Charging cable detection method

Abstract

The invention belongs to the technical field of cable detection, and discloses a charging cable detection method, which comprises the steps of carrying out a dragging test on a charging cable, fixing one end of the charging cable, pulling the other end of the charging cable to swing left and right, carrying out reciprocating swing for thirty thousand times, judging whether the charging cable is abnormal or not, collecting the charging cable if the charging cable is abnormal, and hanging a weight at one end of the charging cable if the charging cable is abnormal. The charging gun rotates clockwise by 110 degrees and anticlockwise by 110 degrees and reciprocates for thirty thousand times, whether a signal line of the charging cable is broken or not is judged, if the signal line is broken, the charging cable is collected, and if the signal line is not abnormal, one end of the charging cable is fixed, straightened and forwards twisted for five circles and reversely twisted for five circles and reciprocates for thirty thousand times; and judging whether the charging cable is abnormal, if so, collecting the charging cable, and if not, meeting the detection requirement. Bending, pulling and twisting of the charging cable in the using process can be detected, and the quality of the charging cable can be judged.

Description

Technical Field

[0001] This invention relates to the field of cable testing technology, and more particularly to a method for testing charging cables. Background Technology

[0002] With the development of the new energy sector, new energy vehicles are gradually becoming a mode of transportation. New energy vehicles are typically charged using a combination of charging piles, charging cables, and charging guns through standardized interfaces. Charging methods for new energy vehicles include DC charging and AC charging. Home charging piles primarily use AC power, with charging times generally ranging from 4 to 6 hours. Public charging stations primarily use DC power, with charging times generally ranging from 30 to 60 minutes, enabling faster charging of new energy vehicles.

[0003] Due to the unreasonable design of the charging interface angle of some existing new energy vehicles, the charging gun is inserted into the charging interface at an angle from top to bottom. The bending degree at the connection between the charging cable and the charging gun is too large. After a period of use, the internal cables of the charging cables used in public charging stations are prone to breakage, affecting the use of the charging cables. At the same time, when new energy vehicle owners plug the charging gun into the vehicle, the charging cable is dragged, and when adjusting the angle of the charging gun, the charging cable is twisted. With prolonged use, the conductors in the internal cable core of the charging cable will undergo significant deformation, affecting the safety of DC charging cables.

[0004] During use, charging cables are dragged and twisted at least once and bent repeatedly. Currently, there are no testing methods for the problems that charging cables experience during use, making it impossible to judge the quality of charging cables used in charging piles. This leads to the need for frequent replacement of charging cables used in charging piles, causing huge losses to charging pile companies and operators.

[0005] Therefore, there is an urgent need for a testing method for charging cables to solve the above-mentioned technical problems. Summary of the Invention

[0006] The purpose of this invention is to provide a method for testing charging cables, which can detect the bending, pulling and twisting that the charging cable experiences during use, quickly determine the quality of the charging cable, control the quality of the charging cable, avoid frequent replacement of charging cables used in charging piles, and significantly reduce losses for charging pile companies and operators.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] A method for testing charging cables, comprising:

[0009] A drag test was conducted on the charging cable. One end of the charging cable was fixed, and the other end of the charging cable was pulled and swung left and right for 30,000 cycles.

[0010] Determine whether the charging cable is internally broken and whether the charging cable sheath is cracked;

[0011] If the charging cable is internally broken or the sheath is cracked, collect the charging cable; if the charging cable is normal, perform a bending test on the charging cable.

[0012] Suspend a weight at one end of the charging cable and attach a charging gun to the other end. Rotate the charging gun 110° clockwise and 110° counterclockwise for 30,000 cycles.

[0013] Determine whether the signal line of the charging cable is broken. If the signal line is broken, collect the charging cable. If the signal line is normal, perform a torsion test on the charging cable.

[0014] Fix one end of the charging cable, straighten the charging cable, twist the charging cable 5 times in the forward direction and 5 times in the reverse direction, repeating this process 30,000 times.

[0015] Adjust the charging cable to an untwisted state and determine whether the charging cable is broken, bulging, or twisted inside. Determine whether the charging cable's withstand voltage is normal. If the charging cable is abnormal, collect it. If the charging cable is normal, then the charging cable meets the test requirements.

[0016] As a preferred technical solution for testing charging cables, a scanner is used to scan the charging cable, and the scanning results are used to determine whether the charging cable has bulges or twists inside and whether the sheath is cracked.

[0017] As a preferred technical solution for testing charging cables, a withstand voltage tester is used to perform a withstand voltage test on the charging cable, and the withstand voltage of the charging cable is judged based on the test results.

[0018] As a preferred technical solution for the testing method of charging cables, the weight has a specification of 50N to 70N.

