Debugging method and equipment for water chilling unit of electric vehicle

Abstract

The method comprises the steps that a whole vehicle CAN interface of debugging equipment is connected to a whole vehicle CAN channel of an electric vehicle, and a water cooling CAN interface of the debugging equipment is connected to a CAN channel of a water cooling unit configured for the electric vehicle; the whole vehicle is powered on, debugging equipment is started after the whole vehicle is powered on, the debugging equipment sends a temperature adjusting instruction to the whole vehicle CAN channel, and the water chilling unit is controlled to conduct refrigeration or heating; and collecting parameters in the temperature regulation process of the water chilling unit, identifying whether a fault is reported or not, and if so, carrying out corresponding debugging. According to the invention, the debugging device actively sends the temperature adjustment instruction, the test process can be forcibly started at any environment temperature, and the test efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle battery temperature control technology, specifically to the debugging method and equipment for electric vehicle water-cooled units. Background Technology

[0002] As a core component of the power battery thermal management system, the performance of the water-cooled unit in electric vehicles directly affects the temperature uniformity, charging and discharging efficiency, and safe service life of the battery pack.

[0003] Traditional commissioning methods have two typical drawbacks: one is that the commissioning process is completely omitted, and the unit is put into use after only basic factory testing. This method cannot detect potential faults in the unit under real operating conditions. The other is a passive commissioning mode that relies on the natural heating of the power battery, requiring a long waiting period for the battery temperature to reach the test threshold. Therefore, both methods have shortcomings and urgently need improvement. Summary of the Invention

[0004] One of the objectives of this invention is to provide a commissioning method for water-cooled units in electric vehicles, which balances commissioning efficiency and accuracy.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A method for commissioning a water-cooled unit for electric vehicles, comprising: Connect the vehicle CAN interface of the debugging equipment to the vehicle CAN channel of the electric vehicle, and connect the water-cooled CAN interface of the debugging equipment to the CAN channel of the water-cooled unit configured in the electric vehicle. The vehicle is powered on, and the debugging equipment is started after power-on. The debugging equipment sends a temperature adjustment command to the vehicle's CAN channel to control the water-cooled unit to cool or heat. During the temperature adjustment process of the water-cooled unit, parameters are collected to identify whether a fault is reported. If so, corresponding adjustments are made.

[0006] Furthermore, the debugging equipment acquires the current temperature of the power battery, activates the heating mode, and raises the temperature of the power battery to the reference temperature. Continue heating the power battery until it reaches the test temperature, and record the first time required for the power battery to heat up from the reference temperature to the test temperature. Turn on the water cooling mode to cool down the power battery until it returns to the reference temperature, and record the second time required for the power battery to cool down from the test temperature to the test temperature. By comparing the difference between the calibrated first time threshold and the actual first time, and the difference between the calibrated second time threshold and the actual second time, it is determined whether the water-cooled unit has any abnormalities.

[0007] Furthermore, the debugging equipment is equipped with a temperature sensor to obtain the ambient temperature; Based on the calibrated mapping table of ambient temperature and time thresholds, the first time threshold and the second time threshold are corrected.

[0008] Furthermore, the debugging equipment is equipped with a temperature sensor to obtain the ambient temperature; based on the ambient temperature, the reference temperature and the test temperature are automatically adjusted according to the calibrated ambient temperature and temperature threshold mapping table.

[0009] Furthermore, during the recording of the first and second time periods, the debugging equipment collects and records the operating parameters of the water-cooled unit, which include at least the coolant flow rate, water pump power, and electronic expansion valve opening. When it is determined that there is an abnormality in the water-cooled unit, the operating parameters are compared with the calibrated standard parameter range to locate the core component where the abnormality occurred.

[0010] Furthermore, after completing a single heating and cooling test, the debugging equipment calculates the ratio of the actual first time to the first time threshold and the ratio of the actual second time to the second time threshold. If the difference in the ratio exceeds the preset value, it is determined that the water-cooled unit has an abnormal stability and a troubleshooting prompt is output.

[0011] Furthermore, the debugging equipment can send virtual extreme ambient temperature signals to the vehicle's CAN channel; control the water-cooled unit to perform preset heating-cooling tests under the extreme ambient temperature, and record fault codes and operating parameters in each cycle to identify whether there are any abnormalities.

