European standard split type charging pile test tool circuit system

Abstract

The invention provides a European standard split type charging pile test tool circuit system. The European standard split type charging pile test tool circuit system comprises a main control board; the power supply input module is connected with the main control board and is used for converting an alternating current input power supply into a working power supply required by the system; the plurality of test units are connected with the main control board in parallel, and each test unit comprises a charging gun interface used for being connected with a charging gun of a charging pile to be tested; the electric vehicle communication controller simulation board is used for simulating the communication behavior of the electric vehicle; the battery management system simulation board is used for simulating the charging characteristics of the battery pack; the load module is used for simulating a vehicle load and consuming charging power; wherein the main control board is configured to send a test instruction to each test unit and independently control the test parameter and the test flow of each test unit. According to the invention, the development efficiency of European standard split charging piles is improved; and meanwhile, sufficient test interfaces can be provided for the European standard split type charging pile, so that the European standard split type charging pile can be fully tested in multiple scenes, and the failure rate of products caused by insufficient test is reduced.

Description

Technical Field

[0001] This disclosure relates to the field of charging pile testing technology, specifically to a European standard split-type charging pile testing fixture circuit system. Background Technology

[0002] With the rapid popularization of new energy vehicles in the European market, the need for research and testing of split-type charging piles that meet European standards (hereinafter referred to as "European standards") is becoming increasingly urgent. These charging piles typically employ a group charging system, where one power pool simultaneously supplies power to multiple charging terminals (charging guns). Their system complexity and interaction logic are far higher than traditional single-gun charging piles. Therefore, during the research and development phase, how to conduct thorough, efficient, and reliable testing of the multiple charging terminals of split-type charging piles has become a key challenge for those skilled in the art.

[0003] In the early stages of testing technology development, the industry generally adopted the most basic testing method: the "one gun, one simulator" testing scheme. This involved configuring a complete testing environment for each charging gun under test, including an Electric Vehicle Communication Controller (EVCC) simulator, a Battery Management System (BMS) simulator, and the corresponding load. The drawbacks of this scheme are obvious: Testing costs are high: Testing a group charging system that supports N guns requires purchasing N sets of simulators and load testing equipment, resulting in a huge investment.

[0004] The testing efficiency is extremely low: testers need to frequently connect, configure, and operate multiple independent devices, which is a cumbersome and time-consuming process.

[0005] Poor test consistency: Due to performance differences between different simulators and the inevitable errors introduced by manual operation, it is difficult to make horizontal comparisons of test results for different charging terminals, resulting in poor test reliability and repeatability.

[0006] To address the aforementioned issues, an improved integrated dual-gun testing fixture has emerged in the prior art. This fixture integrates two sets of testing channels into a single chassis, reducing the number of devices and simplifying some connections to a certain extent. However, when faced with European standard split-type charging piles with a large number of charging terminals (e.g., 12-gun, 24-gun, or even more), its inherent shortcomings are once again exposed: Insufficient system-level integration: Testing a multi-gun charging pile still requires deploying multiple (e.g., 6 or 12) dual-gun testing fixtures. The entire testing system is composed of multiple independent devices, and essentially does not change the distributed architecture of "multi-node, multi-device".

[0007] Complex wiring and risk of errors: Each dual-gun fixture requires an independent AC power supply and physical connection to different charging terminals of the charging station. The numerous external wires not only make the testing site cluttered but also significantly increase the risk of test failures, data anomalies, or even equipment damage due to wiring errors (such as incorrect communication cable connections or reversed power cable connections).

[0008] Decentralized control and difficult management: Each dual-gun fixture typically operates independently, lacking a unified control core. Testers need to set parameters, start tests, and record data on each fixture separately, making it impossible to achieve centralized management of test tasks, unified distribution of parameters, and synchronous acquisition of results. This results in low automation and high management complexity.

[0009] Therefore, there is an urgent need in this field for a novel test fixture circuit design that can fundamentally solve a series of problems caused by the complex system architecture, numerous external wiring, decentralized control, and consequently low test efficiency and high error rate resulting from the stacking of multiple independent test devices. Summary of the Invention

[0010] This invention provides a European standard split-type charging pile testing fixture circuit system, which can at least solve a series of chain problems caused by the above-mentioned complex system architecture, numerous external wiring, decentralized control, and the resulting low testing efficiency and high error rate caused by the stacking of multiple independent testing devices.

