Interchangeable charging system interaction test system and test method based on user big data

Abstract

The application provides an alternating current charging system interaction test system and test method based on user big data, and belongs to the technical field of vehicle electrical system testing. The system comprises: an integrated test bench for carrying and connecting an alternating current charging system to be tested, wherein the alternating current charging system at least comprises a vehicle controller, a vehicle-mounted charging and power distribution unit and a battery pack; a simulation load and power supply module for providing a simulation power grid input for the alternating current charging system to be tested and adjusting the charging and discharging state of the battery pack; a central control and data processing module communicatively connected to the simulation load and power supply module and the integrated test bench, wherein the central control and data processing module comprises a scene construction unit, an interaction simulation unit, a test execution and monitoring unit and a result analysis unit. The system can efficiently, safely and realistically simulate actual vehicle scenes in a laboratory environment and perform integrated and interactive test verification on the alternating current charging system.

Description

Technical Field

[0001] This application belongs to the field of vehicle electrical system testing technology, specifically relating to an interactive testing system and testing method for AC charging systems based on user big data. Background Technology

[0002] As one of the most important functional modules of new energy vehicles, the performance and reliability of the AC charging system directly affect the user experience. This system is a complex system involving the coordinated operation of multiple components, including the charging gun, charging socket, charging and distribution system (on-board charger, DC / DC converter), battery pack, and high-voltage and low-voltage wiring harnesses connecting the above components.

[0003] Currently, the industry's verification of AC charging systems mainly relies on two modes: single component testing and system testing integrated into the entire vehicle. At the component testing level, existing technologies primarily rely on relevant national standards. For example, testing of charging sockets and charging guns follows GB / T 20234-2023, while testing of the charging and distribution system assembly follows GB / T 40432-2021. While these standards provide a basis for evaluating the basic performance of components, their methods have significant limitations: tests are typically based on static parameter settings (such as fixed charging time, ambient temperature, charging power, coolant temperature and flow rate), failing to reflect the real-time data interaction between the AC charging system and other vehicle controllers (such as the vehicle controller and battery management system) under actual operating conditions. Furthermore, they cannot fully reflect the comprehensive impact of dynamic factors such as ambient temperature fluctuations and coolant temperature changes on system performance.

[0004] On the other hand, while vehicle-level testing can reflect the functionality of the integrated system to some extent, it has many shortcomings: the testing cycle is long and cannot adapt to the increasingly shorter product development cycle; the cost of testing equipment is high and the energy consumption is large; when conducting fault injection testing, it is not only difficult to accurately trigger the target fault, but also poses a potential safety risk to personnel at the testing site.

[0005] Therefore, existing technologies lack an effective method and system for efficiently, safely, and realistically simulating actual vehicle usage scenarios in a laboratory environment, and for conducting integrated and interactive testing and verification of AC charging systems. Summary of the Invention

[0006] The purpose of this application is to solve the problems existing in the prior art and provide an interactive testing system and method for AC charging systems based on user big data. This system can efficiently, safely and realistically simulate actual vehicle use scenarios in a laboratory environment and conduct integrated and interactive testing and verification of AC charging systems.

[0007] This application is achieved through the following technical solution:

[0008] The first aspect of the invention provides an interactive testing system for AC charging systems based on user big data, comprising: An integrated test bench is used to support and connect an AC charging system to be tested, the AC charging system including at least a vehicle controller, an on-board charging and distribution unit, and a battery pack; The simulated load and power supply module is used to provide a simulated power grid input to the AC charging system under test and to regulate the charging and discharging state of the battery pack. A central control and data processing module is communicatively connected to the simulated load and power supply module and the integrated test bench. The central control and data processing module includes: The scenario building unit is used to generate test scenario data containing dynamic charging parameters and power grid disturbance parameters based on historical user charging behavior data. The interactive simulation unit is used to simulate the signal interaction between the vehicle control network and the vehicle controller and / or the on-board charging and power distribution unit during the test, so as to simulate the vehicle-level control logic and fault response. The test execution and monitoring unit is used to control the simulated load and power supply module and the integrated test bench based on the test scenario data, automatically execute the integrated interactive test process, and collect electrical signal data and network communication data in real time during the test process; The result analysis unit is used to analyze and process the collected electrical signal data and network communication data to generate test results.

[0009] Preferably, the simulated load and power supply module includes: A power grid simulator is used to output a programmable AC power supply and to superimpose a preset power grid disturbance waveform onto the AC power supply. A programmable DC load is connected to the battery pack to discharge the battery pack to the initial state of charge corresponding to the test scenario data.

