Charging pile detection device and detection method

Abstract

The invention provides a charging pile detection device and detection method, and belongs to the technical field of charging pile detection. The charging pile detection device comprises a dynamic response current sensing module used for acquiring a direct current signal output by a charging pile, converting the direct current signal into a first voltage signal through a magnetic modulation and zero magnetic flux feedback technology, and sending the first voltage signal to a core processing module; the direct-current voltage detection module is used for acquiring a direct-current voltage signal output by the charging pile and sending the direct-current voltage signal to the core processing module; the core processing module is used for receiving and processing the first voltage signal and the direct current voltage signal to obtain a real-time electric energy parameter of the charging pile; a control instruction is generated according to the real-time electric energy parameter and a preset temperature condition, and the control instruction is sent to the liquid cooling module; and the liquid cooling control module is used for controlling and adjusting the heat dissipation power of the charging pile according to the control instruction. The detection efficiency of the charging pile and the accuracy of the identification result can be improved.

Description

Technical Field

[0001] This application relates to the field of charging pile testing technology, and in particular to a charging pile testing device and testing method. Background Technology

[0002] With the rapid development and widespread application of the electric vehicle industry, charging infrastructure, as a key supporting link, has become a crucial factor affecting the healthy development of the industry in terms of its construction scale and service quality. Accurate metering of charging facilities not only directly relates to the economic interests and user experience of charging users, but is also an important guarantee for promoting the large-scale application of electric vehicles and ensuring fair and transparent energy consumption, possessing significant social benefits and strategic importance. Therefore, AC and DC charging facilities have been formally included in the mandatory verification catalog, explicitly requiring that mandatory verification of charging facilities be carried out regularly in accordance with relevant verification procedures to ensure the metering impartiality and service reliability of the charging process.

[0003] However, in the actual operation of mandatory verification work at this stage, the widely used portable DC charger testers still have significant limitations. Their current detection channels lack dynamic response capabilities, making it difficult to accurately and sensitively reproduce the rapidly changing current during the charging process. This results in limited testing effectiveness under high-precision metrology and complex operating conditions. This deficiency not only affects the accuracy of verification results but may also prevent the effective identification of subtle deviations in charging measurement, thus potentially impacting the credibility of metrology and user trust. Summary of the Invention

[0004] This application provides a charging pile testing device and testing method to solve the problem of improving the testing efficiency and the accuracy of the identification results of charging piles.

[0005] In a first aspect, embodiments of this application provide a charging pile testing device, including: a dynamic response current sensing module, a DC voltage detection module, a core processing module, and a liquid cooling control module. The dynamic response current sensing module is used to acquire the DC current signal output by the charging pile, convert the DC current signal into a first voltage signal through magnetic modulation and zero magnetic flux feedback technology, and send the first voltage signal to the core processing module. The DC voltage detection module is used to acquire the DC voltage signal output by the charging pile and send the DC voltage signal to the core processing module. The core processing module is used to receive and process the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile; and to generate a first control command based on the real-time power parameters and preset temperature conditions, and send the first control command to the liquid cooling control module; the real-time power parameters are used to determine the heat dissipation requirement benchmark, and the preset temperature conditions are used to dynamically adjust or correct the heat dissipation requirement benchmark. The liquid cooling control module is used to control and adjust the heat dissipation power of the charging pile according to the first control command.

[0006] In one exemplary embodiment of this application, the core processing module includes a main controller, a magnetic isolator, and an analog-to-digital converter, with the magnetic isolator disposed between the analog-to-digital converter and the main controller; An analog-to-digital converter is used to sample and digitize a first voltage signal and a DC voltage signal to obtain a digitized first voltage signal and a digitized DC voltage signal. A magnetic isolator is used to denoise the digitized first voltage signal and the digitized DC voltage signal to obtain a denoised digital signal; the denoised digital signal includes the denoised first voltage signal and the denoised DC voltage signal. The main controller is used to determine the real-time power parameters of the charging pile based on the denoised digital signal.

[0007] In one exemplary embodiment of this application, the core processing module further includes a programmable logic unit electrically connected to the magnetic isolator; The programmable logic unit is used to receive the denoised digital signal, preprocess the denoised digital signal, and obtain a standardized sampling data frame. The main controller is specifically used to receive standardized sampling data frames output by the programmable logic unit, convert the standardized sampling data frames into real-time energy parameters through an energy metering algorithm, and transmit the real-time energy parameters to the host computer through the host computer interface.

[0008] In one exemplary embodiment of this application, the core processing module further includes a control boot circuit electrically connected to the main controller. The control and guidance circuit is used to output guidance signals or interlock signals that conform to preset safety specifications according to the instructions of the main controller.

[0009] In one exemplary embodiment of this application, the main controller is a microcontroller based on the ARM architecture; the main controller is also used to analyze the ripple content of the digitized first voltage signal and the digitized DC voltage signal respectively, so as to evaluate the power quality of the DC current detection circuit and the power quality in the DC voltage detection circuit.

[0010] In one exemplary embodiment of this application, the main controller is further configured to: receive a second control command sent by the host computer through the host computer interface, so as to realize the monitoring and control of the device.

[0011] In one exemplary embodiment of this application, the core processing module further includes a front-end circuit, and the main controller is connected to the front-end circuit. The main controller includes an analog-to-digital conversion subunit and a digital-to-analog conversion subunit. The front-end circuit includes a first linear optocoupler, a second linear optocoupler, and a high-voltage module. The first linear optocoupler is used to receive the first voltage signal output by the dynamic response current sensing module and the second voltage signal from the charging pile output current shunt, and sends the first voltage signal and the second voltage signal to the main controller through the multi-channel input port of the analog-to-digital conversion subunit; wherein, the first voltage signal is used as a detection signal and the second voltage signal is used as a calibration signal to calibrate the first voltage signal; The analog-to-digital converter subunit is also used to convert the second voltage signal into a digital signal and send the digital signal to the main controller; The main controller is also used to calibrate the digital signal corresponding to the first voltage signal based on the digital signal to obtain the calibrated first voltage digital signal; The digital-to-analog converter subunit is used to convert the calibrated first voltage digital signal output by the main controller into an analog control signal, and send the analog control signal to the second linear optocoupler; The second linear optocoupler is used to isolate the analog control signal and send the isolated analog control signal to the high-voltage module; the isolated analog control signal is used to control the output characteristics of the high-voltage module.

