A two-way communication fault early warning system for charging pile and charging gun

Abstract

The application discloses a kind of two-way communication fault early warning systems of charging pile and charging gun, it is related to electric vehicle charging technical field, contains eight big core modules of two-way communication link, communication signal acquisition and analysis, link state real-time monitoring, communication fault feature extraction, hierarchical fault early warning, fault root cause positioning, cloud data interaction, local emergency control, two-way communication link module establishes the full duplex two-way communication link of charging pile and charging gun, the rest module is respectively completed signal analysis processing, link full period monitoring, fault feature extraction, hierarchical fault early warning, fault root cause positioning, cloud data interaction, local emergency safety control function, guarantee charging process communication stability and electrical safety.The application can accurately identify the two-way communication exception of charging pile and charging gun, realize fault early warning and accurate root cause positioning, effectively guarantee charging electrical safety, substantially reduce operation and maintenance cost, comprehensively improve the stability of charging system operation and operation and maintenance efficiency.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle charging technology, and in particular to a two-way communication fault early warning system between a charging pile and a charging gun. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the number of electric vehicles continues to rise, and the scale of supporting charging infrastructure construction is constantly expanding. As the core carrier for energy replenishment of electric vehicles, the operational stability and safety of charging piles directly affect the user experience and popularization of electric vehicles. The charging gun, as the physical connection and data interaction medium between the charging pile and the electric vehicle, has a bidirectional communication link with the charging pile that is the core foundation for realizing the interaction of charging control commands, real-time feedback of charging status, and execution of electrical safety protection logic. The stable operation of the communication link directly determines the safety and continuity of the charging process. Currently, the research and optimization of most charging pile control systems focus on improving charging power, electrical short-circuit protection, and overcurrent and overvoltage protection. There is a lack of systematic design for the status monitoring and fault early warning of the bidirectional communication link between the charging pile and the charging gun. Most existing charging systems can only trigger shutdown protection after a complete interruption of bidirectional communication, failing to identify abnormal characteristics and issue warnings in the early stages of communication failure. This easily leads to unplanned interruptions during charging, not only affecting the user's charging experience but also potentially causing control logic failure due to communication anomalies, thus leading to electrical safety hazards during charging.

[0003] Existing monitoring solutions for communication faults between charging piles and charging guns mostly only enable post-event identification of severe communication interruptions. They cannot accurately capture and identify early communication anomalies such as data packet loss, excessive command response delays, and signal distortion, making it difficult to provide early warnings and intervention for communication faults. Furthermore, existing monitoring solutions struggle to effectively distinguish between normal communication signal fluctuations caused by environmental electromagnetic interference and grid voltage fluctuations and genuine fault characteristics, easily leading to false and missed warnings. This not only fails to provide effective fault prevention but also disrupts the normal operation of the charging system due to frequent false warnings. In addition, after identifying communication anomalies, existing solutions cannot accurately pinpoint the specific location and root cause of the fault. They struggle to differentiate between different types of faults, such as poor physical link contact, communication protocol incompatibility, equipment hardware performance degradation, and environmental interference. Maintenance personnel must physically visit the site to investigate each issue, significantly increasing the difficulty and cost of maintaining charging infrastructure. This is especially problematic in large-scale charging station clusters where the decentralized fault monitoring model cannot achieve centralized maintenance management, resulting in even more pronounced inefficiencies.

[0004] Existing charging systems generally lack the ability to quantitatively assess the health status of the bidirectional communication link between charging piles and charging guns. They cannot effectively predict the performance degradation trend of the communication link, and can only passively handle faults after they occur, making it difficult to achieve full lifecycle management of the charging gun communication hardware. Furthermore, most existing monitoring systems only support local data storage and fault display, lacking stable cloud data interaction capabilities and remote operation and maintenance debugging functions. After a fault occurs, maintenance personnel cannot remotely retrieve and analyze the full fault data, nor can they remotely perform parameter calibration and fault troubleshooting; they must go to the site to handle the fault, further lengthening the fault handling cycle. In addition, the communication protocols used by charging piles and charging guns from different manufacturers differ, resulting in varying communication fault characteristics. Existing monitoring solutions have fixed fault characteristic databases that cannot be iteratively updated, making it difficult to adapt to the fault identification needs of different brands and models of equipment. Their generalization ability is insufficient, failing to meet the fault early warning and operation and maintenance management needs of charging infrastructure in different application scenarios nationwide. Summary of the Invention