[0010] Preferably, the power grid disturbance waveform superimposed by the power grid simulator includes at least one of the following: a phase change of AC voltage, a transient high voltage spike superimposed on the phase of a preset period, and a step change in AC voltage amplitude.

[0011] Preferably, the integrated test bench further includes a charging interface simulation device; The charging interface simulation device is used to provide a charging connection signal; The on-board charging and distribution unit, the battery pack, and the vehicle controller are connected via vehicle bus and hardwire to reproduce the vehicle electrical topology.

[0012] Preferably, the interactive simulation unit in the central control and data processing module communicates with the vehicle controller and / or the on-board charging and distribution unit via the controller local area network bus, and is used to input simulated fault frames or modify signal values ​​to the controller local area network bus to trigger the fault diagnosis and protection mechanism of the AC charging system.

[0013] Preferably, the scenario construction unit generates the dynamic charging parameters by performing data mining on historical user charging behavior data. The dynamic charging parameters include one or more of the following: charging start and end state of charge, charging power curve, charging time period distribution, ambient temperature, and battery coolant temperature.

[0014] Preferably, the scenario construction unit classifies historical user charging behavior data according to vehicle power type, and generates test scenario data with different parameter feature distributions for pure electric vehicles and plug-in hybrid vehicles respectively.

[0015] A second aspect of this application provides an interactive testing method for an AC charging system based on user big data, characterized in that it is applied to the interactive testing system for an AC charging system based on user big data as described in any of the preceding claims, the method comprising: Based on historical user charging behavior data, test scenario data including dynamic charging parameters and power grid disturbance parameters is generated; Connect the AC charging system to be tested to the integrated test bench, and power and initialize the AC charging system to bring it into a testable state. Based on the test scenario data, the simulated load and power supply module are controlled to provide grid input to the AC charging system and adjust the battery pack status. At the same time, the vehicle control network is simulated to interact with the vehicle controller and / or the on-board charging and distribution unit to simulate the vehicle-level control logic and fault response. Real-time acquisition of electrical signal data and network communication data of the AC charging system during the test; The collected electrical signal data and network communication data are analyzed and processed to generate test results.

[0016] Preferably, the simulated vehicle control network interacts with the vehicle controller and / or the on-board charging and power distribution unit, including: The system sends communication messages containing simulated fault information to the vehicle controller and / or the on-board charging and power distribution unit via the controller area network bus to trigger and verify the fault diagnosis and protection mechanism of the AC charging system.

[0017] Preferably, controlling the analog load and power supply module to provide grid input to the AC charging system includes: The analog load is controlled to output AC power with a preset grid disturbance waveform superimposed on the power supply module; wherein the grid disturbance waveform includes at least one of the following: a phase change of AC voltage, a transient high voltage spike superimposed on the phase of a preset period, and a step change in AC voltage amplitude.

[0018] Compared with the prior art, the beneficial effects of this application are: the test system provided by this application can perform integrated and interactive testing and verification of AC charging systems in a laboratory environment. It not only has a high system-level failure reproduction rate and good test safety, but also has low R&D and verification costs and high ease of operation, providing an efficient, economical and reliable solution for electronic testing of new energy vehicles. Attached Figure Description

[0019] The above and other objects, features, and advantages of this application will become more apparent from the more detailed description of the embodiments of this application in conjunction with the accompanying drawings. The accompanying drawings are used to provide a further understanding of the embodiments of this application and form part of the specification. They are used together with the embodiments of this application to explain this application and do not constitute a limitation thereof.

[0020] Figure 1 A schematic diagram of the structure of an AC charging system interactive testing system based on user big data provided in this application embodiment; Figure 2 A schematic diagram of another interactive testing system for an AC charging system based on user big data provided in this application embodiment; Figure 3 A flowchart illustrating an interactive testing method for an AC charging system based on user big data, provided in an embodiment of this application; Figure 4 This is a schematic diagram illustrating the principle of another interactive testing method for an AC charging system based on user big data, provided in an embodiment of this application. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application more apparent, exemplary embodiments according to this application will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments of this application. It should be understood that this application is not limited to the exemplary embodiments described herein. Based on the embodiments of this application described herein, all other embodiments obtained by those skilled in the art without inventive effort should fall within the protection scope of this application.

[0022] To address the problem that existing methods cannot efficiently, safely, and realistically simulate actual vehicle usage scenarios and conduct integrated, interactive testing and verification of AC charging systems, this application proposes an interactive testing system and method for AC charging systems based on user big data. This system can efficiently, safely, and realistically simulate actual vehicle usage scenarios in a laboratory environment and conduct integrated, interactive testing and verification of AC charging systems. The following is a further detailed description of this application with reference to the accompanying drawings.