[0012] In one exemplary embodiment of this application, the dynamic response current sensing module is a DC detection module based on the zero flux feedback principle. The DC detection module includes a DC comparator, a detection magnetic core, and an amplifier. The DC comparator includes a modulation detection winding, a demodulator, and a modulation oscillator. A detection core is used to couple a DC current signal into a DC flux to be measured in the detection core. A modulation oscillator is used to generate a modulation signal and to excite the modulation detection winding to produce an alternating modulation magnetic field through the modulation signal; The demodulator is used to detect the change in magnetic flux of the detection core under the combined action of the DC magnetic flux to be measured and the alternating modulated magnetic field, and outputs the corresponding error signal based on the change in magnetic flux. An amplifier is used to generate a feedback compensation current based on the error signal. The feedback compensation current is used to control the magnetic flux of the detection core to be zero. The first voltage signal is determined based on the feedback compensation current, and the first voltage signal is a voltage signal that is proportional to the feedback compensation current.

[0013] Secondly, embodiments of this application provide a charging pile detection method, including: The DC current signal output by the charging pile is acquired, and the DC current signal is converted into a first voltage signal through magnetic modulation and zero magnetic flux feedback technology. Obtain the DC voltage signal output by the charging pile; Receive and process the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile; generate the first control command based on the real-time power parameters and the preset temperature conditions; the real-time power parameters are used to determine the heat dissipation demand benchmark, and the preset temperature conditions are used to dynamically adjust or correct the heat dissipation demand benchmark. The heat dissipation power of the charging pile is controlled and adjusted according to the first control command.

[0014] In one exemplary embodiment of this application, receiving and processing a first voltage signal and a DC voltage signal to obtain real-time power parameters of the charging pile includes: The first voltage signal and the DC voltage signal are sampled and digitized to obtain the digitized first voltage signal and the digitized DC voltage signal; The digitized first voltage signal and the digitized DC voltage signal are denoised to obtain a denoised digital signal, which includes the denoised first voltage signal and the denoised DC voltage signal. The real-time power parameters of the charging pile are determined based on the denoised digital signal.

[0015] The beneficial effects of the charging pile testing device and testing method provided in this application are as follows: In this embodiment, the dynamic response current sensing module employs magnetic modulation and zero flux feedback technology, which can quickly and accurately acquire the DC current signal output by the charging pile and convert it into a first voltage signal to be sent to the core processing module. This embodiment can provide a reliable data foundation for subsequent accurate measurement and solves the problem that existing technologies cannot accurately reproduce rapidly changing currents.

[0016] In this embodiment, the core processing module receives the first voltage signal sent by the dynamic response current sensing module and the DC voltage signal sent by the DC voltage detection module, and processes the received signals to obtain the real-time power parameters of the charging pile. This embodiment improves the accuracy of metering by comprehensively processing the current and voltage signals, enabling more reliable results in high-precision metering scenarios and effectively solving the problem of limited detection performance under high-precision metering conditions.

[0017] In this embodiment, the core processing module generates a first control command based on real-time power parameters and preset temperature conditions, and sends it to the liquid cooling control module. The liquid cooling control module then adjusts the heat dissipation power of the charging pile according to this command. In this embodiment, the liquid cooling control module can promptly increase the heat dissipation power based on the commands from the core processing module, ensuring the stability of the detection and solving the problem of limited detection performance under complex operating conditions in existing technologies. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a charging pile testing device provided in one embodiment of this application; Figure 2 This is another structural schematic diagram of a charging pile testing device provided in one embodiment of this application; Figure 3 This is a schematic diagram illustrating the working principle of the ARM processor in a charging pile detection device provided in an embodiment of this application. Figure 4 This is a schematic diagram illustrating the working principle of the main controller of the charging pile detection device provided in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of the DC current detection unit of a charging pile testing device provided in an embodiment of this application; Figure 6 This is a flowchart illustrating a charging pile testing method provided in an embodiment of this application. Detailed Implementation

[0020] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following description will be provided in conjunction with the accompanying drawings and specific embodiments.

[0022] Please refer to Figure 1 , Figure 1 This is a schematic diagram of a charging pile testing device provided in one embodiment of this application. The device can be used to test supercharging piles in high-power (up to 1.5 MW) charging scenarios. The device may include: a dynamic response current sensing module 11, a DC voltage detection module 12, a core processing module 13, and a liquid cooling control module 14. The dynamic response current sensing module 11 is used to acquire the DC current signal output by the charging pile, convert the DC current signal into a first voltage signal through magnetic modulation and zero magnetic flux feedback technology, and send the first voltage signal to the core processing module 13. The DC voltage detection module 12 is used to acquire the DC voltage signal output by the charging pile and send the DC voltage signal to the core processing module 13; The core processing module 13 is used to receive and process the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile; and to generate a first control command based on the real-time power parameters and preset temperature conditions, and send the first control command to the liquid cooling control module 14; the real-time power parameters are used to determine the heat dissipation requirement benchmark, and the preset temperature conditions are used to dynamically adjust or correct the heat dissipation requirement benchmark. The liquid cooling control module 14 is used to control and adjust the heat dissipation power of the charging pile according to the first control command.

[0023] In this embodiment, the charging pile is a supercharging pile, and the charging pile detection device can be a supercharging pile field tester. The real-time power parameters in this embodiment are used to determine the heat dissipation requirement benchmark of the liquid cooling control module. The real-time power parameters may include DC current signals and DC voltage signals, and the heat dissipation power is determined based on the DC current signals and DC voltage signals. Based on this heat dissipation power, the corresponding heat dissipation requirement benchmark is queried within the core processing module 13. In this embodiment, the core processing module 13 pre-stores the correspondence between heat dissipation power and heat dissipation requirement benchmark.