[0005] The present invention proposes a highly efficient encrypted tablet data protection system and implementation method to solve the problems mentioned in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a two-way communication fault early warning system for charging piles and charging guns, comprising a two-way communication link module, a communication signal acquisition and analysis module, a link status real-time monitoring module, a communication fault feature extraction module, a graded fault early warning module, a fault root cause location module, a cloud data interaction module, and a local emergency control module. The bidirectional communication link module establishes a full-duplex bidirectional communication link between the charging pile and the charging gun, supports real-time interaction of control guidance signals and connection confirmation signals, is compatible with CAN bus and power line carrier communication protocols, and realizes bidirectional synchronous transmission of charging control commands, charging status data, and equipment operating parameters. The communication signal acquisition and analysis module acquires raw signal data in the bidirectional communication link in real time, performs filtering and noise reduction and level calibration preprocessing on the acquired signals, completes the protocol parsing and data decoding of the signals, extracts command frames, data frames and response frames in the communication interaction, and synchronously records the timestamp, level amplitude and transmission delay core parameters of the signal transmission. The link status real-time monitoring module continuously monitors the parsed communication data throughout the day, and tracks the signal transmission success rate, data packet loss rate, command response delay, signal level fluctuation range and other operating parameters of the communication link in real time. It also collects the connection status of the charging pile and charging gun, power supply voltage, and ambient temperature and humidity related operating data. The communication fault feature extraction module, based on a preset fault feature library, extracts features from the monitored link operation parameters, identifies feature vectors of abnormal communication states such as communication interruption, data packet loss, no command response, signal distortion, and time delay exceeding limits, and distinguishes between normal communication fluctuations and fault feature signals. The graded fault early warning module, based on the extracted fault feature vector and compared with the preset fault level threshold, divides the fault into three levels: early warning, alarm, and emergency shutdown, triggering different early warning actions accordingly, and simultaneously pushes the early warning information to the local display terminal of the charging pile and the operation and maintenance management platform. The fault root cause localization module combines fault feature vectors, historical link operation data, and device association parameters to locate the location and root cause of communication faults through fault matching algorithms, and distinguishes different types of faults such as physical link faults, protocol mismatch faults, device hardware faults, and environmental interference faults. The cloud data interaction module establishes a data connection with the cloud operation and maintenance platform through a wireless communication network, and uploads communication link operation data, fault warning information, and root cause location results in real time. At the same time, it receives fault feature library update packages, warning threshold adjustment parameters, and remote operation and maintenance instructions issued by the cloud. The local emergency control module is connected to the main control unit of the charging pile. When an emergency communication failure is detected, it automatically triggers a safety shutdown process, cuts off the charging output circuit, blocks the charging gun unlocking operation, and simultaneously stores the fault status in the local storage unit.

[0007] Furthermore, it also includes a communication link health quantification and evaluation module. This module quantifies and scores the overall operating status of the bidirectional communication link based on real-time monitoring data and historical operating data, and introduces a comprehensive health calculation formula for the communication link: ; in A comprehensive health score for the two-way communication link. To improve the success rate of communication signal transmission, For data packet loss rate, To average the response time to the command, The standard response delay threshold, This represents the actual average signal level amplitude. The rated standard level amplitude of the signal is η, and the environmental interference correction coefficient ranges from 0 to 1. The link's operating status is intuitively quantified through a comprehensive health score, providing a preliminary judgment basis for fault warning. When the health score is lower than a preset threshold, an early warning is triggered, enabling the early prediction of communication faults and providing a quantitative reference standard for the daily operation and maintenance of the link.

[0008] Furthermore, it also includes a fault feature library self-updating module. This module continuously collects fault samples, fault confirmation feedback from maintenance personnel, and fault handling result data during system operation. It incrementally updates and iteratively optimizes the fault feature vectors, fault type matching rules, and fault level thresholds in the fault feature library. At the same time, it uses clustering algorithms to mine the feature patterns of newly added fault types and supplements the fault feature library with new fault features, continuously improving the system's ability to identify and adapt to various communication faults.

[0009] Furthermore, it also includes an environmental interference compensation module. This module collects environmental parameters such as temperature and humidity, electromagnetic interference intensity, and voltage fluctuation amplitude at the installation site of the charging pile and charging gun in real time. It establishes a correlation mapping model between environmental parameters and communication signal distortion. Based on the model output results, it performs dynamic compensation and calibration on the collected communication signals to eliminate signal measurement deviations caused by environmental factors, improve the accuracy of identifying abnormal communication states, and reduce false alarms caused by environmental interference.

[0010] Furthermore, it also includes a full lifecycle operation and maintenance management module for charging guns. This module records the historical operation data of the communication link of each charging gun, the number of failures, the type of failure, the number of plugging and unplugging, and the usage time throughout the entire lifecycle. Based on the data, it establishes a charging gun communication performance degradation trend model, predicts the service life of the charging gun communication hardware, and pushes maintenance and replacement reminders for the charging gun in advance, thereby reducing the probability of two-way communication failures from the hardware source.

[0011] Furthermore, it also includes a multi-pile cluster communication status collaborative monitoring module. This module enables centralized monitoring and unified management of the bidirectional communication status of multiple charging piles and their corresponding charging guns within the same charging station. It establishes a cluster communication status topology map of the charging station, intuitively displaying the operating status and health level of each communication link. At the same time, it enables the sharing and cross-verification of fault data within the same station, improving the accuracy of fault identification and the efficiency of operation and maintenance management in cluster scenarios.

[0012] Furthermore, it also includes a fault warning accuracy optimization module. This module iteratively optimizes the parameters of the warning model based on historical warning data and actual fault confirmation results, and introduces a quantitative calculation formula for the comprehensive accuracy of fault warnings: ; in To improve the overall accuracy of fault warnings, The number of fault samples that provide accurate early warnings. This represents the number of samples that triggered false alarms. This represents the number of fault samples that were missed in the early warning system. This represents the average lead time for fault warnings. The standard warning advance time threshold is set, and γ is the fault level matching coefficient, with a value ranging from 0 to 1. The comprehensive performance of the warning model is evaluated by calculation, providing a quantitative basis for the optimization of model parameters, continuously improving the accuracy and advance of fault warnings, and reducing the probability of false and missed warnings.

[0013] Furthermore, the communication link health quantification and evaluation module generates a communication link health report for each charging gun corresponding to a single charging pile according to a set time period. At the same time, it compares the health scores of all charging guns in the same charging station to generate a health ranking and an abnormal link list. This provides a priority ranking basis for the daily operation and maintenance work of the charging station and helps maintenance personnel accurately locate the charging guns and communication links that need to be maintained.