[0023] Figure 1 A schematic diagram of the structure of an AC charging system interactive testing system based on user big data provided in this application embodiment is shown below. Figure 1 This application describes an AC charging system interaction test system based on user big data, according to an embodiment of the present application.

[0024] like Figure 1 As shown, the AC charging system interactive test system 100 based on user big data in this application includes at least: an integrated test bench 110, a simulated load and power supply module 120, and a central control and data processing module 130.

[0025] An integrated test bench 110 is used to carry and connect the AC charging system to be tested, the AC charging system including at least a vehicle controller 111, an on-board charging and distribution unit 112, and a battery pack 113.

[0026] Here, the integrated test bench 110 is a physical load-bearing and electrically integrated structure used to fix, connect, and reconstruct the core components of the AC charging system under test in a laboratory environment, enabling it to operate according to the electrical topology and signal logic of the actual vehicle. This bench not only provides mechanical support but also achieves electrical and fluid connections between the components through wiring harnesses and conduits, forming a functional subsystem that can operate independently of the vehicle environment.

[0027] The Vehicle Control Unit (VCU) 111 is the core control unit of a new energy vehicle and serves as one of the control nodes under test in the testing system. It receives status information from components such as the battery pack and charging / distribution unit, performs control strategy calculations, and sends instructions such as charging power and voltage / current limits to actuators such as the charging / distribution unit to coordinate the entire charging process.

[0028] The On-Board Charger (OBC) unit 112 refers to an integrated or separate unit of the On-Board Charger (OBC) and the on-board DC / DC converter. Its main function is to convert AC power from the grid into DC power to charge the battery pack and supply power to the vehicle's low-voltage system. In testing, it is a critical component for power conversion and execution under test.

[0029] Battery pack 113 refers to the power battery assembly of new energy vehicles, which includes battery cells, battery management system (BMS), and thermal management components. In the testing system, as the energy receiving end and state feedback end of the charging process, its state of charge (SOC), temperature, voltage, and other parameters are key inputs for test scenario construction and process control.

[0030] The simulated load and power supply module 120 is used to provide a simulated power grid input to the AC charging system under test and to regulate the charging and discharging state of the battery pack.

[0031] Here, the simulated load and power supply module 120 can be a hardware combination consisting of a programmable power supply and a load device, used to provide controllable input stimulation to the test system and consume output energy to simulate the boundary conditions of the real world.

[0032] The central control and data processing module 130 is communicatively connected to the analog load and power supply module 120 and the integrated test bench 110. The central control and data processing module 130 includes: The scenario construction unit 131 is used to generate test scenario data containing dynamic charging parameters and power grid disturbance parameters based on historical user charging behavior data. The interactive simulation unit 132 is used to simulate the signal interaction between the vehicle control network and the vehicle controller and / or the on-board charging and power distribution unit during the test, so as to simulate the vehicle-level control logic and fault response. The test execution and monitoring unit 133 is used to control the simulated load and power supply module 120 and the integrated test bench 110 based on the test scenario data, automatically execute the integrated interactive test process, and collect electrical signal data and network communication data in real time during the test process. The result analysis unit 134 is used to analyze and process the collected electrical signal data and network communication data to generate test results.

[0033] Here, the central control and data processing module 130 can be composed of a host computer and corresponding software. It is responsible for the overall control of the test process, the processing and analysis of test data, and human-computer interaction. It connects to the hardware modules and test bench through communication networks, such as Controller Area Network (CAN) or Ethernet, to realize the scheduling, execution, and monitoring of automated tests.

[0034] The scenario construction unit 131 is a functional software unit within the central control and data processing module. Based on massive amounts of real historical user charging behavior data (such as charging start and end times, start and end SOC, geographical location, ambient temperature, and power of the charging equipment used), it performs data mining, statistical analysis, and pattern recognition (cluster analysis) to extract representative typical charging scenarios and edge conditions, and generates structured test scenario data, including dynamic charging parameters (such as SOC change curves and power demand curves) and grid disturbance parameters (such as harmonics and voltage sag sequences).

[0035] The interactive simulation unit 132 is a software unit within the central control and data processing module used to simulate the vehicle's communication environment. Its main function is to simulate the behavior of other vehicle controller nodes (such as the electronic gear shift system, keyless entry and start system, and body controller) besides the controller under test (VCU), and to interact with the VCU via signals from vehicle buses such as the Controller Area Network (CAN). This unit can send simulated sensor signals and other controller status information according to test case requirements. In particular, it can inject simulated fault frames or error signal values ​​to stimulate and verify the diagnostic logic, protection strategies, and interactive responses with other systems of the AC charging system under test under fault conditions, thereby achieving simulation of vehicle-level control logic and fault response.

