it accurately simulates the interaction scenarios of different charging piles (on-board chargers, wall chargers, and seat chargers), thus overcoming the testing barriers caused by closed protocols.

[0022] The discharge load resistor actively consumes the output current of high-voltage components after operation (such as the 450V current of the OBC), eliminating the accumulation of high voltage at no load. The dual-display monitoring instrument (pointer + digital) monitors high-voltage input / output, low-voltage and mains power lines in parallel, with a response speed of ≤50ms. The pointer meter captures transient anomalies (such as voltage sag) in real time, and the digital display meter accurately records the value. Four independent circuit breakers quickly disconnect fault circuits.

[0023] Each unit module can be flexibly enabled on demand according to different high-voltage components; some unit modules can be integrated into a portable test box to support rapid maintenance deployment in maintenance workshops / remote areas.

[0024] Therefore, the present invention has the following beneficial effects:

[0025] 1. Achieve full-scenario, accurate offline testing of high-voltage components: By collaborating with a protocol playback unit and dynamically adjustable CP signals, this system breaks through the closed limitations of automotive communication protocols and accurately reproduces the entire vehicle's charging logic.

[0026] 2. Multiple safety protection mechanisms eliminate high-voltage risks: Discharging the load resistor consumes the output high-voltage current, and combined with millisecond-level monitoring and trip protection of the dual-display instrument, completely eliminates the risk of no-load high-voltage accumulation and electric shock.

[0027] 3. Modular test box design improves test efficiency and universality: Modules are enabled according to the test object, and the test box structure adapts to multi-scenario deployment, significantly improving the efficiency of single tests. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the architecture of the present invention;

[0029] Figure 2 This is a schematic diagram of the electrical connections when testing the on-board charger according to the present invention;

[0030] Figure 3 This is a schematic diagram of electrical connections when testing an air-conditioning compressor according to the present invention;

[0031] Figure 4 This is a schematic diagram of electrical connections when testing a power battery pack according to the present invention;

[0032] Figure 5 This is a schematic diagram of electrical connections when testing a motor controller according to the present invention.

[0033] As shown in the figure: 1. Test box; 2. High-voltage power supply; 3. Discharge load resistor; 4. Signal simulation unit; 5. Low-voltage conversion unit; 6. Safety monitoring unit. DETAILED DESCRIPTION

[0034] The present invention will be further described below with reference to the accompanying drawings and examples.

[0035] The present invention provides an off-line testing device for high-voltage components, which can directly test high-voltage components separately without the need for loading the entire vehicle for testing, and can simulate real working condition signals.

[0036] High-voltage components include on-board chargers, air-conditioning compressors, power battery packs, motor controllers, etc.

[0037] The high-voltage component offline testing device of the present invention includes a high-voltage simulation unit, a discharge load resistor 3, a signal simulation unit 4, a protocol playback unit, a safety monitoring unit 6, a low-voltage conversion unit 5, and a temperature sensing unit.

[0038] Figure 1 This is a schematic diagram of the architecture of the present invention, showing a high-voltage simulation unit and a discharge load resistor 3, and integrating a signal simulation unit 4, a safety monitoring unit 6, a low-voltage conversion unit 5 and a temperature sensing unit in a test box 1. The high-voltage simulation unit, the discharge load resistor 3, the test box 1 and the protocol playback unit together constitute a complete high-voltage component offline testing device.

[0039] When testing different high voltage components, some of the functional units used are also different, such as: Figure 2 As shown, when testing the on-board charger, all the above functional units (i.e., high-voltage simulation unit, discharge load resistor 3, signal simulation unit 4, protocol playback unit, safety monitoring unit 6, low-voltage conversion unit 5, temperature sensing unit) are required.

[0040] like Figure 3 As shown, when testing the air-conditioning compressor, there is no need to use the signal simulation unit and the temperature sensing unit.

[0041] The high voltage simulation unit includes an adjustable DC high voltage power supply 2, such as Figure 4 As shown, when testing the power battery pack, there is no need to use the high voltage power supply 2.

[0042] like Figure 5 As shown, when testing the motor controller, two additional discharge load resistors 3 are required, that is, three discharge load resistors 3 are respectively connected across the three-phase output terminals (U / V / W) of the motor controller to consume the current between the three phases.

[0043] Therefore, the present invention integrates a high-voltage simulation unit, a discharge load resistor 3, a signal simulation unit 4, a protocol playback unit, a safety monitoring unit 6, a low-voltage conversion unit 5 and a temperature sensing unit, and can realize offline testing of various high-voltage components.

[0044] The high-voltage simulation unit is an adjustable DC high-voltage power supply 2. The output end of the high-voltage power supply 2 is connected to the high-voltage input interface of the high-voltage component. The high-voltage power supply 2 can provide a stable DC voltage of 330V and above to simulate the voltage of the power battery pack, so that the high-voltage component can smoothly start the working procedure after testing the initial voltage signal; the high-voltage power supply 2 can use a DC regulated power supply, whose input end is connected to the mains, inputs AC220V±10% AC power, and inverter outputs DC with a maximum of 1000V4A, such as the DC regulated power supply of the brand "Dingqi" model DQ-4000S-1000.