[0014] Furthermore, the fault feature database self-updating module receives fault feature data of the same model of equipment nationwide through the cloud data interaction module, realizing the synchronous update of the fault feature database across the entire network. This enables a single device to quickly adapt to various communication fault types in different regions and application scenarios across the country, greatly improving the system's generalization ability and fault identification ability in different application scenarios.

[0015] Furthermore, it also includes a remote operation and maintenance debugging module. This module receives remote debugging instructions from operation and maintenance personnel through a cloud data interaction module, and remotely completes communication link parameter calibration, signal acquisition threshold adjustment, fault simulation testing, and early warning rule configuration. At the same time, it remotely retrieves full communication link data and equipment operation data before and after the fault occurs, helping operation and maintenance personnel to complete fault analysis and troubleshooting without going to the site, significantly reducing the processing time and operation and maintenance costs of communication faults.

[0016] Compared with existing technologies, the beneficial effects of this invention are: This invention establishes a full-duplex bidirectional communication link between the charging pile and the charging gun, enabling bidirectional synchronous transmission of control commands and operating data during the charging process. It is compatible with mainstream communication transmission protocols and can be adapted to different types and brands of charging piles and charging guns, significantly improving the system's application range and scenario compatibility.

[0017] This invention completes the acquisition and preprocessing of raw communication signals through a communication signal acquisition and analysis module, and achieves continuous monitoring of the communication link at all times through a link status real-time monitoring module. It can comprehensively track the core parameters of the link operation in all dimensions. The communication fault feature extraction module can accurately identify the feature vectors of various abnormal communication states, effectively distinguish between normal communication fluctuations and fault feature signals, and greatly improve the sensitivity and accuracy of abnormal communication state identification, providing reliable data support for fault early warning.

[0018] The graded fault early warning module of this invention can match the corresponding fault level based on the extracted fault feature vector and trigger differentiated early warning actions. In conjunction with the local emergency control module, it automatically triggers a safety shutdown process when an emergency communication fault is detected, cutting off the charging output circuit to ensure electrical safety during the charging process and prevent safety hazards caused by the continued escalation of the fault. The fault root cause localization module can accurately locate the location and root cause of the fault, clearly distinguish different types of communication faults, provide precise guidance for operation and maintenance work, significantly reduce the difficulty of fault diagnosis, and shorten the fault handling cycle.

[0019] This invention enables quantitative assessment of the health status of bidirectional communication links, providing a basis for proactive prediction of communication failures. Combined with a full lifecycle maintenance management module for charging guns, it can effectively identify performance degradation trends in charging gun communication hardware, proactively pushing maintenance and replacement reminders, and reducing the probability of bidirectional communication failures from the hardware source. The cloud-based data interaction module enables real-time uploading and synchronization of operational data and fault information. Combined with a remote maintenance and debugging module, it allows maintenance personnel to complete fault analysis and parameter debugging without going to the site, significantly reducing the maintenance costs of charging infrastructure. The multi-pile cluster communication status collaborative monitoring module enables centralized monitoring and unified management of multiple devices in large charging stations, achieving fault data sharing and cross-verification, improving the accuracy of fault identification and overall maintenance management efficiency in cluster scenarios, and comprehensively ensuring the long-term safe and stable operation of charging infrastructure. Attached Figure Description

[0020] Figure 1 This is a schematic block diagram of a two-way communication fault early warning system between a charging pile and a charging gun proposed in this invention. Figure 2 A flowchart for predictive assessment based on health metrics. Figure 3 Flowchart for the self-learning and incremental update of the fault feature library; Figure 4 For environmental interference compensation and signal optimization control diagram; Figure 5 This is a flowchart for multi-site cluster collaborative monitoring and remote operation and maintenance. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] 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 indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The invention will now be described in further detail with reference to the accompanying drawings.

[0024] Reference Figures 1 to 5 A two-way communication fault early warning system for charging piles and charging guns includes a two-way communication link module, a communication signal acquisition and analysis module, a link status real-time monitoring module, a communication fault feature extraction module, a graded fault early warning module, a fault root cause location module, a cloud data interaction module, and a local emergency control module. The bidirectional communication link module establishes a full-duplex bidirectional communication link between the charging pile and the charging gun, supports real-time interaction of control guidance signals and connection confirmation signals, is compatible with CAN bus and power line carrier communication protocols, and realizes bidirectional synchronous transmission of charging control commands, charging status data, and equipment operating parameters. The communication signal acquisition and analysis module acquires raw signal data in the bidirectional communication link in real time, performs filtering and noise reduction and level calibration preprocessing on the acquired signals, completes the protocol parsing and data decoding of the signals, extracts command frames, data frames and response frames in the communication interaction, and synchronously records the timestamp, level amplitude and transmission delay core parameters of the signal transmission. The link status real-time monitoring module continuously monitors the parsed communication data throughout the day, and tracks the signal transmission success rate, data packet loss rate, command response delay, signal level fluctuation range and other operating parameters of the communication link in real time. It also collects the connection status of the charging pile and charging gun, power supply voltage, and ambient temperature and humidity related operating data. The communication fault feature extraction module, based on a preset fault feature library, extracts features from the monitored link operation parameters, identifies feature vectors of abnormal communication states such as communication interruption, data packet loss, no command response, signal distortion, and time delay exceeding limits, and distinguishes between normal communication fluctuations and fault feature signals. The graded fault early warning module, based on the extracted fault feature vector and compared with the preset fault level threshold, divides the fault into three levels: early warning, alarm, and emergency shutdown, triggering different early warning actions accordingly, and simultaneously pushes the early warning information to the local display terminal of the charging pile and the operation and maintenance management platform. The fault root cause localization module combines fault feature vectors, historical link operation data, and device association parameters to locate the location and root cause of communication faults through fault matching algorithms, and distinguishes different types of faults such as physical link faults, protocol mismatch faults, device hardware faults, and environmental interference faults. The cloud data interaction module establishes a data connection with the cloud operation and maintenance platform through a wireless communication network, and uploads communication link operation data, fault warning information, and root cause location results in real time. At the same time, it receives fault feature library update packages, warning threshold adjustment parameters, and remote operation and maintenance instructions issued by the cloud. The local emergency control module is connected to the main control unit of the charging pile. When an emergency communication failure is detected, it automatically triggers a safety shutdown process, cuts off the charging output circuit, blocks the charging gun unlocking operation, and simultaneously stores the fault status in the local storage unit.