[0011] The technical solution of the present invention is as follows: A European standard split-type charging pile test fixture circuit system includes: Main control board; The power input module, connected to the main control board, is used to convert AC input power into the operating power required by the system. Multiple test units are connected in parallel with the main control board, and the test units include: The charging gun interface is used to connect the charging gun of the charging pile under test. Electric vehicle communication controller simulation board, used to simulate the communication behavior of electric vehicles; Battery management system simulation board, used to simulate the charging characteristics of a battery pack; The load module is used to simulate vehicle load and consume charging power. The main control board is configured to send test commands to each test unit and independently control the test parameters and test process of each test unit. In one possible implementation, the number of test units is 24.

[0012] In one possible implementation, the main control board integrates a human-machine interface, which is configured to receive test parameters input by the user and display the status and data of each test unit in real time.

[0013] In one possible implementation, the test parameters include at least one of output voltage, output current, charging capacity, charging time, communication protocol version, and simulated battery SOC curve.

[0014] In one possible implementation, the main control board is configured to send test instructions to each of the test units, the test instructions including the following steps: S1: Establish a communication connection with the charging pile under test; S2: Set initial parameters for the electric vehicle communication controller simulation board and the battery management system simulation board; S3: Controls the charging station to start the charging process; S4: During the charging process, dynamically adjust the analog parameters of the battery management system simulation board or inject communication fault signals; S5: Record the charging pile's response data and compare it with the expected behavior, and generate test results.

[0015] In one possible implementation, the system further includes a system protection circuit, which is integrated into the power input module and each of the test units; The system protection circuit includes at least one of the following functions: overcurrent protection, short circuit protection, overvoltage protection, and insulation resistance detection.

[0016] In one possible implementation, the main control board is also provided with an external communication interface for connecting to a host computer or server to enable remote uploading of test data and remote updating of test scripts.

[0017] In one possible implementation, the main control board is configured to perform pattern recognition of the fault types of the charging pile based on historical test data and output potential fault warnings.

[0018] In one possible implementation, the load module is a programmable AC load capable of simulating resistive, capacitive, or inductive loads with different power factors.

[0019] In one possible implementation, the test unit is connected to a backplane via a plug-in connection, the backplane providing a power bus and a communication bus.

[0020] The system provided in this embodiment of the invention has at least the following beneficial effects: The system provided by this invention can solve the problem that the testing fixtures for European standard split charging piles are complex and prone to errors due to wiring of multiple nodes, thereby improving the development efficiency of European standard split charging piles. At the same time, it can provide sufficient test interfaces for European standard split charging piles, enabling them to be fully tested in multiple scenarios and reducing the failure rate of products caused by insufficient testing. Attached Figure Description

[0021] The accompanying drawings illustrate exemplary embodiments of the present disclosure and, together with the description thereof, serve to explain the principles of the present disclosure. These drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification.

[0022] Figure 1 A schematic diagram of the circuit system framework for a European standard split-type charging pile test fixture according to some embodiments of this disclosure is shown.

[0023] Figure 2 A schematic diagram of the circuit connection structure of the European standard split-type charging pile test fixture circuit system according to some embodiments of this disclosure is shown.

[0024] Figure label: 1-Main control board, 2-Power input module, 3-Test unit, 4-Electric vehicle communication controller simulation board, 5-Battery management system simulation board, 6-Load module, 7-Charging gun interface. Detailed Implementation

[0025] The present disclosure 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 for illustrative purposes only and are not intended to limit the scope of the disclosure. Furthermore, it should be noted that, for ease of description, only the parts relevant to the present disclosure are shown in the accompanying drawings.

[0026] It should be noted that, where there is no conflict, the embodiments and features described in this disclosure can be combined with each other. The technical solutions of this disclosure will now be described in detail with reference to the accompanying drawings and embodiments.