[0024] In this embodiment, the preset temperature condition can be that the temperature data measured by the temperature sensor inside the supercharger is higher than a preset temperature threshold. This preset temperature condition is used to dynamically adjust or correct the heat dissipation requirement benchmark. For example, if the temperature data measured by the supercharger exceeds the preset temperature threshold, the heat dissipation intensity is increased on top of the supercharger's heat dissipation requirement benchmark.

[0025] The dynamic response current sensing module 11 in this embodiment may include a DC current detection submodule and a current transformer submodule. The DC current detection submodule can be used to collect the DC current signal output by the supercharging pile to achieve real-time monitoring of the charging current. The current transformer submodule can convert the DC current signal output by the DC current detection submodule into a standard current signal according to a preset ratio, and then convert the standard current signal into a first voltage signal for transmission to the core processing module 13. The preset ratio in this embodiment can be dynamically adjusted according to the actual scenario.

[0026] For example, the preset ratio can be set to 1000:1, and the sampling resistor can be set to 3 ohms. If the charging current (DC current signal) is 600A, the converted standard current signal is 0.6A. When this 0.6A current is passed through the aforementioned 3-ohm sampling resistor, a first voltage signal of 1.8V is obtained. This 1.8V first voltage signal is then transmitted to the core processing module 13.

[0027] In this embodiment, if the core processing module 13 detects that the first voltage signal is only 0.03V, that is, the corresponding DC standard current signal is 10A, the core processing module 13 determines that it is currently in a small current range, and sends a proportional adjustment command to the dynamic response current sensing module 11 so that the dynamic response current sensing module 11 adjusts the preset ratio from 1000:1 to 100:1.

[0028] The DC voltage detection module 12 in this embodiment can collect the DC voltage signal output by the supercharging pile and transmit the DC voltage signal to the core processing module 13 to realize real-time monitoring of the charging voltage.

[0029] In this embodiment, the core processing module 13 can be used to receive a first voltage signal and a DC voltage signal, generate real-time power parameters of the supercharging pile based on the first voltage signal and the DC voltage signal, and monitor the power parameters in real time. At the same time, the core processing module 13 can also generate a first control command based on the real-time power parameters and preset temperature conditions, and send the first control command to the liquid cooling control module to control the liquid cooling control module to coordinate and control the heat dissipation power.

[0030] In this embodiment, the liquid cooling control module 14 can adjust the heat dissipation power of the supercharging pile according to the first control command, so as to measure a larger current and reduce the impact of temperature on measurement.

[0031] For example, see Figure 2 The diagram below shows another structural schematic of the charging pile detection device in this embodiment. The charging pile detection device may include a core processing unit (core unit), a current transformer, a DC voltage detection unit (Digital Control Unit, DCU), a DC current detection unit (Direct Client Interface, DCI), and a liquid-cooled control unit.

[0032] In this example, the current transformer and the DC current detection unit are components inside the dynamic response current sensing module 11, the DC voltage detection unit is a component inside the DC voltage detection module 12, the core processing unit is a component inside the core processing module 13, and the liquid cooling control unit is a component inside the liquid cooling control module 14.

[0033] The system comprises several components: a DC current detection unit collects the DC current of the supercharger and transmits it to a current transformer. The current transformer processes the DC current to obtain a processed DC current, which is then transmitted to the core processing unit. A DC voltage detection unit collects the DC voltage of the supercharger and transmits it to the core processing unit. The core processing unit receives the DC current and voltage, determines the heat dissipation power of the supercharger based on these parameters, and monitors the charging data (including DC voltage and current data) in real time. Based on the charging data and a preset temperature condition, it generates a first control command and controls the liquid cooling control unit to adjust the heat dissipation power of the supercharger. The preset temperature condition is defined as a temperature threshold measured by the temperature sensor inside the supercharger. The heat dissipation requirement benchmark for the supercharger can be determined based on the charging data, and this benchmark can be dynamically adjusted or corrected based on the preset temperature condition.

[0034] In one embodiment, the core processing module 13 includes a main controller, a magnetic isolator, and an analog-to-digital converter, with the magnetic isolator disposed between the analog-to-digital converter and the main controller; An analog-to-digital converter is used to sample and digitize a first voltage signal and a DC voltage signal to obtain a digitized first voltage signal and a digitized DC voltage signal. A magnetic isolator is used to denoise the digitized first voltage signal and the digitized DC voltage signal to obtain a denoised digital signal; the denoised digital signal includes the denoised first voltage signal and the denoised DC voltage signal. The main controller is used to determine the real-time power parameters of the charging pile based on the denoised digital signal.

[0035] In this embodiment, real-time power parameters may include DC current signals and DC voltage signals. The core processing module 13 includes a main controller, a magnetic isolator, and an analog-to-digital converter (ADC). The ADC in this embodiment uses a 24-bit successive approximation ADC chip with a sampling rate of 51.2 kHz, a minimum resolution of 0.3 μV, and a minimum current measurement error controlled within 0.05%.

[0036] In this embodiment, the main controller can be a microcontroller based on the ARM architecture (32-bit processor). See also Figure 2 The magnetic isolator is placed between the analog-to-digital converter and the main controller, enabling bidirectional communication between the magnetic isolator and the analog-to-digital converter, as well as communication between the magnetic isolator and the main controller.

[0037] For example, the main controller reads the denoised digital signal, and according to the ADC's reference voltage and resolution, restores the denoised digital signal to the actual voltage value (including the first voltage value corresponding to the first digital signal and the second voltage value corresponding to the second digital signal); the preset ratio in the current sensing module determines the actual current value (DC current signal) corresponding to the first voltage value; the voltage division ratio in the voltage detection module determines the actual voltage value (DC voltage signal) corresponding to the second voltage value; and the actual current value and the actual voltage value are used as real-time power parameters.

[0038] See Figure 3 In this embodiment, the number of analog-to-digital converters (ADCs) can be set to two, and the number can be adjusted according to the actual scenario or experimental situation. A magnetic isolator is positioned between the ADCs and the main controller. In this embodiment, the two ADCs can convert externally input analog signals (e.g., the first voltage signal, DC voltage signal, current, and temperature acquired by the sensor) into digital signals, obtaining a digitized first voltage signal and a digitized DC voltage signal. In this embodiment, the two ADCs can achieve multi-channel parallel acquisition, improving data acquisition efficiency.