[0025] This invention also includes a communication link health quantification and evaluation module. This module quantifies and scores the overall operational status of the bidirectional communication link based on real-time monitoring data and historical operational data, and introduces a comprehensive health calculation formula for the communication link: ; in A comprehensive health score for the two-way communication link. To improve the success rate of communication signal transmission, For data packet loss rate, To average the response time to the command, The standard response delay threshold, This represents the actual average signal level amplitude. The rated standard level amplitude of the signal is η, and the environmental interference correction coefficient ranges from 0 to 1. The link's operating status is intuitively quantified through a comprehensive health score, providing a preliminary judgment basis for fault warning. When the health score is lower than a preset threshold, an early warning is triggered, enabling the early prediction of communication faults and providing a quantitative reference standard for the daily operation and maintenance of the link.

[0026] This invention also includes a fault feature library self-updating module. The fault feature library self-updating module continuously collects fault samples, fault confirmation feedback from maintenance personnel, and fault handling result data during system operation. It incrementally updates and iteratively optimizes the fault feature vectors, fault type matching rules, and fault level thresholds in the fault feature library. At the same time, it uses clustering algorithms to mine the feature patterns of newly added fault types and supplements the fault feature library with new fault features, thereby continuously improving the system's ability to identify and adapt to various communication faults.

[0027] This invention also includes an environmental interference compensation module. The environmental interference compensation module collects environmental parameters such as temperature and humidity, electromagnetic interference intensity, and voltage fluctuation amplitude at the installation site of the charging pile and charging gun in real time, establishes a correlation mapping model between environmental parameters and communication signal distortion, and performs dynamic compensation and calibration on the collected communication signals based on the model output results. This eliminates signal measurement deviations caused by environmental factors, improves the accuracy of identifying abnormal communication states, and reduces false alarms caused by environmental interference.

[0028] This invention also includes a charging gun full lifecycle operation and maintenance management module. The charging gun full lifecycle operation and maintenance management module records the communication link historical operation data, number of failures, failure type, number of plugging and unplugging, and usage time of each charging gun for its entire lifecycle. Based on the data, a charging gun communication performance degradation trend model is established to predict the service life of the charging gun communication hardware and push maintenance and replacement reminders to the charging gun in advance, thereby reducing the probability of two-way communication failures from the hardware source.

[0029] This invention also includes a multi-pile cluster communication status collaborative monitoring module. The multi-pile cluster communication status collaborative monitoring module realizes centralized monitoring and unified management of the bidirectional communication status of multiple charging piles and their corresponding charging guns within the same charging station. It establishes a cluster communication status topology map of the charging station, intuitively displaying the operating status and health level of each communication link. At the same time, it realizes the sharing and cross-verification of fault data within the same station, improving the accuracy of fault identification and the efficiency of operation and maintenance management in cluster scenarios.

[0030] This invention also includes a fault warning accuracy optimization module. This module iteratively optimizes the parameters of the warning model based on historical warning data and actual fault confirmation results, and introduces a quantitative calculation formula for the comprehensive accuracy of fault warnings: ; in To improve the overall accuracy of fault warnings, The number of fault samples that provide accurate early warnings. This represents the number of samples that triggered false alarms. This represents the number of fault samples that were missed in the early warning system. This represents the average lead time for fault warnings. The standard warning advance time threshold is set, and γ is the fault level matching coefficient, with a value ranging from 0 to 1. The comprehensive performance of the warning model is evaluated by calculation, providing a quantitative basis for the optimization of model parameters, continuously improving the accuracy and advance of fault warnings, and reducing the probability of false and missed warnings.

[0031] In this invention, the communication link health quantification and evaluation module generates a communication link health report for a single charging pile corresponding to a charging gun according to a set time period. At the same time, it compares the health scores of all charging guns in the same charging station to generate a health ranking and an abnormal link list. This provides a priority ranking basis for the daily operation and maintenance work of the charging station and helps maintenance personnel accurately locate the charging guns and communication links that need to be maintained.

[0032] In this invention, the fault feature database self-updating module receives fault feature data of the same model of equipment nationwide through the cloud data interaction module, realizing the synchronous update of the fault feature database across the entire network. This enables a single device to quickly adapt to various communication fault types in different regions and application scenarios across the country, greatly improving the system's generalization ability and fault identification ability in different application scenarios.