[0036] The test execution and monitoring unit 133 compiles and generates specific, executable automated test cases based on the test scenario data output by the scenario construction unit. During the test, this unit automatically controls the output of the simulated load and power supply module, controls each component on the test bench to enter the test state, and synchronously collects electrical signal data (voltage, current, power, efficiency) from the power analyzer and network communication data (controller status, fault codes, interactive messages) from buses such as the CAN network in real time, realizing fully automated driving and full-state monitoring of the test process.

[0037] The result analysis unit 134 compares, calculates efficiency, and diagnoses anomalies in the electrical signal data and network communication data collected by the test execution and monitoring unit. Preferably, the result analysis unit 134 is also used to generate a test report containing the test results.

[0038] This application provides an interactive testing system for AC charging systems based on user big data, and its beneficial effects are mainly reflected in the following aspects: 1. High system-level failure reproducibility: Existing AC charging system testing is conducted on each component individually. Through the testing subsystem of this application, the testing coverage can be expanded, and the information interaction verification between various components can be increased. This application is closer to the actual vehicle use scenario of users, which can effectively improve the overall quality of the product and the user experience.

[0039] 2. Improve test safety: Extreme failure conditions at the design boundary are not only difficult to realize in real vehicles, but also usually pose a great threat to the personal safety of test personnel. This application can ensure the personal safety of test personnel while ensuring the completion of the test.

[0040] 3. Significantly reduce R&D and verification costs: Vehicle testing consumes more energy and costs more equipment than bench testing. Vehicle testing laboratories are expensive, and repairing faulty test parts is more difficult and costly. This application can carry out sufficient testing and verification at the bench level, which not only reduces vehicle resource costs, labor costs, and repair costs, but also significantly shortens the testing cycle.

[0041] 4. High ease of operation: The testing system of this application is easy for testers to operate, the test operation is simple and easy to understand, the fault injection test cases have a high reproducibility rate, which helps to discover and solve problems in the product development process, assists in the quality upgrade of vehicle models, and improves the reliability of the product life cycle.

[0042] Next, refer to Figure 2 This application describes another interactive testing system for AC charging systems based on user big data, provided in an embodiment of the present application.

[0043] Figure 2 A schematic diagram of another interactive testing system for an AC charging system based on user big data, provided as an embodiment of this application, is shown below. Figure 2 As shown, the testing system in this embodiment mainly consists of three subsystems: a hardware system, a test bench, and a host computer system. Each subsystem is connected internally and externally through specific electrical and communication lines to form an integrated automated testing platform that can simulate real vehicle use environments and user behaviors.

[0044] 1. Hardware System The hardware system is the physical foundation for providing the simulation environment and performing accurate measurements, and mainly includes: Power Grid Environment Simulator: Used to provide 220V AC power input to the test bench, and can simulate real power grid fluctuations by superimposing harmonic distortion, voltage glitches, phase abrupt changes or voltage amplitude jumps on the standard AC power according to test requirements.

[0045] Power analyzer and matching sampling device: including voltage measurement probe and current clamp, used for high-precision acquisition and analysis of key electrical parameters during the charging process, such as voltage, current, power, efficiency, etc.

[0046] High-voltage DC load: Connected to the battery pack (e.g., via a fast charging port) to rapidly discharge the battery pack and bring it to the specific initial state of charge (SOC) required for the test case.

[0047] Low-voltage DC loads and power supplies: Low-voltage DC loads are used to consume the low-voltage electricity output from the DC / DC converter in the charging and distribution system. The 12V low-voltage DC power supply is used to provide operating power to the controller (vehicle controller), battery pack, and charging and distribution system on the test bench, and to wake up the relevant controllers.

[0048] The hardware system is connected to the test bench via high-voltage wiring harnesses (for transmitting high-power electrical energy) and hard wires (for transmitting low-voltage power and some signals).

[0049] 2. Test bench The test bench is the core platform that supports the AC charging system under test and reconstructs its overall vehicle electrical connections. It integrates the following key components: The power battery assembly serves as the energy receiver during the charging process; The vehicle controller serves as the core of coordination and control for the entire charging process. The charging and distribution system, which includes the on-board charger and the DC / DC converter, is the core power component that performs AC-DC conversion. The charging socket and the charging gun together form a charging interface; A lead-acid battery simulates the low-voltage power supply of the vehicle and provides 12V power to the controller. Voltage sampling devices and current sampling devices are deployed on the input side (between the charging socket) and output side (between the power battery) of the charging and distribution system, respectively, to measure the real-time voltage and current values ​​during the charging process.