[0039] In this embodiment, the magnetic isolator can provide electrical isolation and perform denoising processing on the digitized first voltage signal and the digitized DC voltage signal to obtain a denoised digital signal. This denoised digital signal includes the denoised first voltage signal and the denoised DC voltage signal. The magnetic isolator in this embodiment can block high-voltage signals and interference signals (such as common-mode noise) from being transmitted to subsequent circuits, protecting the safety of subsequent circuits while ensuring stable signal transmission.

[0040] In this embodiment, the main controller can determine the real-time power parameters of the supercharging pile based on the denoised digital signal.

[0041] In one embodiment, the core processing module 13 further includes a programmable logic unit electrically connected to the magnetic isolator; The programmable logic unit is used to receive the denoised digital signal, preprocess the denoised digital signal, and obtain a standardized sampling data frame. The main controller is specifically used to receive standardized sampling data frames output by the programmable logic unit, convert the standardized sampling data frames into real-time energy parameters through an energy metering algorithm, and transmit the real-time energy parameters to the host computer through the host computer interface.

[0042] In this embodiment, the main controller is also used to: receive a second control command sent by the host computer through the host computer interface, so as to realize the monitoring and control of the charging pile detection device.

[0043] In this embodiment, the second control command may include operation control commands (e.g., controlling the operation and pause of the charging pile detection device, controlling the charging pile detection device to reset, etc.), parameter configuration commands (e.g., preset ratio configuration), and data request commands (e.g., real-time power parameter request commands). This embodiment can monitor and control the charging pile detection device in the following ways: The host computer interface sends a second control command to the main controller. Upon receiving the second control command, the main controller verifies and parses its type, determining the command's type and specific parameters. If the parsed second control command is an operation control command, the main controller controls the relevant modules to run or switch operating modes. The main controller then sends the execution result to the host computer.

[0044] In this embodiment, see Figure 3 The Complex Programmable Logic Device (CPLD) is located between the magnetic isolator and the main controller. It interacts with the magnetic isolator via SPI communication and transmits data to the main controller via a 16-bit parallel bus.

[0045] In this embodiment, the programmable logic unit can receive the denoised digital signal output from the magnetic isolator, preprocess the denoised digital signal to obtain a standardized sampling data frame, and transmit the standardized sampling data frame to the main controller at high speed via a 16-bit parallel bus. The main controller can receive the standardized sampling data frame and convert it into real-time energy parameters through an energy metering algorithm; the main controller can also transmit the real-time energy parameters to the host computer via a host computer interface.

[0046] In this embodiment, the main controller can also receive data output by the programmable logic unit, thereby completing core tasks such as calculation, analysis, and storage within the main controller.

[0047] In this embodiment, the programmable logic device (PLD) receives the A / D converter signal processed by the magnetic isolation module, and then transmits the processed data to the main controller at high speed via a 16-bit parallel bus. The data output by the CPLD is the A / D sample value after code conversion. The measurement signal is first preprocessed (e.g., filtered, isolated, etc.) and converted into an effective signal in the range of 0 to 2.5V before being input to the A / D converter.

[0048] In this embodiment, the host computer interface serves as the communication interface between the field testing instrument and an external host computer (e.g., a computer, monitoring equipment, etc.). Data processed by the main controller is uploaded to the host computer through this interface. The main controller in this embodiment can also receive second control commands from the host computer, enabling remote monitoring and operation of the testing device.

[0049] This embodiment uses a 16-bit parallel bus as a high-speed data transmission link between the Central Processing Unit (CPU) and the main controller to achieve short-distance, high-bandwidth digital data interaction.

[0050] In one embodiment, the core processing module 13 further includes a control guidance circuit electrically connected to the main controller. The control and guidance circuit is used to output guidance signals or interlock signals that conform to preset safety specifications according to the instructions of the main controller.

[0051] In this embodiment, the control guidance circuit can simulate charging connection and control logic according to the instructions of the main controller, and output guidance signals or interlock signals that conform to preset safety specifications to the charging pile to verify the compliance of the charging pile. Among them, preset safety specifications refer to the mandatory safety communication and interoperability protocol standards between supercharging piles and electric vehicles (e.g., national standards such as GB / T 18487.1 and GB / T 27930).

[0052] In this embodiment, the guiding signal can be a simulated instruction to guide the supercharging pile to start and complete the safety process; the interlocking signal can be a switch signal to forcibly lock or unlock the safety system.

[0053] In this embodiment, the core processing module 13 further includes a control and guidance circuit electrically connected to the main controller. This control and guidance circuit can output guidance signals or interlock signals that conform to preset safety specifications according to the instructions of the main controller. See also Figure 3 In this embodiment, the control and guidance circuit can handle the hardware control logic of the device, simulating the vehicle's connection and insulation states during charging. Based on these states, it confirms physical connections, simulates fault phenomena, and triggers safety procedures, thereby verifying whether the supercharging pile meets the national standards for connection confirmation, insulation detection, and safety protection. The control and guidance circuit in this embodiment can also work with the main controller to guide the startup and control the operation of the on-site testing instrument.

[0054] In one implementation, the main controller is further configured to analyze the ripple content of the digitized first voltage signal and the digitized DC voltage signal, respectively, to evaluate the power quality of the DC current detection circuit and the power quality of the DC voltage detection circuit.

[0055] In this embodiment, high-frequency voltage and current data from the supercharging pile are acquired in real time via an analog-to-digital converter (ADC). The voltage and current data are then digitized using the ADC to obtain a first digitized voltage signal and a digitized DC voltage signal. Analysis of these signals yields the ripple content in the DC current detection circuit and the DC voltage detection circuit, thereby determining the power quality of the DC monitoring circuit and the DC voltage detection circuit. In this embodiment, ripple content is a key indicator for evaluating power quality; a lower ripple content value indicates higher power quality.

