Fault setting and detecting device for pi-shaped new energy automobile charging system
The fault setting and detection device for new energy vehicle charging systems, with its π-shaped integrated design, solves the problems of cumbersome operation and unstable connection during the testing of new energy vehicle chargers. It achieves efficient and safe multi-interface connection and fault simulation, and is suitable for the production, maintenance and teaching of new energy vehicles.
Patent Information
- Application Number
- CN202511774845.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-03-03
AI Technical Summary
In the existing process of testing and simulating faults in new energy vehicle chargers, the operation is cumbersome, the connection stability is poor, the wiring harness is messy and there are safety hazards, which affects the testing efficiency and reliability.
Design a π-shaped fault setting and detection device for a new energy vehicle charging system. Integrate multiple functional plugs and wiring harnesses into a π-shaped structure to achieve synchronous connection of multiple interfaces. Integrate test function modules and fault setting boxes. Use high-temperature resistant materials and anti-slip design to optimize wiring harness layout.
It simplifies the operation process, improves testing efficiency, ensures connection stability, reduces safety hazards, and is suitable for various testing and fault simulation scenarios of new energy vehicles.
Smart Images
Figure CN121595993A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of new energy vehicle charging technology, and in particular to a π-shaped new energy vehicle charging system fault setting and detection device. Background Technology
[0002] With the increasing popularity of new energy vehicles, the demand for testing, diagnosis, and training of on-board chargers (OBCs) is growing. Currently, the mainstream solution in the industry for testing and simulating faults in on-board chargers is to use multiple separate functional plugs (such as CC, CP, CAN communication interfaces, etc.) to connect to the corresponding ports of the device in a "one-to-one" manner.
[0003] This discrete solution has significant drawbacks: First, it is cumbersome and inefficient to operate, requiring repeated plugging and unplugging of multiple plugs, which can interrupt the testing process, is time-consuming, labor-intensive, and prone to errors; second, the connection stability is poor, as multiple independent plugs are prone to loosening and falling off under vibration or accidental contact, affecting the accuracy and reliability of the test; third, the external wiring harness is numerous and messy, which not only takes up space and is inconvenient for maintenance, but also poses safety hazards such as tangling and short circuits, and has poor compatibility.
[0004] In summary, the industry urgently needs a dedicated device that can integrate multiple interfaces, simplify operation processes, optimize wiring harness layout, and significantly improve connection stability and security, in order to address the core pain points of existing technologies in terms of efficiency, reliability, and security. Summary of the Invention
[0005] This application provides a π-shaped fault setting and detection device for a new energy vehicle charging system to solve the above-mentioned problems.
[0006] On the one hand, this application provides a π-shaped new energy vehicle charging system fault setting and detection device, the device including: on-board charger female terminal connector (1), on-board charger male terminal connector (8), π-shaped device male terminal connector body (2), π-shaped device female terminal connector body (6), first test function lead-out module (3), second test function lead-out module (4), fault setting box (5) and connecting wire harness (7); the connecting wire harness (7) electrically connects the on-board charger female terminal connector (1), on-board charger male terminal connector (8), π-shaped device male terminal connector body (2), π-shaped device female terminal connector body (6), first test function lead-out module (3), second test function lead-out module (4) and fault setting box (5) according to the π-shaped topology structure to form an integrated functional unit, which is used to realize multi-interface synchronous connection with the on-board charger, online electrical parameter testing and simulation setting of multiple fault modes.
[0007] In one implementation of this application, the male plug body (2) and the female plug body (6) of the π-shaped device are made of high-temperature resistant engineering plastic, and their outer surfaces are provided with anti-slip textures, forming the vertical connection parts on both sides of the π-shaped structure.
[0008] In one implementation of this application, the first test function lead-out module (3) or the second test function lead-out module (4) includes at least two test points, which are respectively set at the upstream and downstream nodes of the π-shaped main line. The test points are equipped with standard test interfaces for connecting external test instruments to measure voltage, current, resistance or signal waveforms without disconnecting the main line connection.