[0050] Connection system: The above components are connected according to the actual vehicle electrical topology through high-voltage wiring harness, low-voltage wiring harness (CAN line), hard wire and cooling pipes to form a fully functional subsystem.

[0051] The vehicle controller, as the core, receives information from the battery pack and charging and distribution system via the CAN network and issues control commands to control the voltage and current output by the charging and distribution system to meet the system's charging requirements.

[0052] The charging and power distribution system is responsible for recognizing the CC / CP connection confirmation signal from the charging gun, responding to the charging request from the vehicle controller, and converting AC power to DC power to charge the battery pack.

[0053] 3. Host computer system The host computer system is the command, control, and data processing center for testing, and typically consists of a computer and specialized software. For example... Figure 2 As shown, it connects to the controller network on the test bench via a CAN cable to achieve data interaction and control.

[0054] User Behavior Data Platform: Based on user charging big data, this platform analyzes and models historical user charging behavior by vehicle type (pure electric / hybrid), season, and geographical region to generate typical scenario tags and representative dynamic test scenario parameters, including but not limited to: starting and ending SOC, charging time period distribution, ambient temperature, battery coolant temperature, and charging power curves for different power levels. These parameters are the input sources driving automated testing.

[0055] CAN signal acquisition software: responsible for compiling test cases, controlling the test process, and communicating with the vehicle controller on the test bench via the CAN network to issue commands, monitor status, and inject faults.

[0056] During the testing process, the test parts are first placed on the test bench. The battery pack, charging and distribution system, charging socket, charging gun, lead-acid battery, and vehicle controller are fixed on the bench, and the pipelines and wiring are arranged. The parts are connected by cooling pipelines, low-voltage wiring harnesses and high-voltage wiring harnesses.

[0057] Then, the power grid environment simulator inputs high-voltage electricity to the subsystem test bench; a 12V low-voltage DC power supply is used to power the charging and distribution system, battery pack, and vehicle controller's KL15 and KL30; the power analyzer is connected to the voltage sampling device and current sampling device, and the measurement points are set between the charging and distribution system and the power battery, and between the charging and distribution system and the charging socket; the high-voltage DC load is connected to the fast charging port of the power battery assembly for rapid discharge of the power battery assembly; the low-voltage DC load is connected to the DC / DC output low-voltage electricity of the charging and distribution system.

[0058] Finally, the host computer system is used to build the complete vehicle model and configure the CAN bus model for transmission and reception, enabling communication and information transmission between various components and the host computer. It also automatically controls the hardware system and test bench to execute test procedures, recording test data throughout the process. Additionally, it collects big data on user charging behavior to update test cases.

[0059] This application proposes an integrated testing system for AC charging systems based on user behavior big data, aiming to address the problems existing in current testing technologies. The device integrates an adjustable AC power supply cabinet, low-voltage DC load, high-voltage DC load, power analyzer, charging and distribution system (on-board charger, DC / DC converter), charging socket, battery pack, lead-acid battery, and vehicle controller. It can efficiently, safely, and realistically simulate actual vehicle usage scenarios in a laboratory environment, enabling comprehensive verification and testing of the AC charging subsystem's functions.

[0060] The second aspect of this application provides an interactive testing method for an AC charging system based on user big data, which can be applied to the interactive testing system for an AC charging system based on user big data as described in any of the above embodiments. Figure 3 As shown, the method includes the following steps.

[0061] Step S100: Generate test scenario data containing dynamic charging parameters and grid disturbance parameters based on historical user charging behavior data.

[0062] Historical user charging behavior data refers to a collection of real charging process records collected and stored from a large number of new energy vehicles in actual use through on-board terminals or cloud platforms. This may include, but is not limited to: the start and end times of each charge, the battery state of charge at the start and end of charging, the real-time power curve during charging, the ambient temperature of the vehicle, the battery coolant temperature, the type and power level of the charging equipment used, and the vehicle model and geographical location. Dynamic charging parameters refer to a set of parameters used in test scenario data to describe the charging process and its changes over time or under conditions. These are not fixed values, but rather a sequence of variables or curves extracted from user behavior patterns, mainly including: the initial and target SOC of charging, the curve of charging power demand changing over time, and simulated curves of ambient temperature and coolant temperature changes. Grid disturbance parameters refer to abnormal electrical characteristic parameters set to simulate undesirable conditions of the real power grid. This is used to control the power grid environment simulator to superimpose specific interference waveforms on the standard AC power. These waveforms may include: the phase change angle and timing of the AC voltage, the amplitude, width and occurrence period of transient high voltage spikes superimposed on a specific phase of the sine wave, and the step jump value and timing of the AC voltage amplitude.