[0056] In this embodiment, the core processing module 13 also includes an energy pulser, which can provide a time reference or metering pulse (e.g., a sampling clock or energy metering pulse) to the main controller, thereby providing the main controller with a timestamp, sampling synchronization signal, or for the metering and statistics of energy data.

[0057] For example, the analog-to-digital converter (ADC) uses SPI communication to reduce the burden on the main controller. An additional CPLD is added to process the data after the ADC. The CPLD communicates with the main controller via a 16-bit parallel bus, significantly improving transmission speed. Furthermore, because this embodiment uses a high-speed ADC, FFT analysis of the voltage and current allows for the determination of ripple content in the voltage and current loops. The ADC and digital circuitry are electrically isolated from each other using a magnetic isolator to prevent mutual interference between the analog and digital circuits.

[0058] In this embodiment, the FFT analysis is the Fast Fourier Transform (FFT). The core function of FFT is to convert time-domain signals (signals that change over time, such as sound waveforms and voltage fluctuations) into frequency-domain signals, which can clearly present the various frequency components contained in the signal and their respective intensities.

[0059] In one embodiment, the core processing module 13 further includes a front-end circuit, and the main controller is connected to the front-end circuit. The main controller includes an analog-to-digital conversion subunit and a digital-to-analog conversion subunit. The front-end circuit includes a first linear optocoupler, a second linear optocoupler, and a high-voltage module. The first linear optocoupler is used to receive the first voltage signal output by the dynamic response current sensing module and the second voltage signal from the charging pile output current shunt, and sends the first voltage signal and the second voltage signal to the main controller through the multi-channel input port of the analog-to-digital conversion subunit; wherein, the first voltage signal is used as a detection signal and the second voltage signal is used as a calibration signal to calibrate the first voltage signal; The analog-to-digital converter subunit is also used to convert the second voltage signal into a digital signal and send the digital signal to the main controller; The main controller is also used to calibrate the digital signal corresponding to the first voltage signal based on the digital signal to obtain the calibrated first voltage digital signal; The digital-to-analog converter subunit is used to convert the calibrated first voltage digital signal output by the main controller into an analog control signal, and send the analog control signal to the second linear optocoupler; The second linear optocoupler is used to isolate the analog control signal and send the isolated analog control signal to the high-voltage module; the isolated analog control signal is used to control the output characteristics of the high-voltage module.

[0060] In this embodiment, the first voltage signal can be calibrated in the following manner: The main controller converts the second voltage signal into a first current value, which is then used as a reference value. The main controller then converts the first voltage signal into a second current value and compares the second current value with the reference value. If the second current value is exactly equal to the reference value, it is determined that no calibration of the first voltage signal is required. If there is a deviation between the second current value and the reference value, a calibration coefficient is determined based on this deviation and by the main controller. The first voltage signal is then calibrated using this calibration coefficient to obtain a calibrated first voltage signal.

[0061] The output characteristics in this embodiment may include the voltage level, load characteristics, and equivalent internal resistance of the object under test (e.g., electric vehicle, load, etc.).

[0062] In this embodiment, the output characteristics of the high-voltage module can be controlled in the following manner: The isolated analog control signal is input to the control terminal of the high-voltage module, which can interpret the analog control signal as its own output command. For example, if the analog control signal is 2.5V, the internal circuit of the high-voltage module will interpret it as "clamp the output voltage at 500V".

[0063] In this embodiment, see Figure 4The main control module has four built-in analog-to-digital converter (ADC) channels and one digital-to-analog converter (DAC) channel. It can acquire the CC1 and CC2 voltages and the A+ and A- voltage and current from the control and guidance circuit. The DAC channel converts the small voltage signal output to the high-voltage module into a large voltage signal (the large voltage signal is the vehicle battery voltage simulated by the field tester) according to a preset ratio. In this embodiment, the preset ratio can be configured by a host computer and sent to the main controller, or it can be preset by the debugging personnel. Both the control and guidance circuit and the digital section are linearly optocoupled for isolation.

[0064] Specifically, the main controller's control and computing center is used to receive digital signals transmitted by the ADC and complete data processing (e.g., electrical parameter monitoring and calculation); at the same time, it outputs control signals to control and regulate external modules (high voltage modules) through the DAC.

[0065] In this embodiment, the ADC1-ADC4 are used to convert the isolated analog electrical signals into digital signals for the main controller to perform calculations; the DAC is used to convert the digital control signals output by the main controller into analog signals to drive the external high-voltage module.

[0066] This embodiment also employs two sets of linear optocouplers for electrical isolation, for example, to isolate high-voltage and low-voltage circuits and prevent high-voltage interference / damage to the low-voltage control circuit. Simultaneously, it maintains linear signal transmission, ensuring undistorted analog signal transmission.

[0067] In this embodiment, the first linear optocoupler connects to the ADC, which can isolate the front-end circuit from the main controller and transmit the acquired analog electrical signals; the second linear optocoupler connects to the DAC, which can isolate the main controller from the high-voltage module and transmit the analog signals controlling the high-voltage module.

[0068] In this embodiment, the front-end circuit may include CC1, CC2, A+A- (voltage), and A+A- (current). The current signal acquired by the current acquisition module (e.g., a current sensor) is transmitted to the first linear optocoupler via the CC1 and CC2 ports; the voltage signal from an external circuit acquired by the voltage acquisition module is transmitted to the first linear optocoupler via the A+A- (voltage) port; and the current signal acquired by another current acquisition module is transmitted to the first linear optocoupler via the A+A- (current) port, thereby achieving multi-channel current monitoring (or redundant acquisition). The high-voltage module receives the isolated analog control signal and outputs a high-voltage electrical signal.

[0069] In this embodiment, the auxiliary power supply current output by the charging pile is acquired through CC1 and CC2, the auxiliary power supply voltage output by the charging pile is acquired through A+A- voltage, and the auxiliary power supply current signal output by the charging pile is acquired through A+A- current. These signals are used to determine the timing of the charging process and whether the charging process meets standard requirements, thus obtaining an analog electrical signal. The transmission of the analog signal is isolated by a first linear optocoupler and a second linear optocoupler, achieving isolation between high and low voltage circuits while simultaneously transmitting the analog signal linearly. Through analog-to-digital conversion and processing, the isolated analog signal is sent to the ADC1-ADC4 channels of the main controller, converting it into a digital signal. The main controller then performs data processing, monitoring, and other tasks.