[0009] In one implementation of this application, the standard test interface is a banana plug or a BNC interface.
[0010] In one implementation of this application, the fault setting box (5) is integrated into the middle or lateral connecting part of the π-shaped structure, and contains a switchable fault simulation circuit for simulating at least one fault in the setting charging connection confirmation line, control guidance line or electric vehicle controller local area network communication line.
[0011] In one implementation of this application, the fault simulation circuit can simulate at least one of the following fault types: open circuit, short circuit to the positive terminal of the power supply, short circuit to the vehicle body ground, poor contact, reverse connection of the circuit, abnormal signal frequency, or abnormal bus termination resistance.
[0012] In one implementation of this application, the fault setting box (5) is provided with a fault type selection switch or button on its surface, and a single fault or a combination of faults can be selected and set by operating the switch or button.
[0013] In one implementation of this application, the connecting harness (7) integrates at least one of the following: a charging connection confirmation terminal harness, a control guide terminal harness, an electric vehicle controller local area network (EVLAN) high-level harness, and an electric vehicle controller local area network (EVLAN) low-level harness, and the harness forms a series connection path on both sides of the π-shaped device.
[0014] In one implementation of this application, the on-board charger female connector (1) and the on-board charger male connector (8) are non-replaceable connectors customized according to the on-board charger interface specifications of a preset vehicle model, which are used to ensure reliable matching and connection with the on-board charger body interface.
[0015] The π-shaped fault setting and detection device for a new energy vehicle charging system provided in this application has the following beneficial effects: 1. Simplified Operation, Improved Testing and Fault Setting Efficiency: The "π"-shaped integrated structure design consolidates functions that previously required multiple separate plugs into one unit, enabling simultaneous connection of multiple interfaces and lines between the on-board charger and the testing / fault setting device with a single plug-in. This eliminates the need for repeatedly plugging and unplugging multiple plugs, greatly simplifying the operation process, significantly shortening preparation time for testing and fault setting, and effectively improving overall work efficiency.
[0016] 2. Optimized wiring harness layout, saving space and facilitating maintenance: The "π"-shaped overall layout allows branch lines to be orderly led out from the integrated plug body, reducing the messiness of traditional separate wiring harness designs and making the wiring harness layout more orderly and clear. This not only saves installation space, but more importantly, it enables quick location of branch nodes and functional modules during maintenance or troubleshooting, greatly improving maintenance efficiency. It is especially suitable for precision scenarios with strict space and layout requirements, such as high-position wiring harnesses in new energy vehicles.
[0017] 3. Improved Connection Stability and Reliability: The integrated structural design reduces the number of externally exposed connectors, thereby lowering the risk of failures caused by poor contact, loosening, corrosion, etc. Simultaneously, the integrated plug body, along with possible locking mechanisms such as clips (which can be configured according to actual needs), effectively avoids the problem of traditional discrete plugs easily detaching, ensuring connection stability during testing or fault simulation, guaranteeing accurate data acquisition and effective fault setting, and adapting to complex working environments such as automotive production and repair.
[0018] 4. Reduce safety hazards: The wiring harness is concentrated inside the main body of the device for connection and integration, and the external wiring harness is branched in an orderly manner through a "π"-shaped structure, which effectively avoids tangling, pulling and accidental damage between the wiring harnesses, reduces safety hazards such as short circuits and leakage, and improves the safety of the operation process.
