Power controller detector

Abstract

The application provides a power controller detection instrument, which comprises a plurality of connection plugs corresponding to a plurality of interfaces of a five-in-one power controller, a relay, a control button and an indicator light; the main positive contactor control button is used for receiving a main positive contactor test instruction, and a main positive contactor relay is controlled to send a test signal to a main positive contactor through a first connection plug and an interface of the five-in-one power controller corresponding to the first connection plug according to the main positive contactor test instruction; the main positive contactor indicator light is used for receiving an electric signal returned by the five-in-one power controller according to the test signal, and indicating a state of the main positive contactor according to the returned electric signal; the state includes a normal state and a fault state. The application can improve the fault searching accuracy and the maintenance efficiency of the power controller, and avoid the fault caused by the operation level and the technical ability of the maintenance personnel.

Description

Technical Field

[0001] This invention relates to the field of power control technology, and in particular to a power controller tester. Background Technology

[0002] The five-in-one power controller, or simply power controller, is widely used in new energy electric buses. It is the core control device for the high-voltage electrical energy of electric vehicles, primarily responsible for distributing high-voltage electrical energy, power conversion, power supply to oil and air pumps, and charging control. Prolonged operation and harsh working conditions can cause aging of internal electrical components, overload of electrical loads, or mechanical vibration, ultimately leading to various malfunctions in the power controller. Consequently, the high-voltage electricity cannot provide power to the vehicle's electrical equipment, and the vehicle cannot operate normally.

[0003] Currently, when a power controller malfunctions, due to technical embargoes imposed by some manufacturers, there is a lack of relevant technical information. Repair personnel typically rely on self-exploration methods, using traditional fault diagnosis methods such as multimeters and connecting wires. Because the power controller has many control circuits, repair personnel measure each pin in the power controller control interface one by one to find the fault location. Sometimes, it is even necessary to replace parts to diagnose the fault. This work is time-consuming, labor-intensive, and consumes a lot of materials. Moreover, the skill level of repair personnel varies and their technical capabilities are limited, which can easily cause permanent damage to the vehicle's wiring harness, electrical equipment, etc. In severe cases, it can have a long-term impact on the safe operation of the vehicle and cause a chain of failures. Summary of the Invention

[0004] This invention provides a power controller tester to improve the accuracy of fault finding and maintenance efficiency of power controllers, and to avoid faults caused by the operating level and technical capabilities of maintenance personnel. The power controller tester includes: connectors corresponding one-to-one with multiple interfaces of a five-in-one power controller, relays, control buttons, and indicator lights; the connectors include a first connector, a second connector, a third connector, a fourth connector, and a fifth connector; the five-in-one power controller includes a main positive contactor, a main negative contactor, a charging contactor, and a cooling fan; the relays include a main positive contactor relay, a main negative contactor relay, and a charging contactor relay; the control buttons include a main positive contactor control button, a main negative contactor control button, a charging contactor control button, and a cooling fan control button; the indicator lights include a main positive contactor indicator light, a main negative contactor indicator light, a charging contactor indicator light, and a cooling fan indicator light. The main positive contactor control button is used to receive the main positive contactor test command and control the main positive contactor relay to send a test signal to the main positive contactor through the interface of the first connector and the five-in-one power controller corresponding to the first connector. The main positive contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the main positive contactor based on the returned electrical signal. The main negative contactor control button is used to receive the main negative contactor test command and control the main negative contactor relay to send a test signal to the main negative contactor through the interface of the first connecting plug and the five-in-one power controller corresponding to the first connecting plug according to the main negative contactor test command. The main negative contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the main negative contactor based on the returned electrical signal. The charging contactor control button is used to receive charging contactor test commands and control the charging contactor relay to send test signals to the charging contactor through the second connecting plug, the third connecting plug, the interface of the five-in-one power controller corresponding to the second connecting plug, and the interface of the five-in-one power controller corresponding to the third connecting plug. The charging contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the charging contactor based on the returned electrical signal. The cooling fan control button is used to receive cooling fan test commands and control the cooling fan relay to send test signals to the cooling fan through the fourth connector, the fifth connector, the interface of the five-in-one power controller corresponding to the fourth connector, and the interface of the five-in-one power controller corresponding to the fifth connector. The cooling fan indicator light is used to receive electrical signals returned by the five-in-one power controller based on the test signals, and to indicate the status of the cooling fan based on the returned electrical signals; the status includes normal status and fault status.

[0005] In this embodiment of the invention, multiple interfaces of the five-in-one power controller are represented by connectors, relays, control buttons, and indicator lights. The connectors include a first connector, a second connector, a third connector, a fourth connector, and a fifth connector. The five-in-one power controller includes a main positive contactor, a main negative contactor, a charging contactor, and a cooling fan. The relays include a main positive contactor relay, a main negative contactor relay, and a charging contactor relay. The control buttons include a main positive contactor control button, a main negative contactor control button, a charging contactor control button, and a cooling fan control button. The indicator lights include a main positive contactor indicator light, a main negative contactor indicator light, and a charging contactor indicator light. The system includes indicator lights for the main positive contactor and the cooling fan. The main positive contactor control button receives test commands from the main positive contactor and controls the main positive contactor relay to send test signals to the main positive contactor through the interface of the first connector and the corresponding five-in-one power controller. The main positive contactor indicator light receives the electrical signal returned by the five-in-one power controller based on the test signal and indicates the status of the main positive contactor. The main negative contactor control button receives test commands from the main negative contactor and controls the main negative contactor relay to send test signals to the main negative contactor through the interface of the first connector and the corresponding five-in-one power controller. Test signal; the main negative contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and indicates the status of the main negative contactor based on the returned electrical signal; the charging contactor control button is used to receive the charging contactor test command, and controls the charging contactor relay to send a test signal to the charging contactor through the second connector, the third connector, the interface of the five-in-one power controller corresponding to the second connector, and the interface of the five-in-one power controller corresponding to the third connector; the charging contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and indicates the status of the charging contactor based on the returned electrical signal; the cooling fan control button is used for The system receives a test command for the cooling fan and controls the cooling fan relay to send a test signal to the cooling fan through the fourth connector, the fifth connector, the interface of the five-in-one power controller corresponding to the fourth connector, and the interface of the five-in-one power controller corresponding to the fifth connector. The cooling fan indicator light receives the electrical signal returned by the five-in-one power controller based on the test signal and indicates the status of the cooling fan based on the returned electrical signal. The status includes a normal status and a fault status. Compared with the prior art of manually inspecting the power controller, the embodiments of the present invention can improve the fault finding accuracy and maintenance efficiency of the power controller and avoid faults caused by the operating level and technical ability of maintenance personnel. Attached Figure Description

[0006] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 This is a schematic diagram of the power controller detector in an embodiment of the present invention; Figure 2 This is a schematic diagram of a specific example of the power controller detector in this invention. Figure 3 This is a schematic diagram of a specific example of the power controller detector in this invention. Figure 4 This is a schematic diagram of a specific example of the power controller detector in this invention. Figure 5 This is a schematic diagram of a specific example of the power controller detector in this invention. Among them, 1-first connecting plug, 2-second connecting plug, 3-third connecting plug, 4-fourth connecting plug, 5-fifth connecting plug, 6-main positive contactor control button, 7-main negative contactor control button, 8-cooling fan control button, 9-main positive contactor indicator light, 10-main negative contactor indicator light, 11-cooling fan indicator light, 12-charging contactor control button, 13-defrost contactor control button, 14-oil pump driver control button, 15-air pump driver control button, 16-DC / DC control circuit control button, 17-DC / AC control circuit control button, 18-defrost contactor Indicator lights, 19-Oil pump driver indicator light, 20-Air pump driver indicator light, 21-DC / DC control circuit indicator light, 22-DC / AC control circuit indicator light, 23-Low voltage power supply circuit indicator light, 24-Thermometer, 25-Voltmeter, 121-First charging contactor control button, 122-Second charging contactor control button, 123-Third charging contactor control button, 124-Fourth charging contactor control button, 125-First charging contactor indicator light, 126-Second charging contactor indicator light, 127-Third charging contactor indicator light, 128-Fourth charging contactor indicator light. Detailed Implementation

[0007] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Here, the illustrative embodiments of the present invention and their descriptions are used to explain the present invention, but are not intended to limit the present invention.