[0033] This invention also includes a remote operation and maintenance debugging module. The remote operation and maintenance debugging module receives remote debugging instructions from operation and maintenance personnel through a cloud data interaction module, and remotely completes communication link parameter calibration, signal acquisition threshold adjustment, fault simulation testing, and early warning rule configuration operations. At the same time, it remotely retrieves full communication link data and equipment operation data before and after the fault occurs, helping operation and maintenance personnel to complete fault analysis and problem troubleshooting without going to the site, significantly reducing the processing time and operation and maintenance costs of communication faults.

[0034] The following two examples further illustrate the specific implementation of this system: Example 1: Implementation of a two-way communication fault early warning system for public fast charging stations in the urban core area This embodiment is applied to a public fast-charging station in a core urban area. The station is equipped with 20 120kW DC fast-charging piles, each with two DC charging guns. The station provides charging services for over 800 vehicles daily, with high traffic volume and frequent charging gun insertions and removals. Maintenance requirements include centralized monitoring of the two-way communication status of all charging piles and charging guns, early fault warnings, and precise fault location to reduce the probability of unplanned charging interruptions and improve station maintenance efficiency. This embodiment fully covers all system technical solutions; all module functions correspond completely to the overall system design, with no technical content exceeding the design scope.

[0035] This embodiment deploys a two-way communication fault early warning system for charging piles and charging guns. The two-way communication link module establishes a full-duplex two-way communication link between each charging pile and its corresponding charging gun, supporting real-time interaction of control guidance signals and connection confirmation signals. It is also compatible with both CAN bus and power line carrier dual communication protocols, enabling bidirectional synchronous transmission of charging control commands, charging status data, and equipment operating parameters. The communication signal acquisition and analysis module acquires raw signal data from each two-way communication link in real time, performs filtering and noise reduction, and level calibration preprocessing on the acquired signals. It then completes protocol parsing and data decoding, extracting command frames, data frames, and response frames during the communication interaction process, and synchronously records the timestamp, level amplitude, and transmission delay of each set of signals.

[0036] The real-time link status monitoring module continuously monitors all parsed communication data around the clock, tracking the signal transmission success rate, data packet loss rate, command response delay, and signal level fluctuation range of each communication link in real time. It also simultaneously collects data related to the physical connection status of charging piles and charging guns, DC power supply voltage, and ambient temperature and humidity within the station. The communication fault feature extraction module, based on a pre-set fault feature library, extracts features from the monitored link operating parameters, identifying feature vectors for abnormal communication states such as communication interruption, data packet loss, no command response, signal distortion, and delay exceeding limits, thus distinguishing normal communication fluctuations from fault characteristic signals.

[0037] The graded fault early warning module, based on extracted fault feature vectors and compared with preset fault level thresholds, classifies faults into three levels: early warning, alarm, and emergency shutdown, triggering different early warning actions accordingly. The early warning information is simultaneously pushed to the charging pile's local display terminal and the station's operation and maintenance management platform. The fault root cause localization module, combining fault feature vectors, historical link operation data, and equipment-related parameters, uses a fault matching algorithm to locate the location and root cause of communication faults, distinguishing between different types of faults such as physical link faults, protocol mismatch faults, equipment hardware faults, and environmental interference faults.

[0038] The cloud-based data interaction module establishes a stable data connection with the cloud-based operation and maintenance platform via a 5G wireless communication network. It uploads real-time operational data, fault warning information, and root cause analysis results for all communication links within the station. Simultaneously, it receives fault feature database updates, warning threshold adjustment parameters, and remote operation and maintenance commands from the cloud. The local emergency control module is directly connected to the main control unit of each charging pile. Upon detecting an emergency communication failure, it automatically triggers a safety shutdown procedure, cutting off the charging output circuit of the corresponding charging gun, blocking the charging gun unlocking operation, and simultaneously storing the fault status in the charging pile's local storage unit.

[0039] The communication link health quantification and assessment module quantifies and scores the overall operational status of each bidirectional communication link based on real-time monitoring data and historical operational data. This provides a preliminary judgment basis for fault early warning. When the health score falls below a preset threshold, an early warning is triggered. Simultaneously, it generates daily health reports for all charging guns within the station, producing health rankings and a list of abnormal links. The fault feature library self-updating module continuously collects fault samples, fault confirmation feedback from maintenance personnel, and fault handling results during system operation. It incrementally updates and iteratively optimizes the relevant parameters and rules in the fault feature library, using clustering algorithms to mine the characteristic patterns of newly added fault types and supplementing the fault feature library with new fault features.

[0040] The environmental interference compensation module collects environmental parameters such as temperature and humidity, electromagnetic interference intensity, and grid voltage fluctuation amplitude in real time within the station. It establishes a correlation mapping model between environmental parameters and communication signal distortion, and dynamically compensates and calibrates the collected communication signals based on the model output, eliminating signal measurement deviations caused by environmental factors. The charging gun lifecycle maintenance management module records historical operating data, fault occurrences, fault types, plug-in / plug-out times, and usage duration for each charging gun within the station. Based on this data, it establishes a charging gun communication performance degradation trend model, predicts the lifespan of the charging gun communication hardware, and proactively pushes maintenance and replacement reminders. The multi-pile cluster communication status collaborative monitoring module enables centralized monitoring and unified management of the bidirectional communication status of 20 charging piles and their corresponding 40 charging guns within the station. It establishes a station cluster communication status topology map, intuitively displaying the operating status and health level of each communication link, while also enabling the sharing and cross-validation of fault data within the station. The fault early warning accuracy optimization module iteratively optimizes the parameters of the early warning model based on historical early warning data and actual fault confirmation results, continuously improving the accuracy and lead time of fault early warnings. The remote operation and maintenance debugging module receives remote debugging instructions from operation and maintenance personnel through the cloud data interaction module. It remotely completes communication link parameter calibration, signal acquisition threshold adjustment, fault simulation test, and early warning rule configuration operations. At the same time, it remotely retrieves full communication link data and equipment operation data before and after the fault occurs, realizing remote fault analysis and problem troubleshooting.