[0019] As a preferred technical solution for testing charging cables, when conducting a drag test on the charging cable, the swinging end of the charging cable should be at least 1m above the ground.

[0020] As a preferred technical solution for the testing method of charging cables, when conducting a drag test on the charging cable, one end of the charging cable is fixed to a bracket, and the other end is fixed to a moving vehicle. The moving vehicle is placed on a track, which is laid around the bracket and at least 1m above the ground. The moving vehicle moves back and forth along the track.

[0021] As a preferred technical solution for the detection method of charging cables, the speed of the mobile vehicle is 75m / min.

[0022] As a preferred technical solution for the detection method of charging cables, the two ends of the track are provided with limiting components.

[0023] As a preferred technical solution for the testing method of charging cables, when performing a bending test on the charging cable, the signal lines of the charging cable are connected in series, and a 2A current is applied to the connected signal lines. By monitoring the continuity of the 2A current, it is determined whether the signal lines inside the charging cable are broken during the bending test.

[0024] As a preferred technical solution for testing charging cables, the bending test of the charging cable is performed using a bending testing machine.

[0025] The beneficial effects of this invention are as follows:

[0026] The charging cable testing method provided by this invention involves sequentially performing drag, bending, and torsion tests on sample charging cables. After each test, the performance of the charging cable is assessed, identifying areas where the cable is weak and facilitating targeted improvements. Furthermore, dragging, bending, and torsion are the challenges charging cables encounter during vehicle charging. Therefore, this testing method addresses the actual usage conditions of the charging cable, providing a more comprehensive and targeted assessment of its quality. This avoids frequent replacements of charging cables at charging stations, reducing losses for charging station companies and operators. Attached Figure Description

[0027] Figure 1 This is a flowchart illustrating the testing method for charging cables provided by the present invention. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0029] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0031] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0032] like Figure 1 As shown in the figure, this embodiment provides a method for testing charging cables, which can specifically detect the bending, dragging and twisting that the charging cable experiences during use. This allows charging pile companies and operators to judge the quality of the charging cable, control the quality of the charging cable, avoid frequent replacement of charging cables used in charging piles, and reduce losses for charging pile companies and operators.

[0033] The testing method for charging cables includes the following steps:

[0034] Drag test is carried out on the charging cable. One end of the charging cable is fixed, and the other end is pulled to swing left and right, with 30,000 reciprocating swings. When the vehicle owner charges the vehicle, he will take the charging gun on the charging pile and move it to the charging port of the vehicle for plugging. When the vehicle owner moves the charging gun, the charging cable will be dragged. Since the parked states of the vehicles are inconsistent, the positions of the charging ports are also inconsistent. Conducting the left and right swing test on the charging cable is more in line with the actual usage situation, making the detection method of the charging cable more reasonable and targeted. Due to the fast charging function of the vehicle, a charging pile may charge 15 to 20 vehicles every day. The taking out and putting back of the charging gun will drag the charging cable. Therefore, each charging cable is dragged back and forth at least 30 to 40 times every day. Setting the detection value of 30,000 times can ensure that the charging cable for the charging pile will not be damaged due to frequent dragging within several years. Among them, the unfixed end of the charging cable swings to the left and returns to the center position, and then swings to the right and returns to the center position to complete one reciprocating swing.

[0035] Judge whether the inside of the charging cable is broken and whether the sheath of the charging cable is cracked. If the inside of the charging cable is broken, it will affect the charging of the vehicle. If the sheath of the charging cable is cracked, it will affect the service life of the charging cable.

[0036] If the inside of the charging cable is broken or the sheath is cracked, the quality of the charging cable cannot meet the standard of the drag test and cannot be subjected to subsequent detection. It belongs to unqualified products. At this time, the unqualified charging cables will be collected and recycled. If there is no abnormality after the detection of the charging cable that has passed the drag test, the drag test of the charging cable is qualified, and then the bending test can be carried out on the charging cable. Since one end of the charging cable is fixed to the charging pile and the other end is fixed to the charging gun, when the vehicle owner takes the charging gun and when charging the vehicle, the connection between the charging cable and the charging gun is in a bent state. Therefore, after the drag test of the charging cable, conducting the bending test is in line with the actual usage situation and improves the rationality of the detection method of the charging cable.