[0027] Unless otherwise stated, the exemplary implementations / embodiments shown are to be understood as providing exemplary features of various details that provide ways in which the technical concepts of this disclosure can be implemented in practice. Therefore, unless otherwise stated, the features of various implementations / embodiments may be additionally combined, separated, interchanged and / or rearranged without departing from the technical concepts of this disclosure.

[0028] The terminology used herein is for the purpose of describing particular embodiments and is not restrictive. As used herein, unless the context clearly indicates otherwise, the singular forms “a” and “the” are intended to include the plural forms as well. Furthermore, when the terms “comprising” and / or “including” and variations thereof are used in this specification, it indicates the presence of the stated features, integrals, steps, operations, parts, components, and / or groups thereof, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, parts, components, and / or groups thereof. It should also be noted that, as used herein, the terms “substantially,” “about,” and other similar terms are used as approximate terms rather than as terms of degree, thus explaining the inherent biases in measurements, calculated values, and / or provided values ​​that would be recognized by one of ordinary skill in the art.

[0029] The market for European standard split-type charging piles is developing rapidly, and more and more domestic companies are producing them. Split-type charging piles require thorough testing during the R&D phase to ensure stable operation in the market. Currently, most European standard charging pile testing fixtures in the industry are dual-gun fixtures. Split-type charging piles require multiple, even more than 10, dual-gun fixtures during R&D testing, making the testing fixtures complex and prone to errors due to multi-node wiring. Against this backdrop, a circuit design scheme for a European standard split-type charging pile testing fixture is designed. It should be noted that EVCC stands for Electric Vehicle Communication Controller, mainly used to realize the communication protocol conversion between new energy vehicles and charging facilities, supporting domestically produced electric vehicles to use international standard charging piles in overseas markets. The BMS simulation board is a device used to test and verify the functions of the Battery Management System (BMS). By simulating the charging and discharging characteristics, voltage, current, and other parameters of a real battery, it helps in the development and optimization of the BMS system.

[0030] Please see Figure 1 and Figure 2 This invention provides a European standard split-type charging pile test fixture circuit system, including: a main control board 1, a power input module 2, multiple test units 3, an electric vehicle communication controller (EVCC) simulation board 4, a battery management system (BMS) simulation board 5, and a load module 6.

[0031] Among them, the power input module 2 is connected to the main control board 1 and is used to convert the AC input power into the working power required by the system; Multiple test units 3 are connected in parallel with the main control board 1. The test unit 3 includes: The charging gun interface 7 is used to connect the charging gun of the charging pile under test; Electric vehicle communication controller simulation board 4 is used to simulate the communication behavior of electric vehicles; Battery management system simulation board 5 is used to simulate the charging characteristics of the battery pack; Load module 6 is used to consume charging power; The main control board 1 is configured to send test commands to each test unit 3 and independently control the test parameters and test process of each test unit 3. The system provided in this embodiment of the invention has at least the following beneficial effects: The system provided by this invention can solve the problem that the testing fixtures for European standard split charging piles are complex and prone to errors due to wiring of multiple nodes, thereby improving the development efficiency of European standard split charging piles. At the same time, it can provide sufficient test interfaces for European standard split charging piles, enabling them to be fully tested in multiple scenarios and reducing the failure rate of products caused by insufficient testing.

[0032] For example, the main control board 1 in this embodiment of the invention can be an embedded microprocessor (such as the ARM Cortex series) that communicates with each test unit 3 via a CAN bus or Ethernet. Each test unit 3 is an independent functional board that integrates an EVCC simulation board, a BMS simulation board, and a power load. The power input module 2 converts AC220V to DC low voltage to power the control section and provides an energy loop for the load module 6.

[0033] This invention achieves true parallel testing through a distributed architecture of "main control board 1 - multiple test units 3", resulting in strong system scalability. Each test unit 3 fully simulates the communication and electrical environment of the vehicle, making the test conditions highly realistic and fully verifying the interactive logic and dynamic response capability of the charging pile. This fundamentally avoids wiring errors and signal inconsistencies caused by external simulators.

[0034] In one possible implementation, the number of test units 3 is 24.