[0019] 5. High integration of functions and strong applicability: This device integrates a test function lead-out module and a fault setting box, which can complete parameter measurement and simulation setting of various common faults (such as open circuit, short circuit, loose connection, reverse connection, etc. of CC, CP, and CAN line communication) on a single device. It has comprehensive functions and strong applicability, and can meet the needs of various scenarios such as production testing, maintenance diagnosis, teaching and scientific research of on-board chargers. Attached Figure Description
[0020] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 A schematic diagram of a π-shaped fault setting and detection device for a new energy vehicle charging system provided in this application embodiment; Figure 2 This is a pin layout diagram of the plug cross-section provided in an embodiment of this application; Figure label: Figure 1 The components include: 1. On-board charger female connector; 2. Pi-shaped device male connector body; 3. First test function lead-out module; 4. Second test function lead-out module; 5. Fault setting box; 6. Pi-shaped device female connector body; 7. Connecting wire harness; and 8. On-board charger male connector. Detailed Implementation
[0021] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0022] This application provides a π-shaped fault setting and detection device for a new energy vehicle charging system. The technical solution proposed in this application will be described in detail below with reference to the accompanying drawings.
[0023] Figure 1 This is a schematic diagram of a π-shaped fault setting and detection device for a new energy vehicle charging system provided in an embodiment of this application. Figure 1 As shown, the device includes: a female connector plug (1) for the on-board charger, a male connector plug (8) for the on-board charger, a male connector body (2) for the π-shaped device, a female connector body (6) for the π-shaped device, a first test function lead-out module (3), a second test function lead-out module (4), a fault setting box (5), and a connecting harness (7). The connecting harness (7) electrically connects the female connector plug (1), the male connector plug (8), the male connector body (2), the female connector body (6), the first test function lead-out module (3), the second test function lead-out module (4), and the fault setting box (5) according to a π-shaped topology, forming an integrated functional unit for realizing multi-interface synchronous connection with the on-board charger, online electrical parameter testing, and simulation setting of various fault modes. The on-board charger female connector (1) and the on-board charger male connector (8) are located at both ends of the device. The π-shaped device male connector body (2) and the π-shaped device female connector body (6) form the two vertical lines of the "π". The fault setting box (5) and the like are located on the horizontal bar of the "π" or on the corresponding connection line. The first test function lead-out module (3) and the second test function lead-out module (4) are led out from the main line. The π-shaped fault setting and detection device for a new energy vehicle charging system provided in this application has the following working principle: When in use, first, firmly connect the female connector (1) and male connector (8) of the on-board charger to the corresponding interface on the on-board charger body. At this time, the main circuit and signal path of the on-board charger are connected through the π-shaped male connector body (2), the π-shaped female connector body (6), and the internal connection harness (7) of this device. When parameter testing is required, connect the probe of the testing instrument (such as a multimeter or oscilloscope) to the corresponding interface of the test function lead-out module (3) or (4) to conveniently measure the voltage, resistance, waveform and other parameters of the test point, and realize the monitoring of the working status of the charger. When it is necessary to simulate a fault, operate the corresponding switch or button on the fault setting box (5) to select the fault type to be simulated (such as CC open circuit, CAN line short circuit, etc.). The circuit inside the fault setting box (5) will change the electrical state of the corresponding line accordingly, thereby introducing the set fault into the charging system to test the charger's response under various fault conditions, or to train maintenance personnel in fault diagnosis skills. Since the entire device is laid out in a "π" shape, all functional modules and wiring harnesses are effectively integrated and organized, making operation convenient, connection stable and reliable, and significantly improving work efficiency and safety.
[0024] In this application, the connections between the various components are as follows: (1) On-board charger female connector (1) and on-board charger male connector (8): The two are connected to the corresponding female and male interfaces of the on-board charger body respectively, and are used to realize the mechanical and electrical connection between the device and the on-board charger body. They are the main ports for the device to connect to the charger.
[0025] (2) The male plug body (2) and the female plug body (6) of the π-shaped device constitute the core connection part of the device. They are connected by internal wiring and cooperate with the female connector (1) of the on-board charger, the male connector (8) of the on-board charger, and the connecting harness (7) to form a "π"-shaped arrangement. Its main function is to provide a stable main path connection in normal system connection or emergency situations, and at the same time provide an integrated installation foundation for other functional modules. The male plug body (2) and the female plug body (6) of the π-shaped device are preferably made of high-temperature resistant material to adapt to the possible high-temperature environment inside the car. Their outer surfaces can be provided with anti-slip textures to facilitate plugging and unplugging operations.