[0008] In the description of this specification, the terms "comprising," "including," "having," and "containing" are open-ended terms, meaning that they include but are not limited to. The terms "an embodiment," "a specific embodiment," "some embodiments," and "for example," etc., refer to specific features, structures, or characteristics described in connection with that embodiment or example that are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. The order of steps involved in the various embodiments is used to illustrate the implementation of this application, and the order of steps is not limited and can be adjusted appropriately as needed.

[0009] Currently, repair technicians can only rely on traditional fault diagnosis methods such as multimeters, connecting wires, and test pins during the repair process. They measure each pin in the power controller control interface one by one to locate the fault, and sometimes even need to replace parts to diagnose the problem. Combined with the varying skill levels and limited technical capabilities of repair personnel, this can easily cause permanent damage to the vehicle's wiring harness and electrical equipment, severely impacting long-term vehicle safety and causing cascading failures. Existing technical repair methods also present a series of problems, including damage to the integrated controller and related wiring, time-consuming and labor-intensive work, and high material consumption.

[0010] To address the aforementioned issues, this invention provides a power controller tester that performs tests on the low-voltage control circuit open-circuit and short-circuit faults of a five-in-one power controller, as well as on the supply voltage measurement and internal component testing. This effectively solves the technical bottlenecks in the repair of the internal contactor performance, control functions, and signal output of the five-in-one power controller assembly for electric vehicles. Furthermore, the convenient and quick testing method significantly improves the testing time and accuracy for employees in diagnosing related faults.

[0011] Figure 1 This is a schematic diagram of the power controller tester in an embodiment of the present invention, as shown below. Figure 1As shown, the power controller tester may include: connectors corresponding one-to-one with the multiple interfaces of the five-in-one power controller, relays, control buttons, and indicator lights; the connectors include a first connector 1, a second connector 2, a third connector 3, a fourth connector 4, and a fifth connector 5; the five-in-one power controller includes a main positive contactor, a main negative contactor, a charging contactor, and a cooling fan; the relays include a main positive contactor relay, a main negative contactor relay, and a charging contactor relay; the control buttons include a main positive contactor control button 6, a main negative contactor control button 7, a charging contactor control button 12, and a cooling fan control button 8; the indicator lights include a main positive contactor indicator light 9, a main negative contactor indicator light 10, a charging contactor indicator light, and a cooling fan indicator light 11; The main positive contactor control button 6 is used to receive the main positive contactor test command and control the main positive contactor relay to send a test signal to the main positive contactor through the interface of the first connecting plug 1 and the five-in-one power controller corresponding to the first connecting plug 1. The main positive contactor indicator light 9 is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the main positive contactor based on the returned electrical signal; The main negative contactor control button 7 is used to receive the main negative contactor test command and control the main negative contactor relay to send a test signal to the main negative contactor through the interface of the first connecting plug 1 and the five-in-one power controller corresponding to the first connecting plug 1. The main negative contactor indicator light 10 is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the main negative contactor based on the returned electrical signal. The charging contactor control button 12 is used to receive the charging contactor test command and control the charging contactor relay to send a test signal to the charging contactor through the second connecting plug 2, the third connecting plug 3, the interface of the five-in-one power controller corresponding to the second connecting plug 2, and the interface of the five-in-one power controller corresponding to the third connecting plug 3. The charging contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the charging contactor based on the returned electrical signal. The cooling fan control button 8 is used to receive cooling fan test commands and control the cooling fan relay to send test signals to the cooling fan through the fourth connector 4, the fifth connector 5, the interface of the five-in-one power controller corresponding to the fourth connector 4, and the interface of the five-in-one power controller corresponding to the fifth connector 5. The cooling fan indicator light 11 is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the cooling fan based on the returned electrical signal; the status includes normal status and fault status.

[0012] The charging contactor control button 1212 includes: a charging contactor control button 12 and a charging contactor indicator light.

[0013] The power controller tester is primarily composed of a 24V 10Ah lithium battery powering the core control components, a connector plug (with dedicated aviation wiring, 1.5mm²) for the power controller's control interface, 24V LED indicator lights for status display, a 25V digital voltmeter (0-50V) for detecting the operating and signal voltages within the power controller circuit, push-button switches (normally open, normally closed, and rocker types) for triggering functions during testing, and a 24V 5A relay for switching test circuits and protecting the control loop. Its working principle involves using push-button switches to control the analog trigger signals of the low-voltage section of the power controller. The voltmeter and indicator lights display the operating status of various parts of the vehicle's control circuit. The internal lithium battery provides power for control and other auxiliary functions. The independently developed and designed control circuit allows the power controller tester to quickly and easily detect, test, and simulate various functions of the power controller and locate faults. Its advantages include small size for portability, single-person operation, easy connection, and stable and reliable performance. It has on-board testing capabilities, which monitor the equipment operation at all times, providing a strong basis for accurate fault diagnosis.

[0014] In one embodiment, the main positive contactor indicator light 9 is specifically used to: display red when the main positive contactor control button 6 does not receive a main positive contactor test command and the main positive contactor has an adhesion fault; display red when the main positive contactor control button 6 receives a main positive contactor test command and the main positive contactor is in normal condition; and not illuminate when the main positive contactor control button 6 receives a main positive contactor test command and the main positive contactor has a fault other than an adhesion fault.

[0015] In one embodiment, the first connector 1, the second connector 2, the third connector 3, the fourth connector 4, and the fifth connector 5 each include a plurality of pins.

[0016] In one embodiment, the main positive contactor control button 6 is specifically used to control the main positive contactor relay to send a test signal to the main positive contactor through the first pin of the first connector 1 and the interface of the five-in-one power controller corresponding to the first pin of the first connector 1, according to the main positive contactor test command; the main negative contactor control button 7 is specifically used to control the main negative contactor relay to send a test signal to the main negative contactor through the second pin of the first connector 1 and the interface of the five-in-one power controller corresponding to the second pin of the first connector 1, according to the main negative contactor test command; the cooling fan control button 8 is specifically used to control the cooling fan relay to send a test signal to the cooling fan through the first pin of the second connector 2, the first pin of the fourth connector 4, the first pin of the fifth connector 5, the interface of the five-in-one power controller corresponding to the first pin of the second connector 2, the interface of the five-in-one power controller corresponding to the first pin of the fourth connector 4, and the interface of the five-in-one power controller corresponding to the first pin of the fifth connector 5, according to the cooling fan test command.