[0012] Furthermore, during the heating and cooling tests, the debugging equipment collects real-time temperature data of multiple cells in the power battery pack. If the maximum temperature difference between different cells exceeds a preset threshold, it is determined that there is an abnormality in the heat exchange or pipeline distribution of the water-cooled unit, and the abnormal temperature area is marked and a troubleshooting prompt is output.

[0013] The second objective of this invention is to provide a commissioning system for water-cooled units in electric vehicles, which balances commissioning efficiency and accuracy.

[0014] To achieve the above objectives, the present invention adopts the following technical solution: A commissioning device for a water-cooled unit in an electric vehicle, comprising: The vehicle CAN interface is used to connect to the vehicle's CAN channel in the electric vehicle. The water-cooled CAN interface is used to connect to the CAN channel of the water-cooled unit in the electric vehicle. The control board is connected to the vehicle's CAN structure and the water-cooled CAN interface, and is used to implement the debugging method described above. The interaction unit includes a display screen and buttons for human-machine interaction with the control panel.

[0015] By adopting the above technical solution, the present invention has the following advantages compared with the prior art: 1. By actively sending temperature adjustment commands through the debugging equipment, the test process can be forcibly started at any ambient temperature, improving test efficiency; 2. Traditional methods rely on the natural temperature changes of the power battery for testing, resulting in long testing cycles and significant environmental interference. This solution actively controls temperature changes, limiting the testing range to between the reference temperature and the test temperature. This avoids the need to wait for the battery to naturally heat up or cool down for extended periods. Furthermore, by comparing quantified time parameters with preset thresholds, a repeatable testing standard is established, improving testing efficiency and result consistency.

[0016] 3. This invention introduces an ambient temperature sensing and threshold correction mechanism, or an ambient temperature sensing and time correction mechanism, so that the debugging standard can be adaptively adjusted with changes in ambient temperature, thus solving the test error problem caused by a fixed threshold.

[0017] 4. This invention can further identify local faults such as partial blockage in the flow channels of the water cooling system through test results. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the virtual testing process of the present invention; Figure 2 This is a schematic diagram of the simulation test process for the present invention; Figure 3 This is a topology diagram of the debugging device of the present invention; Figure 4 This is a schematic diagram of the core circuit of the debugging device of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Example

[0020] In existing technologies, water-cooled units are used to heat or cool power batteries, and their stable and reliable operation is extremely important. Currently, water-cooled units in electric vehicles are either not tested during commissioning or require waiting for the power battery temperature to rise naturally before starting the water-cooled unit for commissioning. The former has safety defects, and the latter is time-consuming and labor-intensive to test. For example, in low-temperature environments in winter, the power battery can take several hours to heat up naturally, resulting in low commissioning efficiency.

[0021] Therefore, please refer to Figure 1As shown, this application proposes a method for debugging a water-cooled unit for an electric vehicle, including: connecting the vehicle CAN interface of the debugging equipment to the vehicle CAN channel of the electric vehicle, and connecting the water-cooled CAN interface of the debugging equipment to the CAN channel of the water-cooled unit configured in the electric vehicle; powering on the vehicle, starting the debugging equipment after powering on, and sending a temperature adjustment command to the vehicle CAN channel to control the water-cooled unit to cool or heat; collecting parameters from the temperature adjustment process of the water-cooled unit, identifying whether it reports a fault, and if so, performing corresponding debugging. The debugging equipment refers to a dedicated testing device with dual CAN communication capabilities. Specifically, it can be implemented using an embedded device integrating a vehicle protocol parsing module and a water-cooled unit control module. This device connects to the vehicle's communication bus via a physical interface. The vehicle CAN interface is used to receive vehicle status data and send control commands, while the water-cooled CAN interface is a communication interface matched with the water-cooled unit controller to acquire the water-cooled unit's status data. Specifically, with the vehicle powered on, the testing equipment acquires the vehicle's operating status and water-cooled unit parameters via dual CAN channels. When a cooling command is sent, the testing equipment sends a simulated high-temperature environment signal to the vehicle's CAN channel, triggering the water-cooled unit to start the compressor for cooling. When a heating command is sent, it sends a simulated low-temperature environment signal to the vehicle's CAN channel, activating the water-cooled unit for heating. Throughout this process, the testing equipment continuously collects pressure, temperature, and current parameters from the water-cooled unit, automatically identifying anomalies using a pre-set fault code mapping table. For example, if a mismatch between the electronic expansion valve opening and coolant flow is detected, the testing program immediately triggers to adjust the valve control strategy. Therefore, by actively sending temperature adjustment commands through the debugging equipment, the testing process can be forcibly started at any ambient temperature, thus improving testing efficiency.