[0070] In this embodiment, the main controller generates digital control instructions according to preset requirements. These digital control instructions are converted into analog control signals through a DAC channel. The analog control signals are then passed through a second linear optocoupler isolation high-low voltage circuit to obtain isolated analog signals. The isolated analog signals are then input into the high-voltage module to control it to output the corresponding high-voltage signals.

[0071] The core feature of the entire system is that it achieves high-low voltage isolation through linear optocouplers, which not only ensures the accuracy of electrical parameter acquisition, but also avoids interference and damage to the low-voltage control circuit by the high-voltage circuit.

[0072] In this embodiment, the current transformer uses a nanoampere-level zero-flux current sensor for closed-loop sampling and a multi-stage programmable gain amplifier chain structure to achieve a dynamic range coverage of 120dB, meeting the requirements for sampling across a wide current range of 5-800A.

[0073] In this embodiment, the DC voltage detection unit employs a low-temperature drift precision resistor voltage divider network combined with a temperature compensation algorithm, along with a low-temperature drift chopper amplifier and a programmable gain amplifier, to meet the 100-1500V voltage measurement requirements. This embodiment uses a multi-stage programmable gain amplifier chain cascade architecture. Each stage amplifier can be configured with a gain of 1-8 times. Through the series cascading of two stages, based on the amplifier cascade gain product principle, the total system gain can achieve a signal amplification of 1-64 times. This chain structure combines high-gain amplification with flexible programmable adjustment, and through precise gain matching, it can effectively improve the amplitude output of weak signals, meeting the high-precision signal acquisition requirements under low-current conditions.

[0074] In one embodiment, the dynamic response current sensing module is a DC detection module based on the zero flux feedback principle. The DC detection module includes a DC comparator, a detection core, and an amplifier. The DC comparator includes a modulation detection winding, a demodulator, and a modulation oscillator. A detection core is used to couple a DC current signal into a DC flux to be measured in the detection core. A modulation oscillator is used to generate a modulation signal and to excite the modulation detection winding to produce an alternating modulation magnetic field through the modulation signal; The demodulator is used to detect the change in magnetic flux of the detection core under the combined action of the DC magnetic flux to be measured and the alternating modulated magnetic field, and outputs the corresponding error signal based on the change in magnetic flux. An amplifier is used to generate a feedback compensation current based on the error signal. The feedback compensation current is used to control the magnetic flux of the detection core to be zero. The first voltage signal is determined based on the feedback compensation current, and the first voltage signal is a voltage signal that is proportional to the feedback compensation current.

[0075] In this embodiment, the modulation signal is a high-frequency modulation signal. This high-frequency modulation signal can be a sine wave or square wave of a preset frequency generated by a crystal oscillator circuit, and the sine wave or square wave is used as the high-frequency modulation signal. The preset frequency in this embodiment can be adjusted according to the actual scenario.

[0076] See Figure 5 The DC detection module includes a DC comparator, a precision resistor, and an amplifier. The DC comparator may include a modulation detection winding (detection group D, signal group S), a demodulator, and a modulation oscillator. The detection group D of the modulation detection winding is connected in series with the modulation oscillator and electrically connected to the demodulator. The signal group of the modulation detection winding is electrically connected to a resistor and an amplifier, respectively, and the amplifier is electrically connected to the demodulator. When the DC detection module is operating, if current flows through IP, the magnetic flux of the core is not zero. The magnetic field generated by the primary current will cause the core to saturate prematurely within a certain cycle. The amplifier detects the asymmetrical waveform and generates a secondary current IS through feedback adjustment, causing the core to return to zero magnetic flux.

[0077] The specific algorithmic expression for feedback regulation can be: ,in, , K This is the proportional coefficient of the comparator, which can be determined based on the number of turns in the primary winding. W P and the number of turns of the secondary winding W S Decide, I P The primary current, W P This refers to the number of turns in the primary winding. I S For secondary current, W S This refers to the number of turns in the secondary winding. I D To detect the winding current, W D To detect the number of turns in the winding.

[0078] In this embodiment, the voltage is sampled using a precision resistor. Since the voltage measurement range is wide, a programmable gain amplifier is added in the subsequent stage to ensure measurement accuracy across the entire range.

[0079] In this embodiment, the supercharging pile field tester for high-power charging scenarios is equipped with a liquid cooling system, which can support a maximum charging current of 1000A and a maximum voltage of 1500V, and is capable of measuring and testing supercharging piles.

[0080] The DC current detection unit of the present invention uses a DC comparator in conjunction with precision resistor sampling and programmable gain amplifier data sampling, which has the advantages of fast response speed, wide measurement frequency, primary and secondary isolation, and good linearity.

[0081] As can be seen from the above, this embodiment acquires a DC current signal through a dynamic response current sensing module and converts it into a first voltage signal. A DC voltage detection module acquires a DC voltage signal, and the core processing module 13 receives and processes these signals to obtain real-time power parameters. Then, combined with preset temperature conditions, a first control command is generated to control the liquid cooling control module to adjust the charging pile's heat dissipation power. This embodiment enables the charging pile's heat dissipation to be dynamically adjusted according to actual power parameters and temperature conditions, avoiding energy waste caused by excessive heat dissipation and equipment damage caused by insufficient heat dissipation. This improves the stability and reliability of the charging pile's operation and extends the equipment's service life.

[0082] In this embodiment, the first voltage signal and the DC voltage signal are sampled and digitized using an analog-to-digital converter. The digitized digital signal is then denoised using a magnetic isolator, resulting in a denoised digital signal that the main controller uses to determine real-time power parameters. This embodiment effectively reduces noise interference during signal transmission and processing, improving signal accuracy and reliability. This, in turn, makes the acquisition of real-time power parameters more precise, providing a reliable basis for subsequent operations such as heat dissipation control.