[0017] The buttons and indicator lights mentioned above will be described in detail below: (1) Main positive contactor: The main positive contactor control button 6 is a self-locking button, which includes control functions in the power controller tester. When the main positive contactor control button 6 is pressed, the button switch is normally open, and the contacts close, which turns on the main positive contactor relay in the internal control circuit of the power controller tester, connecting the internal 24V circuit of the power controller tester to the test leads. The pins C and D of the RE red plug-in (first connecting plug-in 1) in the test lead harness are connected to the corresponding interfaces of the five-in-one power controller to realize the control test of the internal main positive contactor coil.

[0018] The main positive contactor indicator light 9 is a red indicator light, which includes a display function in the power controller tester. The control circuit loop of the main positive contactor indicator light 9 is connected to the RE red plug pins E and F in the test harness and is connected to the corresponding interface of the five-in-one power controller to realize the performance test of the internal main positive contactor contacts.

[0019] Usage effect: If the indicator light is on when the main positive contactor control button 6 is not pressed, it means that there is a sticking fault in the main positive contactor contacts inside the five-in-one power controller and it needs to be replaced. If the indicator light is on after pressing, it means that the main positive contactor is working well. If the indicator light is not on, it means that the main positive contactor is faulty and needs to be replaced.

[0020] (2) Main negative contactor: The main negative contactor control button 7 is a self-locking button, which includes control functions in the power controller tester. When the main negative contactor control button 7 is pressed, the button switch is normally open, and the contacts are closed, which turns on the main negative contactor relay in the internal control circuit of the power controller tester, connecting the internal 24V circuit of the power controller tester to the test leads. The pins G and H of the RE red plug-in (first connecting plug-in 1) in the test lead harness are connected to the corresponding interfaces of the five-in-one power controller to realize the control test of the internal main negative contactor coil.

[0021] The main negative contactor indicator light 10 is a red indicator light, which includes a display function in the power controller tester. The control circuit loop of the main negative contactor indicator light 10 is connected to the RE red plug pins J and K in the test harness and is connected to the corresponding interface of the five-in-one power controller to realize the performance test of the internal main negative contactor contacts.

[0022] Usage effect: If the indicator light is on when the main negative contactor control button 7 is not pressed, it means that there is a sticking fault in the contacts of the main negative contactor inside the five-in-one power controller and it needs to be replaced. If the indicator light is on after pressing, it means that the main negative contactor is working well. If the indicator light is not on, it means that the main negative contactor is faulty and needs to be replaced.

[0023] (3) Cooling fan: The cooling fan control button 8 is a toggle switch, which includes control functions in the power controller tester. When this switch is turned to the simulation position, it connects the internal switch contacts of the power controller tester, enabling conduction between the working circuit of the five-in-one power controller and the positive terminal of the power supply. In the test harness, pins D, G, H, and L of the blue BL connector (fourth connector 4), pins J and K of the yellow YE connector (fifth connector 5), and pins A and B of the black BK connector (second connector 2) are connected to the corresponding interfaces of the five-in-one power controller to control its internal working circuit and test the cooling fan.

[0024] The cooling fan indicator light 11 is a red indicator light, and it includes a display function in the power controller tester.

[0025] Usage effect: When the toggle switch is in the OFF position, the test function is turned off; when it is in the simulated position, the test function is turned on, enabling testing of the various control circuits and cooling fan functions within the five-in-one integrated power controller.

[0026] Figure 2 This is a schematic diagram of a specific example of a power controller detector in an embodiment of the present invention. In one embodiment, the charging contactor includes a first charging contactor, a second charging contactor, a third charging contactor, and a fourth charging contactor. The charging contactor control button 12 is specifically used for: controlling the first charging contactor relay to send a test signal to the first charging contactor through the second pin of the second connector 2 and the interface of the five-in-one power controller corresponding to the second pin of the second connector 2, according to the first charging contactor test command; controlling the second charging contactor relay to send a test signal to the second charging contactor through the third pin of the second connector 2 and the interface of the five-in-one power controller corresponding to the third pin of the second connector 2, according to the second charging contactor test command; and controlling the third charging contactor relay to send a test signal to the third connector through the third connector... The first pin of component 3, corresponding to the interface of the five-in-one power controller and the first pin of the third connector 3, sends a test signal to the third charging contactor; according to the test command of the fourth charging contactor, the fourth charging contactor relay is controlled to send a test signal to the fourth charging contactor through the fourth pin of the second connector 2 and the interface of the five-in-one power controller and the fourth pin of the second connector 2; the charging contactor indicator light is specifically used to receive the electrical signal returned by the five-in-one power controller according to the test signal, and to indicate the status of the first charging contactor, the second charging contactor, the third charging contactor, and the fourth charging contactor according to the returned electrical signal.

[0027] In one embodiment, the charging contactor control button 12 may specifically include a first charging contactor control button 12112, a second charging contactor control button 12212, a third charging contactor control button 12312, and a fourth charging contactor control button 12412.

[0028] In one embodiment, the charging contactor indicator light may specifically include a first charging contactor indicator light 125, a second charging contactor indicator light 126, a third charging contactor indicator light 127, and a fourth charging contactor indicator light 128.

[0029] In one embodiment, the first charging contactor control button 12112 and the first charging contactor indicator light 125 can be implemented by a single button that has both control and display functions; the second charging contactor control button 12212 and the second charging contactor indicator light 126 can be implemented by a single button that has both control and display functions; the third charging contactor control button 12312 and the third charging contactor indicator light 127 can be implemented by a single button that has both control and display functions; and the fourth charging contactor control button 12412 and the fourth charging contactor indicator light 128 can be implemented by a single button that has both control and display functions.

[0030] The buttons and indicator lights mentioned above will be described in detail below: (4) First charging contactor: First charging contactor control button 12112: This button is a reset button and includes control functions in the power controller tester. When the first charging contactor control button 12112 is pressed, the normally open contact of the button switch closes, causing the first charging contactor relay in the internal control circuit of the power controller tester to conduct, connecting the internal 24V circuit of the power controller tester to the test leads. The pins G and H of the BK black plug in the test harness are connected to the corresponding interface of the five-in-one power controller to provide control and testing for the coil of the No. 1 charging contactor inside.

[0031] First charging contactor indicator light 125: The green indicator light, part of the control circuit loop, connects to the corresponding interface of the five-in-one power controller via the BK black plug-in pin L and BL blue plug-in pin H in the test harness, enabling performance testing of the internal No. 1 charging contactor contact.

[0032] If the indicator light 125 of the first charging contactor is lit without pressing the first charging contactor control button 12112, it indicates that the contact of the No. 1 charging contactor inside the five-in-one power controller is stuck and needs to be replaced. If the indicator light 125 of the first charging contactor is lit after pressing it, it indicates that the No. 1 charging contactor is working properly. If the indicator light 125 of the first charging contactor is not lit, it indicates that the No. 1 charging contactor is faulty and needs to be replaced.

[0033] (5) Second charging contactor control button 12212: This button is a reset button and includes control functions in the power controller tester. When the second charging contactor control button 12212 is pressed, the normally open contact of the button switch closes, causing the second charging contactor relay in the internal control circuit of the power controller tester to conduct, connecting the internal 24V circuit of the power controller tester to the test leads. Pins J and K of the BK black plug in the test harness are connected to the corresponding interface of the five-in-one power controller to provide control and testing for the coil of its internal No. 2 charging contactor.

[0034] Second charging contactor indicator light 126: The green indicator light is part of the control circuit loop. The BK black plug pin M and BL blue plug pin H connected in the test harness are connected to the corresponding interface of the five-in-one power controller to realize the performance test of the internal No. 2 charging contactor contact.