[0063] Step S200: Connect the AC charging system to be tested to the integrated test bench, and power and initialize the AC charging system to bring it into a testable state.

[0064] Here, power supply and initialization refers to providing the necessary operating power to the system under test on the integrated test bench and enabling its controller to enter normal operating mode from sleep state. Specifically, this includes: providing constant power to KL30 and wake-up signal to KL15 through a low-voltage DC source, simulating the vehicle ignition and power-on process, so that the vehicle controller, charging and power distribution system, etc., can complete self-test, establish communication network, and enter standby state.

[0065] Step S300: Based on the test scenario data, control the simulated load and power supply module to provide grid input to the AC charging system and adjust the battery pack status. At the same time, simulate the vehicle control network and the vehicle controller and / or the on-board charging and distribution unit to perform signal interaction in order to simulate the vehicle-level control logic and fault response.

[0066] Control logic and fault response simulation refers to the process in which, during testing, a simulated vehicle control network is used to actively send specific instructions or abnormal signals (such as simulated sensor failure, network communication error, battery overvoltage, etc.) to the controller under test, in order to stimulate and observe whether the preset software diagnostic strategies and safety protection mechanisms (such as power reduction charging, stopping charging, disconnecting high voltage relays, etc.) of the AC charging system under test are correctly executed.

[0067] Step S400: Real-time acquisition of electrical signal data and network communication data of the AC charging system during the test.

[0068] Electrical signal data refers to raw physical quantities directly measured from the input and output sides of the charging and distribution system by a power analyzer and its associated voltage and current sampling devices during the testing process. Specifically, this may include: AC input voltage / current, DC output voltage / current, real-time power, charging efficiency, and key temperature parameters.

[0069] Network communication data refers to all digital messages transmitted on the simulated vehicle control network captured by CAN bus monitoring equipment during testing. This mainly includes: status information (such as SOC, voltage, current, and temperature) periodically sent by various controllers (vehicle controller, charging and power distribution system, battery management system), control commands, and triggered fault diagnosis codes.

[0070] Step S500: Analyze and process the collected electrical signal data and network communication data to generate test results.

[0071] The testing method presented in this application generates dynamic test scenarios based on real user big data, and reproduces the vehicle charging environment and interaction logic with high fidelity on an integrated test bench, providing an effective system-level dynamic interaction verification testing method. By simulating complex power grid disturbances and input network faults, it can proactively discover and reproduce potential system-level failures, significantly improving test coverage and realism. The fully automated execution of the process avoids the high cost, long cycle, and safety risks of real vehicle testing, achieving cost reduction and efficiency improvement, and providing an efficient, safe, and intelligent advanced testing method for the research and verification of new energy vehicle charging systems.

[0072] Next, refer to Figure 4 This application describes another interactive testing method for an AC charging system based on user big data, provided in the embodiments of this application.

[0073] Figure 4 A schematic diagram illustrating the principle of another interactive testing method for an AC charging system based on user big data provided in this application embodiment, as shown below. Figure 4 As shown, the test method in this embodiment is executed according to the following process: S1. System setup and power-on.

[0074] Secure and connect the battery pack, charging and distribution system, charging socket, charging gun, lead-acid battery and vehicle controller on the test bench, and arrange the high and low voltage wiring harnesses and cooling pipes.

[0075] Turn on the main power supply of the test cabinet to power on the power analyzer, high / low voltage DC loads, DC power supply and AC power source.

[0076] Start the host computer software and CAN communication device, open the control interface, and establish a control and communication link.

[0077] Turn on the 12V DC power supply to provide KL30 and KL15 to the vehicle controller, battery pack, and charging and distribution system in the test bench, and wake up the controller.

[0078] Start the power grid environment simulator and provide AC input power to the system. At this time, the following power grid fluctuation use cases can be superimposed on the 220V AC power supply: a. Phase change: Under standard 220V AC operation, the AC source status is adjusted to control the AC phase change. The phase changes from 45°, 90°, and 135° to 360° in a cycle, and this cycle is repeated every 2 seconds for 2 hours.

[0079] b. Glitches: The input voltage is superimposed with a 250V glitch voltage for 1-3ms at each cycle characteristic (1 / 4, 1 / 2) of the rated value, and this cycle is repeated at 2s intervals for 2 hours.

[0080] c. Voltage transition: With the on-board charger (OBC) fully loaded, input 220V for 20s, then transition to 170-180V for 50ms at 0° and 90° of the phase in the next cycle, and repeat the test for 2 hours.