[0037] The bending test method is as follows: A weight is suspended from one end of the charging cable, and a charging gun is attached to the other end. When the charging gun is raised and fixed, the charging cable is in a vertical state under the action of the weight, which conforms to actual conditions and rationalizes the bending test method. The charging gun is rotated 110° clockwise and 110° counterclockwise, repeating this cycle 30,000 times. With the charging gun attached to the other end of the charging cable, the force at the bending point of the charging cable during rotation more closely reflects actual usage conditions, making the test results more reasonable. Due to the unreasonable design of the charging interface angle of some new energy vehicles, the charging gun may be inserted into the charging interface at an angle from top to bottom, resulting in excessive bending at the connection between the charging cable and the charging gun. Setting the rotation angle of the charging gun to 110° allows the bending angle of the charging cable to adapt to various charging interface designs, making the bending test results more reliable. If the charging cable is undamaged after 30,000 reciprocating bends, it can be guaranteed to function normally for several years, further rationalizing the charging cable testing method. The charging cable is attached to one end of the charging gun. The charging gun rotates 110° clockwise and returns to the center position, and then rotates 110° counterclockwise and returns to the center position, completing one reciprocating rotation.

[0038] The process involves checking if the signal wire of the charging cable is broken. If the signal wire is broken, the charging cable is collected. Because the signal wire is thin and is usually located at the edge of the charging cable, it experiences relatively greater stress when bent. If the signal wire is intact, it can be inferred that the charging cable is internally intact and can be used normally. If the signal wire is broken, the charging cable does not meet the testing requirements and will be collected and recycled.

[0039] If the signal line is normal, a torsion test is performed on the charging cable. After the car owner removes the charging gun, the angle of the charging gun is adjusted so that it aligns with the charging port. The charging gun is then rotated, and the charging cable twists as the gun rotates. The addition of the torsion test more closely reflects the actual usage of the charging cable, further improving the rationality of the charging cable testing method.

[0040] The torsion test method is as follows: Fix one end of the charging cable, straighten the cable, and twist it 5 times in the forward direction and 5 times in the reverse direction, repeating this cycle 30,000 times. Twisting the charging cable in the forward and reverse directions while it is taut places a more stringent stress on the cable than in actual use, allowing for a better assessment of its quality. One complete torsion cycle consists of twisting the cable 5 times in the forward direction and then returning it to an untwisted state, followed by twisting it 5 times in the reverse direction and then returning it to an untwisted state.

[0041] The charging cable is adjusted to an untwisted state to check for internal breaks, bulges, and twisting. At this point, the cable's internal structure is flat, making the detection of bulges and twisting more accurate. Furthermore, if the cable breaks internally after the torsion test, its torsion resistance is poor and it does not meet the testing standards. The withstand voltage test is then performed to determine if the charging cable's voltage is normal. Frequent torsion can cause conductor deformation. The withstand voltage test can identify this deformation, allowing for a quick assessment of the cable's quality. If the charging cable is abnormal, it does not meet the testing requirements and must be collected and recycled. If the charging cable is normal, it meets the testing requirements and possesses good performance and a long service life.

[0042] The charging cable testing method provided in this embodiment involves sequentially performing drag, bending, and torsion tests on the sample charging cable. After each test, the performance of the charging cable is assessed to identify its weaknesses, facilitating targeted improvements. Dragging, bending, and torsion are the challenges charging cables undergo during vehicle charging. Therefore, this testing method addresses the actual usage conditions of the charging cable, providing a more comprehensive and targeted assessment of its quality. This avoids frequent replacements of charging cables at charging stations, reducing losses for charging station companies and operators.

[0043] In this embodiment, a scanner is used to scan the charging cable, and the scan results are used to determine whether the internal structure of the charging cable is bulging, twisted, or whether the sheath is cracked. The scanner is a high-precision dent detector that uses infrared light to scan the charging cable, enabling it to determine whether the entire charging cable has bulges, pits, or sheath defects, thus allowing for the determination of whether the internal structure of the charging cable is bulging, twisted, or cracked.

[0044] Among them, the withstand voltage test of the charging cable is carried out by the withstand voltage tester. Based on the withstand voltage test results detected by the withstand voltage tester, it can be determined whether the withstand voltage of the charging cable is normal, whether the conductor of the charging cable has been deformed, and whether the charging cable meets the usage requirements.

[0045] In this embodiment, the weights are 50N to 70N. If the weights are too light, the charging cable will wobble when the charging gun rotates; if the weights are too heavy, the charging cable is prone to breakage, both affecting the bending test results. Setting the weights to 50N to 70N ensures that the charging cable remains vertical during the bending test and is not easily broken, making the bending test standard more reasonable. The weight specifications can be selected based on the wire diameter of the charging cable being tested; no specific limitations are imposed here.

[0046] In the towing test of the charging cable, the swinging end of the charging cable must be at least 1 meter above the ground. When the vehicle owner charges the vehicle, they need to lift the charging gun and drag the charging cable. The charging gun will be lifted to a certain height by the owner. Therefore, during the towing test, the charging cable is not fixed at one end and swings left and right at a height of at least 1 meter, which more closely reflects actual usage conditions, making the test results more reliable and the testing method more reasonable.