[0035] If the indicator light 126 of the second charging contactor is lit without pressing the control button 12212, it indicates that the contact of the No. 2 charging contactor inside the five-in-one power controller is stuck and needs to be replaced. If the indicator light 126 of the second charging contactor is lit after pressing it, it indicates that the No. 2 charging contactor is working properly. If the indicator light 126 of the second charging contactor is not lit, it indicates that the No. 2 charging contactor is faulty and needs to be replaced.

[0036] (6) Third charging contactor control button 12312: This button is a reset button and includes control functions in the power controller tester. When the third charging contactor control button 12312 is pressed, the normally open contact of the button switch closes, causing the third charging contactor relay in the internal control circuit of the power controller tester to conduct, connecting the internal 34V circuit of the power controller tester to the test leads. The J and K pins of the GE green plug-in (third connecting plug-in 3) in the test harness are connected to the corresponding interface of the five-in-one power controller to provide control and testing for the coil of the internal No. 3 charging contactor.

[0037] Third charging contactor indicator light 127: The green indicator light, part of the control circuit loop, connects to the corresponding interfaces of the GE green plug-in pin G and BL blue plug-in pin H in the test harness, enabling performance testing of the internal No. 3 charging contactor contacts.

[0038] If the indicator light 127 of the third charging contactor is lit without pressing the control button 12312, it indicates that the contact of the third charging contactor inside the five-in-one power controller is stuck and needs to be replaced. If the indicator light 127 of the third charging contactor is lit after pressing it, it indicates that the third charging contactor is working properly. If the indicator light 127 of the third charging contactor is not lit, it indicates that the third charging contactor is faulty and needs to be replaced.

[0039] (7) Fourth charging contactor control button 12412: This button is a reset button and includes control functions in the power controller tester. When the fourth charging contactor control button 12412 is pressed, the normally open contact of the button switch closes, causing the fourth charging contactor relay in the internal control circuit of the power controller tester to conduct, connecting the internal 44V circuit of the power controller tester to the test leads. The L and M pins inside the BK black plug in the test harness are connected to the corresponding interface of the five-in-one power controller to provide control and testing for the coil of the internal No. 4 charging contactor.

[0040] Fourth charging contactor indicator light 128: The green indicator light is part of the control circuit loop. The BK black plug pin H and BL blue plug pin H connected in the test harness are connected to the corresponding interface of the five-in-one power controller to realize the performance test of the internal No. 4 charging contactor contact.

[0041] If the indicator light 128 of the fourth charging contactor is lit without pressing the control button 12412, it indicates that the contact of the fourth charging contactor inside the five-in-one power controller is stuck and needs to be replaced. If the indicator light 128 of the fourth charging contactor is lit after pressing it, it indicates that the fourth charging contactor is working properly. If the indicator light 128 of the fourth charging contactor is not lit, it indicates that the fourth charging contactor is faulty and needs to be replaced.

[0042] Figure 3 The diagram below illustrates a specific example of the power controller detector in this invention. In one embodiment, the five-in-one power controller further includes a defrost contactor, an oil pump driver, an air pump driver, a DC / DC control circuit, a DC / AC control circuit, and a low-voltage power supply circuit. The relay also includes a defrost contactor relay. The control buttons include a defrost contactor control button 13, an oil pump driver control button 14, an air pump driver control button 15, a DC / DC control circuit control button 16, and a DC / AC control circuit control button 17. The indicator lights also include a defrost contactor indicator light 18, an oil pump driver indicator light 19, an air pump driver indicator light 20, a DC / DC control circuit indicator light 21, a DC / AC control circuit indicator light 22, and a low-voltage power supply circuit indicator light 23. The defrost contactor control button 13 is used to receive the defrost contactor test command and control the defrost contactor relay to send a test signal to the defrost contactor through the first pin of the fifth connector 5 and the interface of the five-in-one power controller corresponding to the first pin of the fifth connector 5. The defrost contactor indicator light 18 is connected to the current sensor inside the power controller tester. It is used to receive the electrical signal from the five-in-one power controller based on the test signal and return it to the current sensor, and to indicate the status of the defrost contactor based on the returned electrical signal. The oil pump driver control button 14 is used to receive oil pump driver test commands and send test signals to the oil pump driver through the second pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the second pin of the fourth connector 4 according to the oil pump driver test commands. The oil pump driver indicator light 19 is used to receive the electrical signal from the return current sensor based on the test signal from the five-in-one power controller, and to indicate the status of the defrost contactor based on the returned electrical signal. The air pump driver control button 15 is used to receive air pump driver test commands and send test signals to the air pump driver through the third pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the third pin of the fourth connector 4. The air pump driver indicator light 20 is used to receive the electrical signal returned by the five-in-one power controller through the fourth pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the fourth pin of the fourth connector 4, based on the test signal, and to indicate the status of the air pump driver based on the returned electrical signal. The DC / DC control circuit control button 16 is used to receive DC / DC control circuit test commands and send test signals to the DC / DC control circuit through the fourth pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the fourth pin of the fourth connector 4. The DC / DC control circuit indicator light 21 is used to receive the electrical signal returned by the five-in-one power controller through the fifth pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the fifth pin of the fourth connector 4, based on the test signal, and to indicate the status of the DC / DC control circuit based on the returned electrical signal. The DC / AC control circuit control button 17 is used to receive DC / AC control circuit test commands and send test signals to the DC / AC control circuit through the fifth pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the fifth pin of the fourth connector 4. The DC / AC control circuit indicator light 22 is used to receive the electrical signal returned by the five-in-one power controller through the sixth pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the sixth pin of the fourth connector 4, based on the test signal, and to indicate the status of the DC / AC control circuit based on the returned electrical signal. The low-voltage power supply circuit indicator light 23 is used to receive electrical signals returned by the five-in-one power controller through the fifth pin of the second connector 2, the seventh pin of the fourth connector 4, the second pin of the fifth connector 5, the interface of the five-in-one power controller corresponding to the fifth pin of the second connector 2, the interface of the five-in-one power controller corresponding to the seventh pin of the fourth connector 4, and the interface of the five-in-one power controller corresponding to the second pin of the fifth connector 5, and to indicate the status of the low-voltage power supply circuit according to the returned electrical signals.

[0043] In one embodiment, the defrost contactor indicator light 18 is specifically used to: display green when the defrost contactor control button 13 does not receive a defrost contactor test command and the defrost contactor has a short circuit fault; display green when the defrost contactor control button 13 receives a main positive contactor test command and the defrost contactor is in normal condition; and not illuminate when the defrost contactor control button 13 receives a defrost contactor test command and the defrost contactor has an open circuit fault.

[0044] In one embodiment, the main positive contactor control button 6, the main negative contactor control button 7, and the defrost contactor control button 13 are self-locking buttons; the charging contactor control button 12 is a reset button; and the cooling fan control button 8, the oil pump driver control button 14, the air pump driver control button 15, the DC / DC control circuit control button 16, and the DC / AC control circuit control button 17 are toggle switches.

[0045] In one embodiment, the defrost contactor control button 13 and the defrost contactor indicator light 18 can be implemented by a single button that has both control and display functions; the oil pump driver control button 14 and the oil pump driver indicator light 19 can be implemented by a single button that has both control and display functions; the air pump driver control button 15 and the air pump driver indicator light 20 can be implemented by a single button that has both control and display functions; the DC / DC control circuit control button 16 and the DC / DC control circuit indicator light 21 can be implemented by a single button that has both control and display functions; and the DC / AC control circuit control button 17 and the DC / AC control circuit indicator light 22 can be implemented by a single button that has both control and display functions.