[0083] This embodiment can also analyze the ripple content of the digitized first voltage signal and DC voltage signal separately, and evaluate the power quality of the DC current detection circuit and DC voltage detection circuit. This embodiment can not only provide a comprehensive understanding of the charging pile's power status and promptly detect potential power quality problems, but also provide a reference for other control functions of the main controller.

[0084] In this embodiment, the first voltage signal output from the dynamic response current sensing module and the second voltage signal from the charging pile output current shunt are received by the first linear optocoupler in the front-end circuit. These signals are then sent to the main controller via the multi-channel input port of the analog-to-digital converter subunit. The second voltage signal serves as a calibration signal to calibrate the first voltage signal. This effectively eliminates potential errors in the transmission and detection of the first voltage signal, improving signal accuracy. Furthermore, the analog control signal is isolated by the second linear optocoupler and then sent to the high-voltage module to control its output characteristics, achieving precise control of the high-voltage module. Simultaneously, optocoupler isolation ensures the safety and stability of signal transmission.

[0085] A charging pile detection device corresponding to the above embodiment, Figure 6 This is a schematic flowchart illustrating a charging pile detection method according to an embodiment of this application. For ease of explanation, only the parts relevant to the embodiment of this application are shown. References Figure 6 The charging pile testing method includes: S101: Acquires the DC current signal output by the charging pile, and converts the DC current signal into a first voltage signal through magnetic modulation and zero magnetic flux feedback technology; S102: Obtain the DC voltage signal output by the charging pile; S103: Receive and process the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile; generate the first control command based on the real-time power parameters and the preset temperature conditions; the real-time power parameters are used to determine the heat dissipation requirement benchmark, and the preset temperature conditions are used to dynamically adjust or correct the heat dissipation requirement benchmark. S104: Control and adjust the heat dissipation power of the charging pile according to the first control command.

[0086] In one embodiment, receiving and processing a first voltage signal and a DC voltage signal to obtain real-time power parameters of the charging pile includes: The first voltage signal and the DC voltage signal are sampled and digitized to obtain the digitized first voltage signal and the digitized DC voltage signal; The digitized first voltage signal and the digitized DC voltage signal are denoised to obtain a denoised digital signal, which includes the denoised first voltage signal and the denoised DC voltage signal. The real-time power parameters of the charging pile are determined based on the denoised digital signal.

[0087] In this embodiment, the digitized first voltage signal and the digitized DC voltage signal are filtered and denoised. For example, the digitized first voltage signal and the digitized DC voltage signal can be filtered by a digital filter (such as a low-pass filter or a moving average filter) to suppress high-frequency noise, power frequency interference and random interference, and obtain a smooth and stable denoised digital signal (including the denoised first voltage signal and the denoised DC voltage signal).

[0088] For example, in this embodiment, after acquiring the current signal output by the supercharging pile, the current signal is transmitted to the current transformer; the current transformer isolates or transforms the current signal, converting the current signal into a signal that can be recognized by the core processing module 13, and then transmits the signal to the core processing module 13 to monitor the current signal in real time. After acquiring the voltage signal output by the supercharging pile, the voltage signal is directly transmitted to the core processing module 13 to monitor the voltage signal in real time. The charging power is determined based on the current signal and voltage signal, and a first control command is generated based on the charging power. The first control command is sent to the liquid cooling control module 14 to adjust the heat dissipation power of the supercharging pile.

[0089] This embodiment employs a ripple algorithm. During ripple analysis, the actual sampled voltage or current values ​​are used as ripple points, and the discrete values ​​acquired by the analog-to-digital converter at a specific instant are used as waveform points. The specific instant can be an equal sampling interval (fixed sampling rate) or a non-equal sampling interval.

[0090] In this embodiment, the sampled waveform points are subjected to Discrete Fourier Transform (FFT) to decompose the signal into multiple single-frequency components, thereby obtaining the amplitude and phase information of each frequency component. The collected current waveform data is processed by Fast Fourier Transform (FFT) to extract the frequency domain components (amplitude and phase information), identify indicators such as ripple and power fluctuation, and evaluate the stability and purity of power output based on the ripple content.

[0091] Specifically: 1) Sample the current signal at the frequency specified by the Nyquist sampling theorem. Discretize the sequence to obtain the numerical sequence X(n); 2) Preprocess the digital sequence to reduce spectral leakage; in this embodiment, preprocessing may include noise reduction (e.g., filtering), truncation (selecting a data segment of appropriate length), and window function processing (e.g., Hanning window). 3) Use the FFT algorithm to transform the preprocessed sequence x(n) to obtain the frequency domain sequence X(k); 4) Extract frequency domain components from the frequency domain sequence to identify indicators such as ripple and power fluctuation; 5) Determine the stability and purity of power output based on indicators such as ripple and power fluctuation.

[0092] In this embodiment, the original continuous signal is recovered without distortion from the sampled discrete signal, based on the sampling frequency of the Nyquist sampling theorem. The following relationship must be satisfied: ,in, Indicates the sampling frequency. This represents the highest frequency component in the original signal.

[0093] In this embodiment, the current signal acquisition method uses a DC comparator combined with precision resistor sampling and a programmable gain amplifier to complete data sampling, achieving high dynamic response capability of the current detection channel. This embodiment generates periodic excitation by modulating the magnetic core winding and utilizes the magnetic flux change feedback compensation principle to achieve high-sensitivity current restoration. In this embodiment, the acquired current waveform data is processed by Fast Fourier Transform (FFT) to extract frequency domain components and identify indicators such as ripple and power fluctuations, thereby evaluating the stability and purity of the power output. This embodiment, using a DC comparator combined with precision resistor sampling and a programmable gain amplifier for data sampling, has advantages such as fast response speed, wide measurement frequency, primary and secondary isolation, and good linearity.

[0094] Each step of the charging pile detection method in this embodiment is executed by the modules described in the foregoing corresponding device embodiments. Those skilled in the art should understand that the aforementioned device implementation naturally reveals the complete implementation steps of the charging pile detection method; that is, the method can be implemented by operating each module of the device to perform its corresponding function. For the sake of brevity, the method steps will not be repeated here.