[0022] Please refer to Figure 2 As shown, this application further proposes a debugging device to obtain the current temperature of the power battery, activate the heating mode to raise the temperature of the power battery to the reference temperature; continue to raise the temperature of the power battery until the test temperature is reached, and record the first time required for the power battery to rise from the reference temperature to the test temperature; activate the water cooling mode to cool the power battery until it returns to the reference temperature, and record the second time required for the power battery to cool from the test temperature to the reference temperature; compare the difference between the calibrated first time threshold and the actual first time, and the difference between the calibrated second time threshold and the actual second time, to determine whether there is an abnormality in the water cooling unit. The reference temperature refers to the initial temperature that the power battery must reach before testing. This can be achieved by obtaining the surface temperature data of the power battery through the vehicle's CAN interface, providing consistent starting conditions for subsequent heating and cooling tests. The reference temperature should be as close as possible to the average temperature of the local area for the current season to shorten the heating time. For example, if the average autumn temperature in the local area is 27°C, the reference temperature can be set to 30°C. The test temperature refers to the target temperature that the power battery must reach in heating mode. This can be achieved through a preset temperature value or by dynamically adjusting based on the ambient temperature, for example, setting it to 10°C above the reference temperature.

[0023] The first time refers to the actual time it takes for the power battery to heat up from the reference temperature to the test temperature. This can be achieved by adjusting the built-in timer of the equipment, starting the timer when the heating command is triggered at the reference temperature, and stopping the timer when the temperature reaches the test temperature. Similarly, the second time refers to the actual time it takes for the power battery to cool down from the test temperature to the reference temperature. In this way, by comparing the measured time with a pre-calibrated threshold, for example, when the measured time exceeds the threshold by 20%, an abnormality can be identified, thus identifying efficiency abnormalities in the water-cooled unit during the heating or cooling process. Furthermore, by limiting the test range to between the reference temperature and the test temperature, for example, only requiring testing in the range of 30°C to 40°C, this invention avoids the long process of waiting for natural heating or cooling. It combines virtual debugging with real testing, taking into account both debugging time and accuracy. This application further proposes that the debugging equipment is equipped with a temperature sensor to obtain the ambient temperature, and that the first time threshold and the second time threshold are corrected according to a calibrated mapping table between ambient temperature and time threshold. Among them, the temperature sensor refers to a device used to monitor changes in the external ambient temperature in real time. This is a common sensor and will not be elaborated further. The ambient temperature and time threshold mapping table refers to the pre-calibrated heating and cooling time values ​​corresponding to different ambient temperatures. Its function is to establish the correlation between ambient temperature and time thresholds, allowing the first and second time thresholds to be adjusted based on the mapping table. For example, when the ambient temperature is high, the heating rate of the power battery may be faster. In this case, the mapping table will correspondingly shorten the reference threshold for heating time, avoiding misjudgment of a water-cooled unit malfunction due to a shortened heating time caused by ambient temperature.

[0024] This application also proposes another implementation method, namely, that the debugging equipment is equipped with a temperature sensor to obtain the ambient temperature, and the reference temperature and test temperature are automatically adjusted according to the calibrated ambient temperature and temperature threshold mapping table based on the ambient temperature.

[0025] Specifically, after the commissioning equipment is started, the temperature sensor continuously monitors the ambient temperature data and then calls a preset ambient temperature and temperature threshold mapping table to match the corresponding reference temperature and test temperature combination based on the current ambient temperature. For example, under low-temperature conditions with an ambient temperature of 5℃, the mapping table automatically adjusts the reference temperature to 10℃ and the test temperature to 20℃; while under high-temperature conditions with an ambient temperature of 35℃, the reference temperature is adjusted to 40℃ and the test temperature to 50℃. The commissioning equipment controls the water-cooled unit to perform temperature rise tests based on the adjusted temperature parameters, ensuring the adaptability of test conditions under different ambient temperatures.

[0026] Thus, by automatically matching ambient temperature with temperature threshold, this invention ensures the rationality of test parameters under different environmental conditions and avoids test result deviations caused by improper temperature threshold settings.