[0046] The buttons and indicator lights mentioned above will be described in detail below: (8) Defrosting contactor: Defrosting contactor control button 13: This button is a self-locking button, and in the tester, it includes both control and display functions. The control circuit works as follows: When the defrost contactor test button is pressed, the normally open contact of the button switch closes, activating the defrost contactor relay in the tester's internal control circuit. This connects the internal 24V circuit to the test leads. Pins A and B of the YE yellow plug in the test harness connect to the corresponding interfaces of the five-in-one integrated power controller, providing control and testing for the internal defrost contactor coil. Pressing this button directly supplies power to the defrost contactor coil, forcing the defrost machine to operate. This function can also be used to verify the condition of the defrost heating high-voltage circuit fuse.

[0047] Defrosting contactor indicator light 18: The green indicator light on the test button is connected to the current sensor in the corresponding control circuit of the detector, ensuring that the indicator light illuminates when current flows through the closed control circuit. Usage: If the indicator light illuminates without pressing the test button, it indicates a short circuit in the defrost contactor inside the 5-in-1 integrated power controller, requiring replacement. If the indicator light illuminates after pressing the test button, it indicates the defrost contactor is working properly. If the indicator light does not illuminate, it indicates an open circuit in the defrost contactor coil, requiring replacement.

[0048] (9) Oil pump driver: Oil pump driver control button 14: This is a toggle switch, which includes a control function in the power controller tester. The control circuit: When this switch is moved to the simulated position, it connects the internal switch contacts of the power controller tester, enabling conduction between the oil pump signal circuit and the negative power supply. Pins E and H of the BL blue connector in the test harness are connected to the corresponding interfaces of the five-in-one power controller to control and test the internal oil pump drive electrical signal. Usage: The toggle switch in the OFF position disables the test function; in the simulated position, it enables the oil pump test function, effectively triggering the oil pump drive signal within the five-in-one power controller.

[0049] Oil pump driver indicator light 19: This indicator light is a green LED and includes a display function in the power controller tester. Control circuit: The indicator light connects to the oil pump control circuit and DC / AC control circuit inside the power controller tester. Pins E, H, and L of the blue connector in the BL test harness are connected to the corresponding interfaces of the five-in-one power controller to test the performance of its internal oil pump drive electrical signal. Usage effect: If the indicator light is not lit, it indicates that the oil pump drive signal inside the five-in-one power controller is abnormal; if it is lit, it indicates that the signal is normal.

[0050] (10) Air pump driver: Air pump driver control button 15: This is a toggle switch, which includes a control function in the power controller tester. The control circuit works as follows: when this switch is moved to the simulated position, it connects the internal switch contacts of the power controller tester, enabling conduction between the air pump signal circuit and the negative power supply. Pins A and H of the BL blue connector in the test harness are connected to the corresponding interfaces of the five-in-one power controller to control and test the internal air pump drive electrical signal. Usage: When the toggle switch is in the OFF position, the test function is turned off; when in the simulated position, the air pump test function is turned on, effectively triggering the air pump drive signal within the five-in-one power controller.

[0051] Air pump driver indicator light 20: This indicator light is a blue LED, and it includes a display function in the power controller tester. Control circuit: The indicator light connects to the internal air pump control circuit and DC / AC control circuit of the power controller tester. Pins A, H, and L of the BL blue connector in the test harness are connected to the corresponding interfaces of the five-in-one power controller to test the working efficiency of its internal air pump drive electrical signal. Usage effect: If the indicator light is not lit, it indicates that the air pump drive signal inside the five-in-one power controller is abnormal; if it is lit, it indicates that the signal is normal.

[0052] (11) DC / DC control circuit: DC / DC control circuit control button 16: This is a toggle switch, which includes a control function in the power controller tester. The control circuit: When this switch is moved to the simulated position, it connects the internal switch contacts of the power controller tester, enabling conduction between the DC / DC trigger circuit and the positive terminal of the power supply. Pins G and H of the BL blue connector in the test harness connect to the corresponding interfaces of the 5-in-1 power controller to control its internal DC / DC trigger circuit. Usage: The toggle switch in the OFF position disables the test function; in the simulated position, it enables the DC / DC test function, allowing for testing of the DC / DC function within the 5-in-1 power controller.

[0053] DC / DC control circuit indicator light 21: This indicator light is a white LED and includes a display function in the power controller tester. Control circuit: The indicator light connects to the internal DC / DC control circuit of the power controller tester. Pins G and H of the blue connector in the BL test harness are connected to the corresponding interfaces of the 5-in-1 power controller to test its internal DC / DC operation. Usage effect: If the indicator light is not lit, it indicates that the DC / DC operation inside the 5-in-1 power controller is abnormal; if it is lit, it indicates normal operation.

[0054] (12) DC / AC control circuit: DC / AC control circuit control button 17: This is a toggle switch, which includes a control function in the power controller tester. The control circuit: When this switch is moved to the simulated position, it connects the internal switch contacts of the power controller tester, enabling conduction between the DC / AC trigger circuit, the working circuit, and the positive terminal of the power supply. The D, H, and L pins inside the BL blue connector in the test harness connect to the corresponding interfaces of the 5-in-1 power controller to control its internal DC / AC switching circuit. Usage: The toggle switch in the OFF position disables the test function; in the simulated position, it enables the DC / AC test function, thus performing DC / AC function testing within the 5-in-1 power controller.

[0055] DC / AC control circuit indicator light 22: This indicator light is a yellow LED and includes a display function in the power controller tester. Control circuit: The indicator light connects to the internal DC / AC control circuit of the power controller tester. Pins D, H, and L of the BL blue connector in the test harness are connected to the corresponding interfaces of the 5-in-1 power controller to test its internal DC / AC operation. Usage effect: If the indicator light is not lit, it indicates that the DC / AC operation within the 5-in-1 power controller is abnormal; if it is lit, it indicates normal operation.

[0056] (13) Low-voltage power supply circuit indicator light 23: This indicator light is a red LED and includes a display function in the power controller tester. Its control circuit consists of: low-voltage power supply circuit indicator light 23 connected to the internal DC / AC control circuit and DC / DC control circuit of the power controller tester; and pins D and G of the BL blue plug-in and pin A of the BK black plug-in in the test harness, and pin A of the YE yellow plug-in, connected to the corresponding interfaces of the five-in-one power controller to test the operation of its internal control circuits. If the indicator light is not lit, it indicates that the five-in-one power controller is not receiving power and is malfunctioning; if it is lit, it indicates that the power supply is normal.

[0057] Figure 4 The diagram below shows a specific example of a power controller detector according to an embodiment of the present invention. In one embodiment, the power controller detector further includes: a temperature gauge 24; the relay further includes a temperature signal switching relay; the temperature gauge 24 is connected to the temperature signal switching relay and is used to control the temperature signal switching relay to measure the internal ambient temperature of the five-in-one power controller through the eighth pin of the fourth connector 4 and the interface of the five-in-one power controller corresponding to the eighth pin of the fourth connector 4, and to display the measured temperature.

[0058] In one embodiment, the temperature gauge 24 can be a digital LCD display with a measurement range of -35℃ to 150℃, and includes temperature detection and display functions in the power controller tester. Its internal control circuit is as follows: the temperature gauge 24 is connected to the temperature signal switching relay in the oil pump and air pump control circuit inside the power controller tester. Pins B, C, F, and M of the BL blue plug in the test harness are connected to the corresponding interfaces of the five-in-one power controller to detect its internal temperature information circuit. Its effect is that it automatically switches and displays relevant temperature information values ​​according to the selected oil pump or air pump function.