[0045] Discharge load resistor 3 is a high-power wirewound resistor connected to the high-voltage output interface of the high-voltage component to form a complete high-voltage current loop. For example, the wirewound resistor model RX20T-5000W / 200RJ can safely consume at least 5000W of power. Discharge load resistor 3 is used to consume the discharge current of the high-voltage component, ensuring that the current is released after the high-voltage component is working. This solves the problem of high-voltage components not being able to work normally due to the accumulation of high voltage under no-load conditions, and eliminates the risk of high-voltage electric shock.

[0046] like Figure 2 As shown in the figure, the protocol playback unit consists of a host computer software and a CAN analyzer that can collect and store standard CAN messages of multiple vehicle models. The host computer software and the CAN analyzer are connected to the original vehicle diagnostic port through the CAN-L line and CAN-H line to obtain standard working messages, breaking through the closed protocol restrictions, pre-collecting vehicle model standard messages and storing them in the host computer software.

[0047] When testing high-voltage components, the host computer software and CAN analyzer are connected to the communication interface of the low-voltage interface of the high-voltage component through the CAN-L line and CAN-H line, and the corresponding message is sent to trigger the working program of the high-voltage component, so as to realize the offline playback of the message to trigger the operation of the high-voltage component.

[0048] Currently, there are a variety of host computer software and CAN analyzers on the market that can achieve the above functions, such as the CAN analyzer model CANalyst-II of the brand "Zhuhai Chuangxin" and the corresponding "CANPro Protocol Analysis Platform" host computer software.

[0049] The low-voltage conversion unit 5 is a 12V switching power supply that provides 12V low-voltage direct current for high-voltage components. Its input end is connected to the mains, and its output end is connected to the low-voltage power interface of the high-voltage component. The low-voltage conversion unit 5 can invert the input AC220V alternating current and output DC12V direct current, such as the switching power supply model S-200-12 of the brand "Hongming".

[0050] The signal simulation unit 4 is only connected and used when testing the on-board charger. It includes a CP signal module and a CC signal module. The CP signal module simulates the wake-up and handshake signal interaction between the charging gun and the on-board charger. The CC signal module simulates the connection confirmation of the charging gun, so that the on-board charger can normally identify the charging gun.

[0051] The CP signal module consists of a PWM signal generator, which is provided with a 12V working voltage by the low-voltage conversion unit 5. The output end of the CP signal module is connected to the signal terminal of the low-voltage interface of the vehicle charger; the PWM signal generator can output square wave signals, support independent adjustment of duty cycle, frequency, and output voltage, and can cover the entire scene from slow charging to fast charging, as well as accurately restore the interaction scenes of different charging piles (on-board charger / wall pile / seat pile); the PWM signal generator can be directly purchased and selected from existing devices on the market that can generate square waves, such as the oscilloscope model STM_OSC of the brand "Aiersay", which has a duty cycle adjustment range of 0%-97% and a frequency adjustment range of 1kHz-8kHz.

[0052] The CC signal module is a 680Ω resistor. One end of the module is connected to the corresponding signal terminal of the low-voltage interface of the on-board charger, and the other end can be connected to the ground of the on-board charger casing. It is used to simulate the resistance of the charging cable and confirm that the charging gun is properly connected to the vehicle.

[0053] The temperature sensing unit is also only connected and used when testing the on-board charger. It is a resistor element with a resistance value of 10kΩ. One end of the temperature sensing unit is connected to the corresponding terminal of the low-voltage interface of the on-board charger, and the other end can be connected to the ground of the on-board charger casing to simulate the charging seat contact temperature NTC and simulate the on-board charger to detect the charging environment temperature feedback signal.

[0054] The safety monitoring unit 6 integrates multi-level voltage monitoring and responds to overvoltage / overcurrent faults in real time; pointer voltmeters and digital voltmeters for measuring high-voltage DC are provided on the high-voltage DC lines of the high-voltage power supply 2 and the discharge load resistor 3, pointer voltmeters and digital voltmeters for measuring low-voltage DC are provided on the low-voltage DC line of the low-voltage conversion unit 5, and pointer voltmeters and digital voltmeters for measuring 220V AC are provided on the AC220V mains power line.

[0055] The analog and digital voltmeters on these four lines form a safety monitoring unit 6, capable of real-time monitoring of key voltage points with a response speed of ≤50ms. The digital voltmeter intuitively displays voltage values ​​for easy monitoring, while the analog voltmeter eliminates latency and, in some testing scenarios, can respond in real time, instantly identifying abnormal fluctuations such as voltage dips and large waveform changes. All four lines are equipped with circuit breakers to ensure testing safety and accurate workflow.