[0041] Table 1 Comparison of the performance of the present invention system and traditional charging systems in charging stations

[0042] Table 1 provides a clear overview of the comprehensive performance advantages of this invention's system in urban public fast-charging station scenarios. Traditional charging systems can only trigger shutdown protection after a complete communication interruption, lacking early warning capabilities for faults. Their communication fault identification accuracy is low, they cannot pinpoint the root cause of faults, and their false alarm rate is high. After a fault occurs, maintenance personnel must conduct on-site inspections, resulting in lengthy processing times and a high risk of unplanned charging interruptions. This invention's system provides advanced warnings for communication faults, accurately identifies various communication anomalies, and locates the root cause of faults. It has a low false alarm rate, and combined with remote maintenance capabilities, significantly shortens fault handling time, effectively reducing unplanned charging interruptions. It is perfectly suited to the high-load, high-frequency application scenarios of urban public fast-charging stations.

[0043] Example 2: Implementation of a two-way communication fault early warning system for charging stations in inter-provincial highway service areas. This embodiment is applied to a charging station in a service area of ​​an inter-provincial highway. The station is equipped with 12 high-power DC charging piles (240kW each), each with two high-voltage DC charging guns. Located in a remote area with significant day-night temperature differences and a complex surrounding electromagnetic environment, the station experiences explosive growth in charging vehicle traffic during holidays. Maintenance requirements include early identification and remote maintenance of charging communication faults to ensure electrical safety during high-power charging and reduce the difficulty and cost of maintenance in remote locations. This embodiment fully covers all technical solutions of the system; all module functions correspond completely to the overall system design, with no technical content exceeding the design scope.

[0044] This embodiment deploys a two-way communication fault early warning system for charging piles and charging guns. The two-way communication link module establishes a full-duplex two-way communication link between each high-power charging pile and its corresponding charging gun. It supports high real-time interaction of control guidance signals and connection confirmation signals in high-power charging scenarios, and is compatible with CAN bus and power line carrier communication protocols. It enables bidirectional synchronous transmission of charging control commands, charging status data, and equipment operating parameters during high-current charging. The communication signal acquisition and analysis module acquires the raw signal data from each two-way communication link in real time, performs filtering and noise reduction, and level calibration preprocessing on the acquired signals. It completes protocol parsing and data decoding of signals in high-power charging scenarios, extracts command frames, data frames, and response frames in the communication interaction, and synchronously records the timestamp, level amplitude, and transmission delay core parameters of the signal transmission.

[0045] The real-time link status monitoring module continuously monitors the parsed communication data around the clock, tracking the signal transmission success rate, data packet loss rate, command response delay, and signal level fluctuation range of the communication link in real time. It also simultaneously collects data related to the connection status of the charging pile and charging gun, charging circuit voltage and current, station environment temperature and humidity, and electromagnetic interference intensity. The communication fault feature extraction module, based on a pre-set fault feature library, extracts features from the monitored link operating parameters, identifying feature vectors of abnormal communication states such as communication interruption, data packet loss, no command response, signal distortion, and delay exceeding limits under high-power charging scenarios. This distinguishes between normal communication fluctuations caused by power grid fluctuations and fault characteristic signals.

[0046] The graded fault early warning module, based on extracted fault feature vectors and compared with preset fault level thresholds, classifies faults into three levels: early warning, alarm, and emergency shutdown, triggering different early warning actions accordingly. Simultaneously, the early warning information is pushed to the local display terminal of the charging pile, the service area maintenance room, and the cloud-based maintenance platform. The fault root cause localization module, combining fault feature vectors, historical link operation data, and device-related parameters, uses a fault matching algorithm to locate the location and root cause of communication faults, distinguishing between different types of faults such as physical link faults, protocol mismatch faults, device hardware faults, and environmental interference faults.

[0047] The cloud-based data interaction module establishes a data connection with the cloud-based operation and maintenance platform via 4G and 5G wireless communication networks. It uploads real-time operational data, fault warning information, and root cause analysis results for all communication links within the station. Simultaneously, it receives fault feature database update packages, warning threshold adjustment parameters, and remote operation and maintenance commands from the cloud. The local emergency control module is connected to the main control unit of each charging pile. Upon detecting an emergency communication failure, it automatically triggers a safety shutdown procedure, cutting off the high-power charging output circuit of the corresponding charging gun, locking the charging gun unlocking operation, and simultaneously temporarily storing the fault status in the charging pile's local large-capacity storage unit. The data is automatically re-transmitted after the network is restored.

[0048] The communication link health quantification and assessment module quantifies and scores the overall operational status of each bidirectional communication link based on real-time monitoring data and historical operational data. When the health score falls below a preset threshold, an early warning is triggered. A weekly health report of the charging guns within the station is generated, providing a priority ranking basis for daily maintenance in the service area. The fault feature database self-updating module continuously collects fault samples, maintenance fault confirmation feedback, and fault handling results during system operation, incrementally updating and iteratively optimizing the fault feature database. Simultaneously, it receives fault feature data from similar equipment across national highways via a cloud data interaction module, achieving synchronized updates of the fault feature database across the entire network.