[0035] In this embodiment of the invention, the main control board 1 connects to 24 test units 3 via a multi-channel CAN bus or a switch. Each bus carries a certain number of units to ensure real-time communication. A single fixture meets the maximum test channel requirements of current European standard group charging products, significantly reducing the number of test units 3, floor space, and wiring complexity, while improving test density and laboratory space utilization.

[0036] In one possible implementation, the main control board 1 integrates a human-machine interface, which is configured to receive test parameters input by the user and display the status and data of each test unit 3 in real time.

[0037] For example, the human-computer interaction interface of this invention can be a touch screen, which is connected to the main control processor through a UART or MIPI interface, runs an embedded GUI program, and provides functions such as parameter setting, start / stop test, and data display.

[0038] The embodiments of the present invention provide an intuitive and centralized operation view through a human-computer interaction interface, enabling engineers to quickly configure complex multi-channel test tasks and monitor the global test progress in real time, which significantly improves test efficiency and ease of operation.

[0039] In one possible implementation, the test parameters include at least one of the following: output voltage, output current, charging capacity, charging time, communication protocol version, and simulated battery SOC curve.

[0040] For example, users can set parameters via a touchscreen, and the main control board 1 compiles these parameters into control commands and sends them to the simulation boards and load modules 6 of each test unit 3.

[0041] The embodiments of the present invention support comprehensive and customizable testing of charging pile performance. In particular, by simulating different battery SOC curves, the adaptability and stability of charging piles under different operating conditions can be verified, and potential problems can be exposed in advance.

[0042] In one possible implementation, the main control board 1 is configured to send test instructions to each test unit 3, the test instructions including the following steps: S1: Establish a communication connection with the charging pile under test.

[0043] S2: Configure the initial parameters for the electric vehicle communication controller simulation board 4 and the battery management system simulation board 5.

[0044] S3: Controls the charging station to start the charging process.

[0045] S4: During the charging process, dynamically adjust the simulation parameters of the battery management system simulation board 5 or inject communication fault signals.

[0046] S5: Record the charging pile's response data and compare it with the expected behavior, and generate test results.

[0047] The embodiments of the present invention achieve automation and standardization of the testing process by setting test sequences, avoiding the uncertainty of manual operation; through dynamic parameter adjustment and fault injection, it can proactively discover defects of charging piles under abnormal operating conditions, greatly enhancing the depth and reliability of testing.

[0048] In one possible implementation, the system also includes a system protection circuit, which is integrated into the power input module 2 and each test unit 3. The system protection circuit includes at least one of the following functions: overcurrent protection, short circuit protection, overvoltage protection, and insulation resistance detection.

[0049] For example, in embodiments of the present invention, a fuse and a varistor may be provided at the power input, a current sampling and comparator circuit may be provided on the power path of each test unit 3, and the insulation detection module may be monitored using an unbalanced bridge method.

[0050] The embodiments of the present invention ensure system safety during high-power, multi-channel parallel testing through multi-level protection design, preventing the entire tooling from being paralyzed due to the failure of a single unit; the insulation detection function is directly related to safety standard compliance and is a key link in European standard certification testing.

[0051] In one possible implementation, the main control board 1 is also provided with an external communication interface for connecting to a host computer or server to enable remote uploading of test data and remote updating of test scripts.

[0052] For example, the external communication interface can be an Ethernet port or a 4G / 5G module, supporting MQTT or HTTP protocols, to package and upload structured test data to a cloud database.

[0053] In this way, centralized management and analysis of test data are achieved, providing a foundation for big data quality analysis; remote updates of test cases are supported, enabling the system to quickly adapt to new test specifications or product models, thus enhancing the long-term usability of the system.

[0054] In one possible implementation, the main control board 1 is configured to perform pattern recognition of the fault types of the charging pile based on historical test data and output potential fault warnings.

[0055] For example, a lightweight machine learning algorithm (such as a decision tree or SVM) can be run on the main control board 1 or a cloud server to learn abnormal features from historical test records, and trigger an alert when real-time data matches a specific pattern. This embodiment of the invention can achieve predictive maintenance and improve product quality.