[0056] High voltage component test steps:

[0057] First, prepare to send the message. Connect the CAN analyzer to the corresponding communication diagnostic interface of the original vehicle through the CAN-H and CAN-L lines. Insert the charging gun to check whether the instrument prompts whether the charging is normal. If normal, use the upper computer software to directly collect the message, save the collected message and name it.

[0058] Then connect each line, collect the original vehicle message, and then the upper computer software and CAN analyzer are connected to the low-voltage communication interface of the high-voltage component through the CAN-H and CAN-L lines, waiting for the message to be sent to start the working program of the high-voltage component; the low-voltage conversion unit 5 is connected to the AC220V mains and connected to the low-voltage power supply interface of the high-voltage component to provide a 12V DC power supply to the high-voltage component; according to the different high-voltage components to be tested, the high-voltage power supply 2 and the discharge load resistor 3 in the high-voltage simulation unit are selectively increased or decreased and connected to the high-voltage interface of the high-voltage component to simulate the high-voltage current loop; if testing OBC, the signal simulation unit and the temperature sensor unit are both connected to the low-voltage interface.

[0059] Finally, start the test. Taking the OBC test as an example, first send a low-voltage 12V DC power supply and observe whether the low-voltage voltmeter displays normal results; turn on the high-voltage power supply switch and adjust it to 330V stable DC high voltage; after waiting for the DC / DC to work, the low-voltage DC meter displays a voltage of 11.3V-13V; start the signal simulation unit and the temperature sensor unit to simulate the CP, CC, and temperature signals; open the upper computer software to set the baud rate, frame number, and time, send the message, and start the high-voltage component; observe the voltmeter value set on the high-voltage power supply 2 line. If the displayed voltage value fluctuates between 330V and 450V, it means that the corresponding high-voltage component has successfully started and run; then use the CP signal module to independently adjust the duty cycle, frequency, and output voltage to simulate and restore various charging scenarios and states, and use the safety monitoring unit 6 to observe the various values, the upper computer software to read and monitor the data, and the working status of the high-voltage component to test whether the high-voltage component is working properly.

[0060] The present invention is not limited to the above-mentioned optimal implementation mode. Any other products that are identical or similar to the present invention and are derived by anyone under the inspiration of the present invention shall fall within the protection scope of the present invention.

Claims

1. A high-voltage component offline testing device, the high-voltage components include an on-board charger, an air-conditioning compressor, a power battery pack, and a motor controller, characterized in that: include: High-voltage simulation unit: high-voltage power supply, outputting DC voltage above 330V, connected to the high-voltage input interface of high-voltage components; Discharge load resistor: a high-power wirewound resistor connected to the high-voltage output interface of the high-voltage component; Protocol playback unit: host computer software and CAN analyzer, connected to the communication interface of high-voltage components; Test box and unit modules arranged in the test box: Signal simulation unit: includes a CP signal module composed of a PWM signal generator and a CC signal module composed of a 680Ω resistor element, and is only connected to the signal terminal of the on-board charger; Safety monitoring unit: pointer voltmeter and digital voltmeter installed in parallel on the high-voltage DC line, low-voltage DC line and AC mains line; Low voltage conversion unit: 12V switching power supply, connecting the low voltage power interface of high voltage components; Temperature sensing unit: 10kΩ resistor, connected only to the onboard charger.

2. The off-line testing device for high-voltage components according to claim 1, characterized in that: When testing the air conditioning compressor, disable the signal simulation unit and temperature sensing unit; When testing the power battery pack, disable the signal simulation unit, temperature sensor unit, and high-voltage simulation unit; When testing the motor controller, disable the signal simulation unit and the temperature sensing unit, and enable three discharge load resistors connected across the three-phase output terminals of the motor controller.

3. The off-line testing device for high-voltage components according to claim 1, characterized in that: The discharge load resistor is a wire-wound resistor with a rated power of 5000W and a resistance of 200Ω.

4. The high-voltage component offline testing device according to claim 1, characterized in that: The PWM signal generator can support independent adjustment of duty cycle, frequency and output voltage. The duty cycle adjustment range is 0%-97%, and the frequency adjustment range is 1kHz-8kHz.

5. The off-line testing device for high-voltage components according to claim 1, characterized in that: The protocol playback unit collects standard CAN messages through the original vehicle communication diagnostic interface and stores them in the host computer software, supporting offline playback to trigger the high-voltage component working program.

6. The off-line testing device for high-voltage components according to claim 1, characterized in that: The safety monitoring unit further comprises a circuit breaker arranged on the high voltage DC line, the low voltage DC line and the AC mains line.

7. The high-voltage component offline testing device according to claim 1, characterized in that: The high-voltage power supply model is DQ-4000S-1000, the discharge load resistor model is RX20T-5000W / 200RJ, the CAN analyzer model is CANalyst-II, the 12V switching power supply model is S-200-12, and the PWM signal generator model is STM_OSC.

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