[0095] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A charging pile testing device, characterized in that, include: The system includes a dynamic response current sensing module, a DC voltage detection module, a core processing module, and a liquid cooling control module. The dynamic response current sensing module is used to acquire the DC current signal output by the charging pile, convert the DC current signal into a first voltage signal through magnetic modulation and zero magnetic flux feedback technology, and send the first voltage signal to the core processing module. The DC voltage detection module is used to acquire the DC voltage signal output by the charging pile and send the DC voltage signal to the core processing module. The core processing module is used to receive and process the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile. Based on the real-time power parameters and preset temperature conditions, a first control command is generated and sent to the liquid cooling control module. The real-time power parameters are used to determine the heat dissipation requirement benchmark, and the preset temperature conditions are used to dynamically adjust or correct the heat dissipation requirement benchmark. The liquid cooling control module is used to control and adjust the heat dissipation power of the charging pile according to the first control command.

2. The apparatus as claimed in claim 1, characterized in that, The core processing module includes a main controller, a magnetic isolator, and an analog-to-digital converter, with the magnetic isolator disposed between the analog-to-digital converter and the main controller; The analog-to-digital converter is used to sample and digitize the first voltage signal and the DC voltage signal to obtain the digitized first voltage signal and the digitized DC voltage signal. The magnetic isolator is used to denoise the digitized first voltage signal and the digitized DC voltage signal to obtain a denoised digital signal; the denoised digital signal includes the denoised first voltage signal and the denoised DC voltage signal. The main controller is used to determine the real-time power parameters of the charging pile based on the denoised digital signal.

3. The apparatus as described in claim 2, characterized in that, The core processing module also includes a programmable logic unit electrically connected to the magnetic isolator; The programmable logic unit is used to receive the denoised digital signal, preprocess the denoised digital signal, and obtain a standardized sampling data frame. The main controller is specifically used to receive the standardized sampling data frame output by the programmable logic unit, convert the standardized sampling data frame into the real-time power parameters through the power metering algorithm, and transmit the real-time power parameters to the host computer through the host computer interface.

4. The apparatus as described in claim 2, characterized in that, The core processing module also includes a control and guidance circuit electrically connected to the main controller. The control and guidance circuit is used to output guidance signals or interlock signals that conform to preset safety specifications according to the instructions of the main controller.

5. The apparatus according to any one of claims 2-4, characterized in that, The main controller is a microcontroller based on the ARM architecture; the main controller is also used to analyze the ripple content of the digitized first voltage signal and the digitized DC voltage signal respectively, so as to evaluate the power quality of the DC current detection circuit and the power quality in the DC voltage detection circuit.

6. The apparatus as claimed in claim 1, characterized in that, The main controller is further configured to: receive a second control command sent by the host computer through the host computer interface, so as to monitor and control the device.

7. The apparatus as claimed in claim 2, characterized in that, The core processing module also includes a front-end circuit, and the main controller is connected to the front-end circuit. The main controller includes an analog-to-digital conversion subunit and a digital-to-analog conversion subunit. The front-end circuit includes a first linear optocoupler, a second linear optocoupler, and a high-voltage module. The first linear optocoupler is used to receive the first voltage signal output by the dynamic response current sensing module and the second voltage signal from the charging pile output current shunt, and to send the first voltage signal and the second voltage signal to the main controller through the multi-channel input port of the analog-to-digital conversion subunit; wherein, the first voltage signal is used as a detection signal and the second voltage signal is used as a calibration signal to calibrate the first voltage signal; The analog-to-digital converter subunit is further configured to convert the second voltage signal into a digital signal and send the digital signal to the main controller; The main controller is further configured to calibrate the digital signal corresponding to the first voltage signal according to the digital signal to obtain the calibrated first voltage digital signal. The digital-to-analog converter subunit is used to convert the calibrated first voltage digital signal output by the main controller into an analog control signal, and send the analog control signal to the second linear optocoupler; The second linear optocoupler is used to isolate the analog control signal and send the isolated analog control signal to the high-voltage module; the isolated analog control signal is used to control the output characteristics of the high-voltage module.

8. The apparatus as claimed in claim 1, characterized in that, The dynamic response current sensing module is a DC detection module based on the zero flux feedback principle. The DC detection module includes a DC comparator, a detection core, and an amplifier. The DC comparator includes a modulation detection winding, a demodulator, and a modulation oscillator. The detection magnetic core is used to couple the DC current signal into a DC magnetic flux to be measured in the detection magnetic core. The modulation oscillator is used to generate a modulation signal and to excite the modulation detection winding to generate an alternating modulation magnetic field through the modulation signal; The demodulator is used to detect the change in magnetic flux of the detection core under the combined action of the DC magnetic flux to be measured and the alternating modulated magnetic field, and output a corresponding error signal based on the change in magnetic flux. The amplifier is used to generate a feedback compensation current based on the error signal, and the feedback compensation current is used to control the magnetic flux of the detection core to be zero. The first voltage signal is determined based on the feedback compensation current, and the first voltage signal is a voltage signal that is proportional to the feedback compensation current.

9. A method for detecting charging piles, characterized in that, include: The DC current signal output by the charging pile is acquired, and the DC current signal is converted into a first voltage signal through magnetic modulation and zero flux feedback technology. Obtain the DC voltage signal output by the charging pile; Receive and process the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile; A first control command is generated based on the real-time power parameters and preset temperature conditions; The real-time power parameters are used to determine the heat dissipation requirement benchmark, and the preset temperature conditions are used to dynamically adjust or correct the heat dissipation requirement benchmark. The heat dissipation power of the charging pile is controlled and adjusted according to the first control command.

10. The method as described in claim 9, characterized in that, The step of receiving and processing the first voltage signal and the DC voltage signal to obtain the real-time power parameters of the charging pile includes: The first voltage signal and the DC voltage signal are sampled and digitized to obtain the digitized first voltage signal and the digitized DC voltage signal; The digitized first voltage signal and the digitized DC voltage signal are denoised to obtain a denoised digital signal, which includes the denoised first voltage signal and the denoised DC voltage signal. The real-time power parameters of the charging pile are determined based on the noise-reduced digital signal.

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