[0049] The environmental interference compensation module collects real-time environmental parameters such as day and night temperature and humidity changes, surrounding electromagnetic interference intensity, and power grid voltage fluctuation amplitude at the station. It establishes a correlation mapping model between environmental parameters and communication signal distortion, and dynamically compensates and calibrates the collected communication signals based on the model output, eliminating signal measurement deviations caused by complex environmental factors in highway service areas. The charging gun full lifecycle operation and maintenance management module records historical operating data, fault occurrences, plugging / unplugging times, and usage duration for each charging gun within the station. It establishes a charging gun communication performance degradation trend model, predicts the lifespan of the charging gun communication hardware, and sends out maintenance and replacement reminders in advance. The multi-pile cluster communication status collaborative monitoring module enables centralized monitoring and unified management of the bidirectional communication status of 12 charging piles and 24 charging guns within the station. It establishes a station cluster communication status topology map, intuitively displaying the operating status and health level of each communication link, and enabling the sharing and cross-validation of fault data within the station. The fault early warning accuracy optimization module iteratively optimizes the parameters of the early warning model based on historical early warning data and actual fault confirmation results, reducing the probability of false and missed early warnings in complex environments. The remote operation and maintenance debugging module receives remote debugging instructions from operation and maintenance personnel through the cloud data interaction module, and remotely completes communication link parameter calibration, signal acquisition threshold adjustment, fault simulation test, and early warning rule configuration operations. At the same time, it remotely retrieves all fault data to realize remote fault analysis and problem troubleshooting in remote stations.

[0050] Table 2 Comparison of the performance of the present invention system and traditional charging systems in high-speed scenarios

[0051] Table 2 clearly demonstrates the application advantages of the system of this invention in remote and complex scenarios of highway service areas. Traditional charging systems suffer from significantly reduced fault identification accuracy, short stable communication link operation time, and lack of remote maintenance capabilities in the complex environment of highway service areas with large temperature differences and strong electromagnetic interference. All faults require maintenance personnel to travel across regions for on-site handling, resulting in high annual maintenance costs and persistently high charging interruption rates during peak traffic periods such as holidays. The system of this invention improves fault identification accuracy in complex environments through environmental interference compensation, ensures long-term stable operation of the communication link, and enables remote handling of most faults in conjunction with a remote maintenance and debugging module, significantly reducing maintenance costs. Furthermore, early fault warnings reduce charging interruptions during holidays, making it perfectly suited to the application characteristics of remote, complex, and difficult-to-maintain highway service areas.

[0052] Reference Figure 2The document details how the system transforms abstract communication quality into an intuitive health score. The process integrates core parameters such as transmission success rate, packet loss rate, response latency, and signal level amplitude, calculating a comprehensive health score through a quantitative evaluation module. When the score falls below a preset threshold, the system proactively predicts faults rather than issuing reactive alarms. Furthermore, the illustration demonstrates the health ranking logic for multiple piles within the station, providing maintenance personnel with precise guidance on maintenance priorities and enabling a shift from "passive maintenance" to "proactive prevention."

[0053] Reference Figure 3 This demonstrates the system's intelligent evolution process. The system continuously collects fault samples and human feedback, and uses clustering algorithms to uncover new fault patterns. The diagram specifically marks the cloud interaction path: features collected from individual faults are uploaded to the cloud, cross-validated with data from all devices of the same model across the network, and the generated update package is then sent back to the local machine. This two-way iterative mechanism continuously optimizes the fault warning accuracy (Aw), ensuring the system can continuously adapt to complex application scenarios and reduce false alarms and false negatives.

[0054] Reference Figure 4 The presentation highlighted the system's anti-interference capabilities in complex physical environments. The environmental sensing unit monitors temperature, humidity, electromagnetic interference, and voltage fluctuations in real time, generating compensation parameters through a correlation mapping model. The flowchart illustrates how the compensation logic operates in the original signal processing stage, eliminating measurement biases through dynamic calibration. This mechanism effectively solves the signal distortion problem caused by environmental factors, ensuring the purity of fault feature extraction, and is a key technological path to improve the reliability of the system's early warning system under harsh outdoor conditions.

[0055] Reference Figure 5 This demonstrates the site-level topology management and remote interaction logic. The system constructs a cluster communication status topology diagram, enabling centralized display and data sharing of multi-link status. The remote operation and maintenance module issues debugging commands from the cloud, achieving online calibration and fault simulation. The diagram clearly presents the multi-level interactive architecture of "pile-gun-site-cloud," allowing operation and maintenance personnel to access all historical data for root cause analysis without being physically present on-site, significantly improving operation and maintenance efficiency and reducing costs in cluster scenarios.