[0059] Figure 5 The diagram below illustrates a specific example of a power controller tester according to an embodiment of the present invention. In one embodiment, the power controller tester further includes: a voltmeter 25; the relay further includes a voltage signal switching relay; the voltmeter 25 is connected to the voltage signal switching relay and is used to control the voltage signal switching relay to measure the node voltage of the internal circuit of the five-in-one power controller through the sixth pin of the second connector 2, the ninth pin of the fourth connector 4, the third pin of the fifth connector 5, the interface of the five-in-one power controller corresponding to the sixth pin of the second connector 2, the interface of the five-in-one power controller corresponding to the ninth pin of the fourth connector 4, and the interface of the five-in-one power controller corresponding to the third pin of the fifth connector 5, and to display the measured voltage.

[0060] In one embodiment, the voltmeter 25 can be in the form of an LED digital tube display, with a measurement range of 0-50V, and includes voltage measurement and display functions in the power controller tester. Its control circuit is as follows: the voltmeter 25 is connected to the voltage signal switching relay in the DC / DC, DC / AC, and other control circuits inside the power controller tester. Pins D, G, H, L of the blue BL plug-in and pins A, B of the black BK plug-in, and pins J, K of the yellow YE plug-in in the test harness are connected to the corresponding interfaces of the five-in-one power controller to detect its internal control voltage. Its effect is that, depending on the selection of various triggering circuits of the five-in-one power controller, the voltmeter 25 can automatically display relevant voltage information values.

[0061] In one embodiment, the following button also includes the following functions: 1. Main positive contactor control button 6: This button is a self-locking button. If the main positive contactor indicator light 9 is lit when not pressed, it indicates that there is a sticking fault in the main positive contactor control contacts inside the five-in-one power controller and it needs to be replaced. If the indicator light is lit after pressing, it indicates that the main positive contactor control circuit and the components themselves are working effectively and the control contacts are sensitive. If the indicator light is not lit, it indicates that there is a fault in the control circuit and the components themselves and they need to be replaced.

[0062] 2. Main negative contactor control button 7: This button is a self-locking button. If the main negative contactor indicator light 10 is lit when not pressed, it indicates that there is a sticking fault in the main negative contactor control contacts inside the five-in-one power controller and it needs to be replaced. If the indicator light is lit after pressing, it indicates that the main negative contactor control circuit and the components themselves are working effectively and the control contacts are sensitive. If the indicator light is not lit, it indicates that there is a fault in the control circuit and the components themselves and they need to be replaced.

[0063] 3. Defrosting contactor control button 13: This button is a self-locking button. When the vehicle circuit is connected and not pressed, the defrosting contactor indicator light 18 will light up, indicating that the defrosting contactor is under the control of the vehicle. When the indicator light is off, it means that it is not under the control of the vehicle. Pressing this button will directly supply power to the defrosting contactor coil and force the defrosting machine to work. This function can also be used to verify the condition of the defrosting heating high voltage circuit fuse.

[0064] 4. Charging Contactor Control Button 12: This button is a reset button. If the charging contactor indicator light is on when not pressed, it indicates that the control contacts of the charging contactor inside the five-in-one power controller are stuck and need to be replaced. If the charging contactor indicator light is on when pressed, it indicates that the charging contactor control circuit and components themselves are working effectively and the control contacts are making sensitive contact. If the charging contactor indicator light is not on, it indicates that the control circuit and components themselves are faulty and need to be replaced. There are four buttons on this button, each representing a different charging contactor test position.

[0065] 5. Oil pump driver control button 14: This switch is a lever switch used to assist in controlling the low-voltage control function of the power steering pump motor. When the vehicle control circuit is damaged, it can force the operation of the power steering pump motor.

[0066] 6. Oil pump driver indicator light 19: When this indicator light is on, it means that the low-pressure control circuit of the power steering oil pump motor is normal. When it is off, it means that the control circuit is damaged or not turned on.

[0067] 7. Air pump driver control button 15: This switch is a toggle switch used to assist in controlling the low-pressure control function of the air compressor motor. When the vehicle control circuit is damaged, it can force the air compressor motor to run.

[0068] 8. Air pump driver indicator light 20: When this indicator light is on, it means that the low-pressure control circuit of the air compressor motor is normal. When it is off, it means that the control circuit is damaged or is not started.

[0069] 9. DC / DC Control Circuit Control Button 16: This switch is a toggle switch used to assist in controlling the low-voltage control function of the power converter. When the vehicle control circuit is damaged, it can force the normal operation of the DC / DC power converter.

[0070] 10. DC / DC control circuit indicator light 21: When this indicator light is on, it means that the low-voltage control circuit of the power converter is operating normally. When it is off, it means that the low-voltage control circuit is damaged or not turned on.

[0071] 11. DC / AC Control Circuit Control Button 17: This switch is a toggle switch used to assist in controlling the low-voltage control function of the power inverter. When the vehicle control circuit is damaged, it can force the DC / AC power inverter to return to normal operation.

[0072] 12. DC / AC control circuit indicator light 22: When this indicator light is on, it means that the low-voltage control circuit of the power inverter is operating normally. When it is off, it means that the low-voltage control circuit is damaged or not turned on.

[0073] 13. Cooling Fan Control Button 8: This switch is a toggle switch used to assist in controlling the low-voltage power supply circuit of the five-in-one integrated power controller. When the vehicle's power supply circuit is damaged, it can force the five-in-one integrated power controller to start so that it can maintain normal operation and can force power to the cooling fan.

[0074] 14. Low-voltage power supply circuit indicator 23: When this indicator is lit, it means that the low-voltage power supply circuit is normal. When it is off, it means that the low-voltage power supply circuit is damaged or in a power outage state.

[0075] 15. Thermometer 24: Used to measure the ambient temperature of the working area and compare it with the temperature status of the controller to determine abnormal high temperature faults.

[0076] 16. Voltmeter 25: Used to detect the real-time operating voltage of the vehicle's low-voltage system and the internal battery power supply voltage of the instrument.

[0077] The specifications of the power controller tester can be as follows: Operating voltage: DC 22V-28V; Operating temperature: -20℃ to 60℃; Battery capacity: 10000mA (ternary polymer lithium battery); Product weight: 2.2KG; External dimensions: 300mm x 180mm x 150mm (length x width x height).

[0078] The power controller tester is very easy to operate. Simply connect the power controller tester to the low-voltage interface plug of the integrated power controller, press the function buttons on the tester according to the test items, and judge the fault location and test the functional performance based on the indicator lights and instrument display.

[0079] Basic test: After the vehicle circuit control power supply is cut off, connect the low voltage wiring harness connector of the power controller tester to the five-in-one assembly control interface, turn on the main power switch of the power controller tester, press or turn on the test button as needed, and confirm the condition of the measured and tested parts according to the indicator light status.

[0080] On-vehicle testing: After disconnecting the power supply to the circuit control, connect the low-voltage wiring harness connector of the power controller tester to the control interface of the five-in-one assembly, and connect the body wiring harness interface to the test interface on the upper end of the power controller tester. Turn on the main power switch of the power controller tester and then turn on the main power switch of the vehicle. Test the control circuit between the vehicle control panel and the five-in-one power controller as required. If there is a problem with the vehicle control circuit, after confirming the cause of the fault, the analog switch on the power controller tester can be used for auxiliary testing to verify the cause of the fault.