[0081] S2, Test Configuration and Execution.

[0082] Launch the host computer automated testing software, import the data collected from the user behavior data platform into the software, and edit the test case program. The automated test case program includes functions such as simulating the discharge of the power battery to a specified SOC, simulating users charging at different power levels (1.6kW vehicle-mounted charging gun, 3.5kW charging pile, 7kW charging pile), charging to the specified SOC, AC input superimposed with grid fluctuation testing, and charging abnormal interruption fault testing. User big data behavior data is referenced below: a. Pure Electric Vehicle (EV) Models: Use a high-voltage DC electronic load to discharge the battery pack's SOC to 20%, 30%, 40%, and 50% respectively. Turn on the power grid environment simulator and input 220V AC power to charge to SOC 70%, 80%, 90%, and 100% (after reaching the specified SOC, it needs to be discharged again to the starting SOC of the next stage). At this time, the coolant and ambient temperature should be adjusted to 50-60℃. The charging power involves a 1.6kW (25%) on-board charging gun, a 3.5kW (43%) charging station, and a 7kW (32%) charging station. After full charging, it needs to be left to stand for 1 hour.

[0083] b. Plug-in Hybrid Electric Vehicle (PHEV) models: Use a high-voltage DC electronic load to discharge the battery pack's SOC to 15%, 20%, 25%, and 30% respectively. Turn on the grid environment simulator and input 220V AC power to charge to SOC 90%, 95%, and 100% (after reaching the specified SOC, it needs to be discharged again to the starting SOC of the next stage). At this time, the coolant and ambient temperature should be adjusted to 40-50℃. The charging power involves a 1.6kW (60%) on-board charging gun, a 3.5kW (31%) charging station, and a 7kW (9%) charging station. After full charging, it needs to be left to stand for 2 hours.

[0084] It should be noted that the above data varies depending on the battery pack energy capacity and the power of the charging and power distribution system of different vehicle models.

[0085] When the automated test case program is executed, each controller on the test bench will receive control commands and execute the program sequentially according to the pre-set test cases.

[0086] S3. Data Acquisition and Monitoring.

[0087] During the test, the power analyzer collects the input and output current and voltage data of the charging and distribution system to analyze the efficiency of the charging and distribution system under different power and SOC scenarios, and to confirm whether there are any abnormal points in the input and output data, and whether the error between the voltage and current collected inside the charging and distribution system is within the calibration tolerance range.

[0088] During the test, the detection circuit of the charging and distribution system recognizes the connection confirmation signal (CC) and control pilot signal (CP) input from the sensor, and interacts with the vehicle controller and battery pack through the CAN network. Based on the current SOC, temperature, maximum input current and other strategies, it outputs current and voltage to perform charging behavior.

[0089] By exchanging CAN signals, the system collects CAN message information exchanged between controllers, providing data for the host computer testing software.

[0090] S4. Results Analysis and Report Generation.

[0091] After the test is completed, the automated test platform integrates the electrical performance data from the power analyzer and the interaction and status data from the CAN network.

[0092] The platform automatically analyzes the execution results of all test cases to determine whether each function and performance indicator meets the standards, and records the analysis results and raw data into the test report.

[0093] Ultimately, a complete test report can be generated, including a test overview, execution details, data charts, pass / fail conclusions, etc., for developers to analyze.

[0094] The testing method in this embodiment can not only simulate users charging their vehicles using an AC charging system, but also adjust the automatic testing program based on big data of user AC charging behavior. The constructed testing interface can intuitively display the current operating status of the AC charging system and parameters such as the operating current, operating voltage, power, internal temperature, and pipeline pressure of the charging socket, charging distribution system, and battery pack. It can also simulate grid harmonic distortion and faults in system components and modules via a host computer. By sending a fault value in a CAN signal frame, the fault is transmitted and interacted with via the CAN bus. After receiving the fault command, the vehicle controller handles the fault according to the logic of its internal software and issues post-fault execution instructions, such as protective measures like disconnecting the power battery output. Therefore, it achieves efficient, safe, and highly reproducible integrated interactive testing of new energy vehicle AC charging systems in a laboratory bench environment, closely resembling real-world user scenarios, which helps improve product quality and user experience.

[0095] Finally, it should be noted that the above technical solution is only one implementation method of this application. For those skilled in the art, based on the application methods and principles disclosed in this application, it is easy to make various types of improvements or modifications, and not limited to the methods described in the specific implementation methods above. Therefore, the methods described above are only preferred and have no limiting significance.