[0027] This application further proposes to collect and record the operating parameters of the water-cooled unit while recording the heating and cooling time parameters of the power battery. The operating parameters include at least the coolant flow rate, water pump power, and electronic expansion valve opening. When it is determined that there is an abnormality in the water-cooled unit, the operating parameters are compared with the calibrated standard parameter range to locate the core component where the abnormality occurred. Coolant flow rate refers to the volume of liquid flowing through the circulation pipes of the water-cooled unit per unit time. This can be monitored in real time using an electromagnetic flow meter or ultrasonic flow meter to determine if there is any blockage or leakage in the circulation system. Pump power refers to the electrical energy consumed by the pump driving the coolant circulation. This can be measured using a combination of current and voltage sensors to assess whether the pump's power output deviates from normal operating conditions. Electronic expansion valve opening refers to the degree of opening or closing of the valve that regulates refrigerant flow. This can be obtained using a stepper motor angle sensor or position encoder to analyze whether the refrigerant flow control accuracy is abnormal. Specifically, during the power battery temperature regulation test, the debugging equipment synchronously acquires parameters such as coolant flow rate, water pump power, and electronic expansion valve opening through a multi-channel data acquisition module, and forms a correlated dataset with the temperature regulation time data. When the system detects that the heating or cooling time exceeds the threshold, it automatically retrieves the operating parameters at the corresponding time point and compares them one by one with the preset standard parameter range. For example, if the coolant flow rate is lower than the lower limit of the standard value, and the water pump power increases significantly, it is determined that the water pump efficiency has decreased or the pipeline is blocked; if the electronic expansion valve opening deviates from the standard curve beyond the allowable range, it indicates that the expansion valve control is abnormal or that the refrigerant is leaking. Through the correlation analysis between parameters, the specific component causing the abnormal temperature regulation performance can be quickly identified. This application further proposes that after completing a single heating and cooling test, the debugging equipment calculates the ratio of the actual first time to the first time threshold and the ratio of the actual second time to the second time threshold. If the difference in the ratio exceeds the preset value, it is determined that the water-cooled unit has an abnormal stability and a troubleshooting prompt is output.

[0028] The ratio of the actual first time to the first time threshold refers to the ratio of the actual time taken to raise the power battery from the reference temperature to the test temperature to the standard heating time. The ratio of the actual second time to the second time threshold refers to the ratio of the actual time taken for the power battery to return from the test temperature to the reference temperature to the standard cooling time. A difference exceeding the preset value means that the relative deviation between the heating ratio and the cooling ratio exceeds the allowable range. Specifically, it can be set to an absolute value greater than or equal to 15%, used to identify coordination anomalies between cooling and heating modes. That is, when the difference between the calculated heating ratio and the cooling ratio exceeds the preset threshold, it indicates that there is a mismatch in response speed between the cooling and heating modes of the water-cooled unit, and an alarm is output for user troubleshooting.

[0029] This application further proposes to send a virtual extreme ambient temperature signal to the vehicle's CAN channel through debugging equipment, and control the water-cooled unit to perform a preset heating-cooling test under extreme ambient temperature. Among them, the virtual extreme ambient temperature signal refers to the ambient temperature data that exceeds the conventional test range, which is generated by software simulation. Specifically, it can be achieved by rewriting the value of the temperature parameter bits in the CAN protocol. It is used to trigger the water-cooled unit to enter the extreme condition test mode to verify the unit's operational stability under extreme temperatures.

[0030] This application further proposes that during the heating and cooling test, the debugging equipment collects real-time temperature data of multiple cells in the power battery pack. If the maximum temperature difference between different cells exceeds a preset threshold, it is determined that there is an abnormality in the heat exchange or pipeline distribution of the water-cooled unit, and the abnormal temperature area is marked and a troubleshooting prompt is output. The real-time temperature data collection of multiple cells within the power battery pack refers to multi-point monitoring of cell temperatures at different locations within the battery pack using a temperature sensor array or distributed temperature acquisition module. This is part of the vehicle's built-in battery pack thermal management technology and will not be elaborated upon here. When the maximum temperature difference exceeds a preset threshold, the coordinates of the cell location corresponding to the abnormal temperature area (highest or lowest) are highlighted in the interactive interface. This allows users to troubleshoot the cause of the temperature anomaly, such as uneven coolant flow distribution or pipe blockage. Please refer to Figure 3 and Figure 4As shown, this application further proposes a debugging device for an electric vehicle water-cooled unit, including a vehicle CAN interface for connecting to the vehicle CAN channel of the electric vehicle; a water-cooled CAN interface for connecting to the CAN channel of the water-cooled unit configured in the electric vehicle; a control board connected to the vehicle CAN interface and the water-cooled CAN interface for implementing the debugging method; and an interaction unit including a display screen and buttons for human-machine interaction with the control board. Example 2 is a system configuration for implementing Example 1. Therefore, for any parts not described in detail, please refer to the description of Example 1. It will not be repeated here.