[0081] Effective fault diagnosis and performance testing can be performed on the following items: 1. Testing the main positive (main negative) contactor; 2. Testing the charging contactor and its operation; 3. Testing and simulating the defrosting heating control function; 4. Testing and simulating the low-voltage control circuit of the air compressor motor; 5. Testing and simulating the low-voltage control circuit of the power assist pump motor; 6. Testing, simulating, and triggering the low-voltage control circuit of the power converter; 7. Testing the working condition of the cooling fan; 8. Measuring the DC / DC output voltage and the low-voltage control circuit voltage; 9. Testing and measuring the ambient temperature of the working environment.

[0082] During the testing of charging contactors using the first-generation power controller tester, it was found that the time required to operate the equipment, which used to be 2 to 5 hours with the cooperation of at least two people, has been reduced to just 20 minutes with one person. This has greatly improved the efficiency of maintenance and the accuracy of fault location.

[0083] The first-generation power controller tester underwent multiple tests. It tested three types of difficult faults in electric drive vehicles (power failure during driving, failure of power-on self-test, restart) and seven common faults (air compressor not running, oil pump not running, DC / DC control circuit not working, vehicle not charging, defrost contactor not heating, main positive and main negative contactors not engaging, and air conditioning not receiving power). Its accuracy in detecting and diagnosing faults reached 100%.

[0084] In summary, in this embodiment of the invention, multiple interfaces of the five-in-one power controller are corresponding to connector plugs, relays, control buttons, and indicator lights. The connector plugs include a first connector plug 1, a second connector plug 2, a third connector plug 3, a fourth connector plug 4, and a fifth connector plug 5. The five-in-one power controller includes a main positive contactor, a main negative contactor, a charging contactor, and a cooling fan. The relays include a main positive contactor relay, a main negative contactor relay, and a charging contactor relay. The control buttons include a main positive contactor control button 6, a main negative contactor control button 7, a charging contactor control button 12, and a cooling fan control button 8. The indicator lights include a main positive contactor indicator light 9 and a main negative contactor indicator light 9. Light 10, charging contactor indicator light, cooling fan indicator light 11; Main positive contactor control button 6 is used to receive the main positive contactor test command, and according to the main positive contactor test command, controls the main positive contactor relay to send a test signal to the main positive contactor through the interface of the first connecting plug 1 and the five-in-one power controller corresponding to the first connecting plug 1; Main positive contactor indicator light 9 is used to receive the electrical signal returned by the five-in-one power controller according to the test signal, and indicates the status of the main positive contactor according to the returned electrical signal; Main negative contactor control button 7 is used to receive the main negative contactor test command, and according to the main negative contactor test command, controls the main negative contactor relay to send a test signal to the main negative contactor through the interface of the first connecting plug 1 and the five-in-one power controller corresponding to the first connecting plug 1. The contactor sends a test signal; the main negative contactor indicator light 10 receives the electrical signal returned by the five-in-one power controller based on the test signal, and indicates the status of the main negative contactor based on the returned electrical signal; the charging contactor control button 12 receives the charging contactor test command, and controls the charging contactor relay to send a test signal to the charging contactor through the second connecting plug 2, the third connecting plug 3, the interface of the five-in-one power controller corresponding to the second connecting plug 2, and the interface of the five-in-one power controller corresponding to the third connecting plug 3; the charging contactor indicator light receives the electrical signal returned by the five-in-one power controller based on the test signal, and indicates the status of the charging contactor based on the returned electrical signal; the cooling fan control button... Button 8 is used to receive cooling fan test commands and, according to the cooling fan test commands, controls the cooling fan relay to send test signals to the cooling fan through the fourth connecting plug 4, the fifth connecting plug 5, the interface of the five-in-one power controller corresponding to the fourth connecting plug 4, and the interface of the five-in-one power controller corresponding to the fifth connecting plug 5. The cooling fan indicator light 11 is used to receive the electrical signal returned by the five-in-one power controller according to the test signal and to indicate the status of the cooling fan according to the returned electrical signal. The status includes normal status and fault status. Compared with the prior art of manually inspecting the power controller, the embodiment of the present invention can improve the fault finding accuracy and maintenance efficiency of the power controller and avoid faults caused by the operation level and technical ability of maintenance personnel.

[0085] The beneficial effects of this invention are as follows: It effectively addresses the technical bottlenecks in troubleshooting the low-voltage control circuit open / short circuit faults, power supply voltage measurement, and internal component testing of the five-in-one power controller assembly for electric vehicles, particularly regarding contactor performance, control functions, and signal output. Furthermore, the convenient and quick testing method significantly improves the time and accuracy of fault diagnosis for operators. Operation is extremely convenient; simply connect the power controller tester to the integrated power controller low-voltage interface plug, press the function buttons on the tester according to the test items, and determine the fault location and test functional performance based on the indicator lights and instrument displays.

[0086] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program operating systems. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program operating system implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0087] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program business systems according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0088] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0089] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0090] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A power controller tester, characterized in that, include: The system includes connectors, relays, control buttons, and indicator lights, each corresponding to one of the multiple interfaces of the five-in-one power controller. The connectors include a first connector, a second connector, a third connector, a fourth connector, and a fifth connector. The five-in-one power controller includes a main positive contactor, a main negative contactor, a charging contactor, and a cooling fan. The relays include a main positive contactor relay, a main negative contactor relay, and a charging contactor relay. The control buttons include a main positive contactor control button, a main negative contactor control button, a charging contactor control button, and a cooling fan control button. The indicator lights include a main positive contactor indicator light, a main negative contactor indicator light, a charging contactor indicator light, and a cooling fan indicator light. The main positive contactor control button is used to receive the main positive contactor test command and control the main positive contactor relay to send a test signal to the main positive contactor through the interface of the first connector and the five-in-one power controller corresponding to the first connector. The main positive contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the main positive contactor based on the returned electrical signal. The main negative contactor control button is used to receive the main negative contactor test command and control the main negative contactor relay to send a test signal to the main negative contactor through the interface of the first connecting plug and the five-in-one power controller corresponding to the first connecting plug according to the main negative contactor test command. The main negative contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the main negative contactor based on the returned electrical signal. The charging contactor control button is used to receive charging contactor test commands and control the charging contactor relay to send test signals to the charging contactor through the second connecting plug, the third connecting plug, the interface of the five-in-one power controller corresponding to the second connecting plug, and the interface of the five-in-one power controller corresponding to the third connecting plug. The charging contactor indicator light is used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the charging contactor based on the returned electrical signal. The cooling fan control button is used to receive cooling fan test commands and control the cooling fan relay to send test signals to the cooling fan through the fourth connector, the fifth connector, the interface of the five-in-one power controller corresponding to the fourth connector, and the interface of the five-in-one power controller corresponding to the fifth connector. The cooling fan indicator light is used to receive electrical signals returned by the five-in-one power controller based on the test signals, and to indicate the status of the cooling fan based on the returned electrical signals; the status includes normal status and fault status.

2. The power controller tester as described in claim 1, characterized in that, The main positive contactor indicator light is specifically used to: display red when the main positive contactor control button does not receive a main positive contactor test command and the main positive contactor has an adhesion fault; and display red when the main positive contactor control button receives a main positive contactor test command and the main positive contactor is in a normal state. The light will not illuminate when the main positive contactor control button receives a test command for the main positive contactor and the main positive contactor has a fault other than adhesion.

3. The power controller tester as described in claim 1, characterized in that, The first, second, third, fourth, and fifth connectors each include multiple pins.