[0047] For example, when conducting a drag test on a charging cable, one end of the charging cable is fixed to a bracket, and the other end is fixed to a moving trolley. The moving trolley is placed on a track, which is laid around the bracket and at least 1 meter above the ground. The moving trolley moves back and forth along the track. As the moving trolley moves back and forth along the track, it causes the charging cable undergoing the drag test to swing left and right, simplifying the drag test operation and reducing the workload for testing personnel. The track and the bracket are separated by a certain distance; this distance needs to be determined based on the length of the charging cable being tested and is not specifically limited here. The moving trolley's speed is 75 m / min, close to human walking speed, making the drag test results more reliable. Furthermore, limiting devices are provided at both ends of the track to prevent the moving trolley from leaving the track. The reciprocating movement of the moving trolley is achieved by controlling the forward and reverse rotation of a motor inside the trolley. Preferably, the track is an arc-shaped track, making the drag test path more rational.

[0048] In this embodiment, during the bending test of the charging cable, the continuity of the signal lines in the charging cable is simultaneously detected. This helps the testing personnel determine how many bends the charging cable must undergo before the internal signal lines break, facilitating subsequent reinforcement of the charging cable. During the bending test, the signal lines in the charging cable are connected in series, and a 2A current is applied to the series-connected signal lines. The continuity of the 2A current is monitored in real time using a current monitoring device, allowing the determination of whether the internal signal lines of the charging cable break during the bending test. Connecting multiple signal lines in series means that a break in any one of them will affect the conduction of the 2A current, enabling the testing personnel to more quickly determine whether one or more of the signal lines are broken. A load cell can be used to apply a 2A current to both ends of the series-connected signal lines. The bending test of the charging cable is performed using a bending testing machine, which drives the charging gun to rotate back and forth. Specifically, the load cell can be connected to the bending tester via electrical signal. When the signal line breaks, the load cell sends an electrical signal to the bending tester, and the charging gun stops rotating. A counter is set on the bending tester, and the signal line breaks after the charging cable has undergone how many reciprocating bends based on the counter's display number, further improving the convenience of the testing personnel's work.

[0049] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for testing charging cables, characterized in that, include: A drag test was conducted on the charging cable. One end of the charging cable was fixed, and the other end of the charging cable was pulled and swung left and right for 30,000 cycles. Determine whether the charging cable is internally broken and whether the charging cable sheath is cracked; If the charging cable is internally broken or the sheath is cracked, collect the charging cable. If the charging cable is normal, a bending test is performed on the charging cable. Suspend a weight at one end of the charging cable and attach a charging gun to the other end. Rotate the charging gun 110° clockwise and 110° counterclockwise for 30,000 cycles. Determine whether the signal line of the charging cable is broken. If the signal line is broken, collect the charging cable. If the signal line is normal, perform a torsion test on the charging cable. Fix one end of the charging cable, straighten the charging cable, twist the charging cable 5 times in the forward direction and 5 times in the reverse direction, repeating this process 30,000 times. Adjust the charging cable to an untwisted state and determine whether the charging cable is broken, bulging, or twisted inside. Determine whether the charging cable's withstand voltage is normal. If the charging cable is abnormal, collect it. If the charging cable is normal, then the charging cable meets the test requirements.

2. The method for detecting charging cables according to claim 1, characterized in that, The charging cable is scanned using a scanner, and the results are used to determine whether there are bulges or twists inside the charging cable and whether the sheath is cracked.

3. The method for detecting charging cables according to claim 1, characterized in that, The charging cable is subjected to a withstand voltage test using a withstand voltage tester, and the withstand voltage of the charging cable is determined based on the test results.

4. The method for detecting charging cables according to claim 1, characterized in that, The weights have a specification of 50N to 70N.

5. The method for detecting charging cables according to claim 1, characterized in that, When the charging cable is dragged, the swinging end of the charging cable is at least 1m above the ground.

6. The method for detecting charging cables according to claim 5, characterized in that, When conducting a drag test on the charging cable, one end of the charging cable is fixed to a bracket, and the other end is fixed to a mobile vehicle. The mobile vehicle is placed on a track, which is laid around the bracket and is at least 1m above the ground. The mobile vehicle moves back and forth along the track.

7. The method for detecting charging cables according to claim 6, characterized in that, The speed of the mobile vehicle is 75 m / min.

8. The method for detecting charging cables according to claim 6, characterized in that, The track is equipped with limiting components at both ends.

9. The method for detecting charging cables according to claim 1, characterized in that, When performing a bending test on the charging cable, the signal lines of the charging cable are connected in series, and a 2A current is applied to the connected signal lines. By monitoring the continuity of the 2A current, it is determined whether the signal lines inside the charging cable break during the bending test.

10. The method for detecting a charging cable according to claim 1, characterized in that, The bending test of the charging cable is performed using a bending tester.

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