[0031] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for commissioning a water-cooled unit for electric vehicles, characterized in that, include: Connect the vehicle CAN interface of the debugging equipment to the vehicle CAN channel of the electric vehicle, and connect the water-cooled CAN interface of the debugging equipment to the CAN channel of the water-cooled unit configured in the electric vehicle. The vehicle is powered on, and the debugging equipment is started after power-on. The debugging equipment sends a temperature adjustment command to the vehicle's CAN channel to control the water-cooled unit to cool or heat. During the temperature adjustment process of the water-cooled unit, parameters are collected to identify whether a fault is reported. If so, corresponding adjustments are made.

2. The commissioning method for electric vehicle water-cooled units as described in claim 1, characterized in that: The debugging equipment acquires the current temperature of the power battery, turns on the heating mode, and raises the temperature of the power battery to the reference temperature. Continue heating the power battery until it reaches the test temperature, and record the first time required for the power battery to heat up from the reference temperature to the test temperature. Turn on the water cooling mode to cool down the power battery until it returns to the reference temperature, and record the second time required for the power battery to cool down from the test temperature to the test temperature. By comparing the difference between the calibrated first time threshold and the actual first time, and the difference between the calibrated second time threshold and the actual second time, it is determined whether the water-cooled unit has any abnormalities.

3. The electric vehicle water-cooled unit commissioning method as described in claim 2, characterized in that: The debugging equipment is equipped with a temperature sensor to obtain the ambient temperature; Based on the calibrated mapping table of ambient temperature and time thresholds, the first time threshold and the second time threshold are corrected.

4. The commissioning method for electric vehicle water-cooled units as described in claim 2, characterized in that: The debugging equipment is equipped with a temperature sensor to obtain the ambient temperature; Based on the ambient temperature, the reference temperature and test temperature are automatically adjusted according to the calibrated ambient temperature and temperature threshold mapping table.

5. The commissioning method for electric vehicle water-cooled units as described in claim 2, characterized in that: During the recording of the first and second time periods, the debugging equipment collects and records the operating parameters of the water-cooled unit, including at least the coolant flow rate, water pump power, and electronic expansion valve opening. When an abnormality is detected in the water-cooled unit, the operating parameters are compared with the calibrated standard parameter range to locate the core component where the abnormality occurred.

6. The commissioning method for electric vehicle water-cooled units as described in claim 2, characterized in that: After completing a single heating and cooling test, the debugging equipment calculates the ratio of the actual first time to the first time threshold and the ratio of the actual second time to the second time threshold. If the difference in the ratio exceeds the preset value, it is determined that the water-cooled unit has an instability, and a troubleshooting prompt is output.

7. The commissioning method for electric vehicle water-cooled units as described in claim 1, characterized in that: The debugging equipment can send virtual extreme ambient temperature signals to the vehicle's CAN channel; control the water-cooled unit to perform preset heating-cooling tests under the extreme ambient temperature, and record fault codes and operating parameters in each cycle to identify whether there are any abnormalities.

8. The commissioning method for electric vehicle water-cooled units as described in claim 1, characterized in that: During the heating and cooling tests, the debugging equipment collects real-time temperature data of multiple cells in the power battery pack. If the maximum temperature difference between different cells exceeds a preset threshold, it is determined that there is an abnormality in the heat exchange or pipeline distribution of the water-cooled unit, and the abnormal temperature area is marked and a troubleshooting prompt is output.

9. A commissioning device for a water-cooled unit of an electric vehicle, characterized in that, include: The vehicle CAN interface is used to connect to the vehicle's CAN channel in the electric vehicle. The water-cooled CAN interface is used to connect to the CAN channel of the water-cooled unit in the electric vehicle. A control board, connected to the vehicle CAN structure and the water-cooled CAN interface, is used to implement the debugging method as described in any one of claims 1-8; The interaction unit includes a display screen and buttons for human-machine interaction with the control panel.

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