4. The power controller tester as described in claim 3, characterized in that, The main positive contactor control button is specifically used to control the main positive contactor relay to send a test signal to the main positive contactor through the first pin of the first connector and the interface of the five-in-one power controller corresponding to the first pin of the first connector, according to the main positive contactor test command. The main negative contactor control button is specifically used to control the main negative contactor relay to send a test signal to the main negative contactor through the second pin of the first connector and the interface of the five-in-one power controller corresponding to the second pin of the first connector, according to the main negative contactor test command. The cooling fan control button is specifically used to control the cooling fan relay to send a test signal to the cooling fan according to the cooling fan test command, through the first pin of the second connector, the first pin of the fourth connector, the first pin of the fifth connector, the interface of the five-in-one power controller corresponding to the first pin of the second connector, the interface of the five-in-one power controller corresponding to the first pin of the fourth connector, and the interface of the five-in-one power controller corresponding to the first pin of the fifth connector.

5. The power controller tester as described in claim 3, characterized in that, The charging contactor includes a first charging contactor, a second charging contactor, a third charging contactor, and a fourth charging contactor. The charging contactor control button is specifically used for: controlling the first charging contactor relay to send a test signal to the first charging contactor through the second pin of the second connector and the interface of the five-in-one power controller corresponding to the second pin of the second connector, according to the first charging contactor test command; controlling the second charging contactor relay to send a test signal to the second charging contactor through the third pin of the second connector and the interface of the five-in-one power controller corresponding to the third pin of the second connector, according to the second charging contactor test command; controlling the third charging contactor relay to send a test signal to the third charging contactor through the first pin of the third connector and the interface of the five-in-one power controller corresponding to the first pin of the third connector, according to the third charging contactor test command; and controlling the fourth charging contactor relay to send a test signal to the fourth charging contactor through the fourth pin of the second connector and the interface of the five-in-one power controller corresponding to the fourth pin of the second connector, according to the fourth charging contactor test command. The charging contactor indicator light is specifically used to receive the electrical signal returned by the five-in-one power controller based on the test signal, and to indicate the status of the first charging contactor, the second charging contactor, the third charging contactor, and the fourth charging contactor based on the returned electrical signal.

6. The power controller tester as described in claim 5, characterized in that, The five-in-one power controller also includes a defrost contactor, an oil pump driver, an air pump driver, a DC / DC control circuit, a DC / AC control circuit, and a low-voltage power supply circuit; the relay also includes a defrost contactor relay; the control buttons also include a defrost contactor control button, an oil pump driver control button, an air pump driver control button, a DC / DC control circuit control button, and a DC / AC control circuit control button; the indicator lights also include a defrost contactor indicator light, an oil pump driver indicator light, an air pump driver indicator light, a DC / DC control circuit indicator light, a DC / AC control circuit indicator light, and a low-voltage power supply circuit indicator light. The defrost contactor control button is used to receive defrost contactor test commands and control the defrost contactor relay to send test signals to the defrost contactor through the first pin of the fifth connector and the interface of the five-in-one power controller corresponding to the first pin of the fifth connector. The defrost contactor indicator light is connected to the current sensor inside the power controller detector. It is used to receive the electrical signal returned by the five-in-one power controller to the current sensor based on the test signal, and to indicate the status of the defrost contactor based on the returned electrical signal. The oil pump driver control button is used to receive oil pump driver test commands and send test signals to the oil pump driver through the second pin of the fourth connector and the interface of the five-in-one power controller corresponding to the second pin of the fourth connector, according to the oil pump driver test commands. The oil pump driver indicator light is used to receive the electrical signal from the return current sensor based on the test signal from the five-in-one power controller, and to indicate the status of the defrost contactor based on the returned electrical signal. The air pump driver control button is used to receive air pump driver test commands and send test signals to the air pump driver through the third pin of the fourth connector and the interface of the five-in-one power controller corresponding to the third pin of the fourth connector. The air pump driver indicator light is used to receive the electrical signal returned by the five-in-one power controller through the fourth pin of the fourth connector and the interface of the five-in-one power controller corresponding to the fourth pin of the fourth connector, based on the test signal, and to indicate the status of the air pump driver based on the returned electrical signal. The DC / DC control circuit control button is used to receive DC / DC control circuit test commands and send test signals to the DC / DC control circuit through the fourth pin of the fourth connector and the interface of the five-in-one power controller corresponding to the fourth pin of the fourth connector. The DC / DC control circuit indicator light is used to receive the electrical signal returned by the five-in-one power controller through the fifth pin of the fourth connector and the interface of the five-in-one power controller corresponding to the fifth pin of the fourth connector, based on the test signal, and to indicate the status of the DC / DC control circuit based on the returned electrical signal. The DC / AC control circuit control button is used to receive DC / AC control circuit test commands and send test signals to the DC / AC control circuit through the fifth pin of the fourth connector and the interface of the five-in-one power controller corresponding to the fifth pin of the fourth connector. The DC / AC control circuit indicator light is used to receive the electrical signal returned by the five-in-one power controller through the sixth pin of the fourth connector and the interface of the five-in-one power controller corresponding to the sixth pin of the fourth connector, based on the test signal, and to indicate the status of the DC / AC control circuit based on the returned electrical signal. The low-voltage power supply circuit indicator light is used to receive electrical signals returned by the five-in-one power controller through the fifth pin of the second connector, the seventh pin of the fourth connector, the second pin of the fifth connector, the interface of the five-in-one power controller corresponding to the fifth pin of the second connector, the interface of the five-in-one power controller corresponding to the seventh pin of the fourth connector, and the interface of the five-in-one power controller corresponding to the second pin of the fifth connector, and to indicate the status of the low-voltage power supply circuit according to the returned electrical signals.

7. The power controller tester as described in claim 6, characterized in that, The defrost contactor indicator light is specifically used to: display green when the defrost contactor control button does not receive a defrost contactor test command and the defrost contactor has a short circuit fault; display green when the defrost contactor control button receives a main positive contactor test command and the defrost contactor is in normal condition; and not illuminate when the defrost contactor control button receives a defrost contactor test command and the defrost contactor has an open circuit fault.

8. The power controller tester as described in claim 6, characterized in that, The main positive contactor control button, the main negative contactor control button, and the defrost contactor control button are self-locking buttons; the charging contactor control button is a reset button; and the cooling fan control button, the oil pump driver control button, the air pump driver control button, the DC / DC control circuit control button, and the DC / AC control circuit control button are toggle switches.

9. The power controller tester as described in claim 3, characterized in that, Also includes: Thermometer; The relay also includes a temperature signal switching relay; The thermometer is connected to the temperature signal switching relay and is used to control the temperature signal switching relay to measure the internal ambient temperature of the five-in-one power controller through the eighth pin of the fourth connector and the interface of the five-in-one power controller corresponding to the eighth pin of the fourth connector, and display the measured temperature.

10. The power controller tester as described in claim 3, characterized in that, Also includes: Voltmeter; The relay also includes a voltage signal switching relay; The voltmeter is connected to the voltage signal switching relay and is used to control the voltage signal switching relay to measure the node voltage of the internal circuit of the five-in-one power controller through the sixth pin of the second connector, the ninth pin of the fourth connector, the third pin of the fifth connector, the interface of the five-in-one power controller corresponding to the sixth pin of the second connector, the interface of the five-in-one power controller corresponding to the ninth pin of the fourth connector, and the interface of the five-in-one power controller corresponding to the third pin of the fifth connector, and display the measured voltage.

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