[0026] Specifically, these two plug bodies form the two vertical branches of the "π" shape of the device, used for emergency connection in the main path or as the main connection node during testing, forming a π-shaped arrangement with other components. The plug bodies are made of high-temperature and aging-resistant engineering plastic material (such as PA66+GF30) to withstand temperature changes and vibrations in the automotive environment. Their outer surface has anti-slip textures for easy insertion and removal by operators. The specific arrangement order and internal pin definitions of the male plug body (2) and female plug body (6) of the π-shaped device are as follows: Figure 2 As shown, ensure that each line is correctly connected.
[0027] (3) First test function lead-out module (3) and second test function lead-out module (4): These two test function lead-out modules are connected to the wire harness led out from the π-shaped device plug body. Specifically, they can be set in the upstream and downstream lines of the plug body respectively. They are used to conveniently measure and acquire relevant electrical parameters such as voltage, resistance, current, and waveform of the upstream and downstream nodes of the plug body connection line. The test can be performed without disconnecting the main line.
[0028] For example, the first test function lead-out module (3) can be set on the line between the female connector plug (1) of the on-board charger and the male connector plug body (2) of the π-shaped device, and is used to test the parameters of the upstream (charger side) and downstream (device side) of this node; the second test function lead-out module (4) can be set on the line between the female connector plug body (6) of the π-shaped device and the male connector plug (8) of the on-board charger. These modules are usually equipped with standard test interfaces (such as banana plug sockets, BNC interfaces, etc.), which make it convenient to use multimeters, oscilloscopes and other test instruments to test the upstream and downstream of the connector body connection line separately, such as measuring voltage, resistance, current, or collecting CP signal waveforms, CAN bus data and other related parameters, without disconnecting the main connection line.
[0029] (4) The fault setting box 5 is integrated in the middle or a suitable position of the “π”-shaped structure and is connected to the plug body and internal circuitry through the connecting harness. Its main function is to simulate and set various common faults in the charging system, such as CC (charging connection confirmation) line fault, CP (control guidance) line fault, EVCAN (electric vehicle controller area network) communication line fault from the J533 gateway to the on-board charger (such as the A11 on-board charger), etc. The specific fault types that can be set include, but are not limited to: line open circuit, short circuit to power supply, short circuit to ground, poor contact (lack connection), reverse connection, etc. For the on-board charger of a certain German car, the fault setting box (5) can accurately set the following fault types: CC (Charging Connection Confirmation) faults include: open circuit in CC circuit, short circuit in CC circuit to the positive terminal of the power supply, short circuit in CC circuit to the vehicle body ground, and loose connection in CC circuit.
[0030] CP (Control and Guidance) faults include: open circuit in CP line, short circuit in CP line to positive power supply, short circuit in CP line to vehicle body ground, loose connection in CP line, and abnormal CP signal frequency (simulated by internal circuit).
[0031] J533 gateway to A11 on-board charger EV CAN (Electric Vehicle Controller Area Network) faults include: CAN_H line open circuit, CAN_L line open circuit, short circuit between CAN_H and CAN_L, CAN_H short circuit to positive power supply, CAN_H short circuit to vehicle ground, CAN_L short circuit to positive power supply, CAN_L short circuit to vehicle ground, abnormal CAN bus termination resistor, CAN signal loose connection, and CAN_H and CAN_L reverse connection.