[0056] In one possible implementation, load module 6 is a programmable AC load capable of simulating resistive, capacitive, or inductive loads with different power factors.

[0057] For example, embodiments of the present invention may employ a digital power amplifier architecture based on IGBTs and DSPs, and simulate various types of grid loads by programming to control the phase and waveform of the output current.

[0058] In one possible implementation, the circuit board of test unit 3 is connected to the backplane via a plug-in connection, and the backplane provides a power bus and a communication bus.

[0059] For example, the system of this embodiment of the invention can use a backplane with blind-mating connectors, and the test unit 3 is inserted into the backplane slot as a board. The backplane integrates a power plane and a CAN / Ethernet bus. The modular design makes system maintenance and expansion extremely convenient. If a single test unit 3 fails, it can be quickly replaced without affecting the testing of other units, and it also provides the possibility of adding new types of test units 3 in the future (such as supporting new standards).

[0060] In the description of this specification, the references to terms such as "one embodiment / mode," "some embodiments / modes," "example," "specific example," or "some examples," etc., refer to specific features, structures, or characteristics described in connection with that embodiment / mode or example, which are included in at least one embodiment / mode or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment / mode or example. Moreover, the specific features, structures, or characteristics described may be combined in any suitable manner in one or more embodiments / modes or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments / modes or examples described in this specification, as well as the features of different embodiments / modes or examples.

[0061] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this disclosure, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0062] Those skilled in the art should understand that the above embodiments are merely for illustrating the present disclosure and are not intended to limit the scope of the disclosure. Those skilled in the art can make other changes or modifications based on the above disclosure, and these changes or modifications still fall within the scope of the present disclosure.

Claims

1. A European standard split-type charging pile testing fixture circuit system, characterized in that, include: Main control board; The power input module, connected to the main control board, is used to convert AC input power into the operating power required by the system. Multiple test units are connected in parallel with the main control board, and the test units include: The charging gun interface is used to connect the charging gun of the charging pile under test. Electric vehicle communication controller simulation board, used to simulate the communication behavior of electric vehicles; Battery management system simulation board, used to simulate the charging characteristics of a battery pack; The load module is used to simulate vehicle load and consume charging power. The main control board is configured to send test commands to each test unit and independently control the test parameters and test process of each test unit.

2. The test fixture circuit system according to claim 1, characterized in that, The number of test units is 24.

3. The test fixture circuit system according to claim 1, characterized in that, The main control board integrates a human-machine interface, which is configured to receive test parameters input by the user and display the status and data of each test unit in real time.

4. The test fixture circuit system according to claim 3, characterized in that, The test parameters include at least one of the following: output voltage, output current, charging capacity, charging time, communication protocol version, and simulated battery SOC curve.

5. The test fixture circuit system according to claim 1, characterized in that, The main control board is configured to send test instructions to each of the test units, the test instructions including the following steps: S1: Establish a communication connection with the charging pile under test; S2: Set initial parameters for the electric vehicle communication controller simulation board and the battery management system simulation board; S3: Controls the charging station to start the charging process; S4: During the charging process, dynamically adjust the analog parameters of the battery management system simulation board or inject communication fault signals; S5: Record the charging pile's response data and compare it with the expected behavior, and generate test results.

6. The test fixture circuit system according to claim 1, characterized in that, The system also includes a system protection circuit, which is integrated into the power input module and each of the test units; The system protection circuit includes at least one of the following functions: overcurrent protection, short circuit protection, overvoltage protection, and insulation resistance detection.

7. The test fixture circuit system according to claim 1, characterized in that, The main control board is also equipped with an external communication interface for connecting to a host computer or server to enable remote uploading of test data and remote updating of test scripts.

8. The test fixture circuit system according to claim 1, characterized in that, The main control board is configured to perform pattern recognition of the fault types of the charging pile based on historical test data and output potential fault warnings.

9. The test fixture circuit system according to claim 1, characterized in that, The load module is a programmable AC load.

10. The test fixture circuit system according to claim 1, characterized in that, The test unit is connected to the backplane via a plug-in connection, and the backplane provides a power bus and a communication bus.

Images