Claims

1. An interactive testing system for AC charging systems based on user big data, characterized in that, include: An integrated test bench is used to support and connect an AC charging system to be tested, the AC charging system including at least a vehicle controller, an on-board charging and distribution unit, and a battery pack; The simulated load and power supply module is used to provide a simulated power grid input to the AC charging system under test and to regulate the charging and discharging state of the battery pack. A central control and data processing module is communicatively connected to the simulated load and power supply module and the integrated test bench. The central control and data processing module includes: The scenario building unit is used to generate test scenario data containing dynamic charging parameters and power grid disturbance parameters based on historical user charging behavior data. The interactive simulation unit is used to simulate the signal interaction between the vehicle control network and the vehicle controller and / or the on-board charging and power distribution unit during the test, so as to simulate the vehicle-level control logic and fault response. The test execution and monitoring unit is used to control the simulated load and power supply module and the integrated test bench based on the test scenario data, automatically execute the integrated interactive test process, and collect electrical signal data and network communication data in real time during the test process; The result analysis unit is used to analyze and process the collected electrical signal data and network communication data to generate test results.

2. The AC charging system interactive testing system based on user big data according to claim 1, characterized in that, The simulated load and power supply module includes: A power grid simulator is used to output a programmable AC power supply and to superimpose a preset power grid disturbance waveform onto the AC power supply. A programmable DC load is connected to the battery pack to discharge the battery pack to the initial state of charge corresponding to the test scenario data.

3. The AC charging system interactive testing system based on user big data according to claim 2, characterized in that, The power grid disturbance waveform superimposed on the power grid simulator includes at least one of the following: a sudden phase change of AC voltage, a transient high-voltage spike superimposed on the phase of a preset period, and a step change in the amplitude of AC voltage.

4. The AC charging system interactive testing system based on user big data according to claim 1, characterized in that, The integrated test bench also includes a charging interface simulation device; The charging interface simulation device is used to provide a charging connection signal; The on-board charging and distribution unit, the battery pack, and the vehicle controller are connected via vehicle bus and hardwire to reproduce the vehicle electrical topology.

5. The AC charging system interactive testing system based on user big data according to claim 1, characterized in that, The interactive simulation unit in the central control and data processing module communicates with the vehicle controller and / or the on-board charging and power distribution unit through the controller local area network bus, and is used to input simulated fault frames or modify signal values ​​to the controller local area network bus to trigger the fault diagnosis and protection mechanism of the AC charging system.

6. The AC charging system interactive testing system based on user big data according to claim 1, characterized in that, The scenario construction unit generates the dynamic charging parameters by performing data mining on historical user charging behavior data. The dynamic charging parameters include one or more of the following: charging start and end state of charge, charging power curve, charging time period distribution, ambient temperature, and battery coolant temperature.

7. The AC charging system interactive testing system based on user big data according to claim 6, characterized in that, The scenario construction unit classifies historical user charging behavior data according to vehicle power type, and generates test scenario data with different parameter feature distributions for pure electric vehicles and plug-in hybrid vehicles respectively.

8. A method for interactive testing of an AC charging system based on user big data, characterized in that, The method, applied to the AC charging system interactive testing system based on user big data as described in any one of claims 1-7, comprises: Based on historical user charging behavior data, test scenario data including dynamic charging parameters and power grid disturbance parameters is generated; Connect the AC charging system to be tested to the integrated test bench, and power and initialize the AC charging system to bring it into a testable state. Based on the test scenario data, the simulated load and power supply module are controlled to provide grid input to the AC charging system and adjust the battery pack status. At the same time, the vehicle control network is simulated to interact with the vehicle controller and / or the on-board charging and distribution unit to simulate the vehicle-level control logic and fault response. Real-time acquisition of electrical signal data and network communication data of the AC charging system during the test; The collected electrical signal data and network communication data are analyzed and processed to generate test results.

9. The interactive testing method for an AC charging system based on user big data according to claim 8, characterized in that, The simulated vehicle control network interacts with the vehicle controller and / or on-board charging and power distribution unit, including: The system sends communication messages containing simulated fault information to the vehicle controller and / or the on-board charging and power distribution unit via the controller area network bus to trigger and verify the fault diagnosis and protection mechanism of the AC charging system.

10. The interactive testing method for an AC charging system based on user big data according to claim 8, characterized in that, Controlling the analog load and power supply module to provide grid input to the AC charging system includes: The analog load is controlled to output AC power with a preset grid disturbance waveform superimposed on the power supply module; wherein the grid disturbance waveform includes at least one of the following: a phase change of AC voltage, a transient high voltage spike superimposed on the phase of a preset period, and a step change in AC voltage amplitude.

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