[0032] (5) The connecting harness (7) is used to electrically connect the above components, namely the on-board charger female connector (1), the on-board charger male connector (8), the π-shaped device male connector body (2), the π-shaped device female connector body (6), the test function lead-out module (3), the test function lead-out module (4), and the fault setting box (5), etc., in a π-shaped topology. The connecting harness (7) integrates a variety of necessary terminal harnesses, such as the CC terminal harness, the CP terminal harness, the EV CAN harness from the J533 gateway to the A11 on-board charger, etc., and makes these harnesses form a series connection path on both sides of the π-shaped device to ensure effective signal and power transmission. The connecting harness (7) is integrated inside the device and on both sides of the π-shaped device, organically connecting all the above components. The wiring harness internally includes: CC terminal wiring harness, CP terminal wiring harness, EV CAN_H and CAN_L terminal wiring harness from the J533 gateway to the A11 on-board charger, and possible power positive and negative wiring harnesses (if required). These wiring harnesses are connected in series on both sides of the π-shaped device via internal connectors to ensure that signals and power are transmitted according to the designed path. The wiring harness uses high-temperature resistant, oil-resistant, low-smoke halogen-free insulated wires and is properly bundled and protected to ensure its durability and signal transmission quality in complex environments.
[0033] The various embodiments in this application are described in a progressive manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, the device embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions of the method embodiments.
[0034] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0035] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.
Claims
1. A fault setting and detection device for a π-shaped new energy vehicle charging system, characterized in that, The device includes: a female connector plug (1) for an on-board charger, a male connector plug (8) for an on-board charger, a male connector body (2) for a π-shaped device, a female connector body (6) for a π-shaped device, a first test function lead-out module (3), a second test function lead-out module (4), a fault setting box (5), and a connecting harness (7). The connecting harness (7) electrically connects the female connector plug (1), the male connector plug (8), the male connector body (2), the female connector body (6), the first test function lead-out module (3), the second test function lead-out module (4), and the fault setting box (5) according to a π-shaped topology, forming an integrated functional unit for realizing multi-interface synchronous connection with the on-board charger, online electrical parameter testing, and simulation setting of various fault modes.
2. The apparatus according to claim 1, characterized in that, The male plug body (2) and the female plug body (6) of the π-shaped device are made of high-temperature resistant engineering plastic. Their outer surfaces are provided with anti-slip textures and form the vertical connection parts on both sides of the π-shaped structure.
3. The apparatus according to claim 1, characterized in that, The first test function lead-out module (3) or the second test function lead-out module (4) includes at least two test points, which are respectively set at the upstream and downstream nodes of the π-shaped main line. The test points are equipped with standard test interfaces for connecting external test instruments to measure voltage, current, resistance or signal waveforms without disconnecting the main line connection.
4. The apparatus according to claim 3, characterized in that, The standard test interface is a banana plug or a BNC connector.
5. The apparatus according to claim 1, characterized in that, The fault setting box (5) is integrated in the middle or lateral connection part of the π-shaped structure. It contains a switchable fault simulation circuit for simulating at least one fault in the charging connection confirmation line, control guidance line or electric vehicle controller local area network communication line.
6. The apparatus according to claim 5, characterized in that, The fault simulation circuit can simulate at least one of the following fault types: open circuit, short circuit to the positive power supply, short circuit to the vehicle body ground, poor contact, reverse connection of the circuit, abnormal signal frequency, or abnormal bus termination resistance.
7. The apparatus according to claim 5, characterized in that, The fault setting box (5) is provided with a fault type selection switch or button on its surface. By operating the switch or button, a single fault or a combination of faults can be selected and set.
8. The apparatus according to claim 1, characterized in that, The connecting harness (7) integrates at least one of the following: charging connection confirmation terminal harness, control guide terminal harness, electric vehicle controller local area network high-level harness, and electric vehicle controller local area network low-level harness, and the harness forms a series connection path on both sides of the π-shaped device.
9. The apparatus according to claim 1, characterized in that, The on-board charger female connector (1) and the on-board charger male connector (8) are non-replaceable connectors customized according to the preset vehicle model on-board charger interface specifications, which are used to ensure reliable matching and connection with the on-board charger body interface.