[0056] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A two-way communication fault early warning system between a charging pile and a charging gun, characterized in that, include: The two-way communication link module establishes a full-duplex two-way communication link between the charging pile and the charging gun, supports real-time interaction of control guidance signals and connection confirmation signals, and is compatible with CAN bus and power line carrier communication protocols. The communication signal acquisition and analysis module acquires raw signal data in the bidirectional communication link in real time, performs filtering and noise reduction and level calibration preprocessing on the acquired signals, completes the protocol parsing and data decoding of the signals, extracts command frames, data frames and response frames in the communication interaction, and synchronously records the timestamp, level amplitude and transmission delay core parameters of the signal transmission. The link status real-time monitoring module continuously monitors the parsed communication data throughout the day, and tracks the signal transmission success rate, data packet loss rate, command response delay, signal level fluctuation range and other operating parameters of the communication link in real time. It also collects the connection status of the charging pile and charging gun, power supply voltage, and ambient temperature and humidity related operating data. The communication fault feature extraction module, based on a preset fault feature library, extracts features from the monitored link operation parameters, identifies feature vectors of abnormal communication states such as communication interruption, data packet loss, no command response, signal distortion, and time delay exceeding limits, and distinguishes between normal communication fluctuations and fault feature signals. The graded fault early warning module, based on the extracted fault feature vector and compared with the preset fault level threshold, divides the fault into three levels: early warning, alarm, and emergency shutdown, triggering different early warning actions accordingly, and simultaneously pushes the early warning information to the local display terminal of the charging pile and the operation and maintenance management platform. The fault root cause localization module combines fault feature vectors, historical link operation data, and device association parameters to locate the location and root cause of communication faults through fault matching algorithms, and distinguishes different types of faults such as physical link faults, protocol mismatch faults, device hardware faults, and environmental interference faults. The cloud data interaction module establishes a data connection with the cloud operation and maintenance platform through a wireless communication network, and uploads communication link operation data, fault warning information, and root cause location results in real time. At the same time, it receives fault feature library update packages, warning threshold adjustment parameters, and remote operation and maintenance instructions issued by the cloud. The local emergency control module is connected to the main control unit of the charging pile. When an emergency communication failure is detected, it automatically triggers the safety shutdown process, cuts off the charging output circuit, locks the charging gun unlocking operation, and simultaneously stores the fault status in the local storage unit. The communication link health quantification and evaluation module, based on real-time monitoring data and historical operational data, quantifies and scores the overall operational status of the bidirectional communication link, introducing a comprehensive health calculation formula for the communication link: ； in A comprehensive health score for the two-way communication link. To improve the success rate of communication signal transmission, For data packet loss rate, To average the response time to the command, The standard response delay threshold, This represents the actual average signal level amplitude. The rated standard level amplitude of the signal is η, and the environmental interference correction coefficient is η, which ranges from 0 to 1. The operation status of the link is intuitively quantified by the comprehensive health score, providing a basis for early judgment of fault warning. When the health score is lower than the preset threshold, an early warning prompt is triggered, realizing the early prediction of communication faults.

2. The bidirectional communication fault early warning system between a charging pile and a charging gun according to claim 1, characterized in that, It also includes a fault feature library self-updating module, which continuously collects fault samples, fault confirmation feedback from maintenance personnel, and fault handling result data during system operation, and performs incremental updates and iterative optimizations on fault feature vectors, fault type matching rules, and fault level thresholds in the fault feature library.

3. The bidirectional communication fault early warning system between a charging pile and a charging gun according to claim 1, characterized in that, It also includes an environmental interference compensation module, which collects environmental parameters such as temperature and humidity, electromagnetic interference intensity, and voltage fluctuation amplitude at the installation site of the charging pile and charging gun in real time, establishes a correlation mapping model between environmental parameters and communication signal distortion, and performs dynamic compensation and calibration on the collected communication signals based on the model output results.

4. The bidirectional communication fault early warning system between a charging pile and a charging gun according to claim 1, characterized in that, It also includes a charging gun full life cycle operation and maintenance management module. The charging gun full life cycle operation and maintenance management module records the communication link historical operation data, number of failures, failure type, number of plugging and unplugging, and usage time of each charging gun for the entire life cycle. Based on the data, a charging gun communication performance degradation trend model is established to predict the service life of the charging gun communication hardware.

5. A two-way communication fault early warning system for charging piles and charging guns according to claim 1, characterized in that, It also includes a multi-pile cluster communication status collaborative monitoring module, which realizes centralized monitoring and unified management of the two-way communication status of multiple charging piles and their corresponding charging guns within the same charging station, and establishes a cluster communication status topology map of the charging station.

6. The bidirectional communication fault early warning system between a charging pile and a charging gun according to claim 1, characterized in that, It also includes a fault warning accuracy optimization module, which iteratively optimizes the parameters of the warning model based on historical warning data and actual fault confirmation results, and introduces a quantitative calculation formula for the comprehensive accuracy of fault warnings: ; in To improve the overall accuracy of fault warnings, The number of fault samples that provide accurate early warnings. This represents the number of samples that triggered false alarms. This represents the number of fault samples that were missed in the early warning system. This represents the average lead time for fault warnings. The standard early warning time threshold is set, and γ is the fault level matching coefficient, with a value ranging from 0 to 1. The comprehensive performance of the early warning model is evaluated through calculation, providing a quantitative basis for the optimization of model parameters.

7. A two-way communication fault early warning system for charging piles and charging guns according to claim 1, characterized in that, The communication link health quantification and evaluation module generates a communication link health report for each charging gun corresponding to a single charging pile according to a set time period. At the same time, it compares the health scores of all charging guns in the same charging station to generate a health ranking and a list of abnormal links.

8. A two-way communication fault early warning system between a charging pile and a charging gun according to claim 2, characterized in that, The fault feature database self-updating module receives fault feature data of the same model of equipment nationwide through the cloud data interaction module, realizing the synchronous update of the fault feature database across the entire network, enabling a single device to quickly adapt to various communication fault types in different regions and application scenarios across the country.

9. A two-way communication fault early warning system between a charging pile and a charging gun according to claim 1, characterized in that, It also includes a remote operation and maintenance debugging module, which receives remote debugging instructions from operation and maintenance personnel through a cloud data interaction module, and remotely completes communication link parameter calibration, signal acquisition threshold adjustment, fault simulation test, and early warning rule configuration operations. At the same time, it remotely retrieves full communication link data and equipment operation data before and after the fault occurred.

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