A method and device for automatically testing a light storage DCDC converter

Abstract

This application belongs to the field of new energy power electronics testing technology, specifically relating to an automated testing method and device for photovoltaic-storage DC-DC converters. The method involves a host computer control system executing preset test tasks, generating coordinated control commands to drive the first and second energy storage converters, which are powered by electrical isolation circuits, respectively. This dynamically synthesizes realistic operating conditions at the photovoltaic and battery ends of the converters, while simultaneously acquiring data and dynamically adjusting liquid cooling. The corresponding device includes a dual-split isolation transformer, dual energy storage converters, a liquid cooling system, and a control system. This application achieves high-precision, high-fidelity, high-stability, and high-efficiency automated testing by integrating isolated power supply, dual-source coordinated simulation, liquid cooling temperature control, and full-process automatic control.

Description

Technical Field

[0001] This application belongs to the field of new energy power electronics testing technology, specifically relating to an automated testing method and device for photovoltaic-storage DC-DC converters. Background Technology

[0002] In photovoltaic energy storage systems, the photovoltaic-storage DC-DC converter is the core power component for achieving maximum power point tracking (MPPT, an optimization technology that ensures the photovoltaic panel always outputs maximum power), bidirectional charging and discharging of the battery, and voltage conversion. Its performance directly determines the efficiency, safety, and reliability of the entire system. Therefore, its electrical performance, dynamic response, and protection functions must be accurately and comprehensively tested during research and development, manufacturing, and type testing.

[0003] Currently, mainstream testing solutions typically employ a single programmable DC power supply or energy storage converter (PCS) powered by the grid via a standard isolation transformer, providing a single DC input to the converter under test. The testing process relies on manual wiring, parameter configuration, operating condition switching, and data recording. While common, this approach suffers from several inherent drawbacks affecting test quality and efficiency: First, its simple AC-side isolation measures fail to completely suppress grid harmonics and common-mode interference, and electrical crosstalk exists between the two power loops within the test system, leading to low test accuracy and data distortion. Second, the single DC source architecture cannot simultaneously and independently simulate the dynamic interaction between the photovoltaic and battery-side ports in a real system, resulting in insufficient test coverage and realism. Third, its heat dissipation relies heavily on air cooling, which is insufficient for the heat dissipation requirements of high-power, long-term testing. Power devices are prone to overheating and test interruption, preventing full-load aging and stability verification. Finally, the entire process is highly dependent on manual operation, with cumbersome steps, poor consistency, and low efficiency, making automated batch testing impossible.

[0004] Therefore, existing testing technologies for photovoltaic-storage DC-DC converters have long faced multiple challenges, including poor anti-interference capabilities, difficulty in simulating real-world dual-port operating conditions, insufficient stability in high-power testing, and low levels of automation. Summary of the Invention

[0005] This application proposes an automated testing scheme for photovoltaic-storage DC-DC converters, aiming to solve the problems existing in the current testing technology: poor anti-interference capability due to insufficient AC side isolation, difficulty in simulating dual-port real operating conditions due to single DC source architecture, insufficient stability of high-power long-term testing due to heat dissipation design limitations, and low degree of automation due to the reliance on manual operation in the testing process.

[0006] The first aspect of this application provides an automated testing method for an optical-storage DC-DC converter, including: Obtain a preset test task, the test task definition of which includes the overall operating conditions of the converter under test; Based on the test task, a collaborative control command is generated to control the first energy storage converter to simulate the photovoltaic side characteristics at the photovoltaic input terminal of the converter under test, and to control the second energy storage converter to simulate the battery side characteristics at the battery terminal of the converter under test. The DC outputs of the two energy storage converters are combined to form the test electrical conditions corresponding to the overall operating condition. The first energy storage converter and the second energy storage converter are powered by an electrically isolated AC power supply circuit. While synthesizing the test electrical conditions, the performance data of the converter under test is automatically collected; Monitor the heating status of the first energy storage converter and / or the second energy storage converter, and dynamically adjust the operating parameters of the liquid cooling system based on the heating status.

[0007] In some embodiments of this application, obtaining the preset test task includes: The test task is defined by at least one of the following overall operating conditions: photovoltaic fluctuation, battery charge and discharge, and high and low voltage ride-through.

[0008] In some embodiments of this application, before controlling the first energy storage converter to simulate photovoltaic-side characteristics at the photovoltaic input terminal of the converter under test, and controlling the second energy storage converter to simulate battery-side characteristics at the battery terminal of the converter under test, the method further includes: Soft start is performed on the first energy storage converter and the second energy storage converter respectively.

[0009] In some embodiments of this application, monitoring the thermal state of the first energy storage converter and / or the second energy storage converter includes: Monitor the temperature of the power modules within the first energy storage converter and / or the second energy storage converter.

[0010] In some embodiments of this application, the dynamic adjustment of the liquid cooling system operating parameters based on the heating state includes: The heating state is compared with a preset temperature threshold, and the operating parameters of the liquid cooling system are adjusted based on the comparison result to control the temperature of the power module within a safe range.

[0011] A second aspect of this application provides an automated testing apparatus for an optical-storage DC-DC converter, comprising: A double-split isolation transformer, in which the primary side is used to connect to an AC power source, and the first secondary winding and the second secondary winding are electrically isolated from each other; The first energy storage converter has its AC side connected to the first secondary winding of the double-split isolation transformer, and its DC side is used to connect to the photovoltaic input terminal of the photovoltaic-storage DC-DC converter under test. The second energy storage converter has its AC side connected to the second secondary winding of the double-split isolation transformer, and its DC side is used to connect to the battery terminal of the photovoltaic-storage DC-DC converter under test. The liquid cooling system has its cooling circuit thermally coupled to the power modules in the first energy storage converter and the second energy storage converter. The control system is communicatively connected to the first energy storage converter, the second energy storage converter, and the liquid cooling system. The control system is configured to perform an automated testing method for a photoelectric storage DC-DC converter according to the first aspect of the embodiments of this application.

[0012] In some embodiments of this application, the AC power source is the power grid.

[0013] In some embodiments of this application, the cooling pipes of the liquid cooling system are respectively connected to the coolant inlet and outlet of the first energy storage converter and the second energy storage converter to form a closed-loop heat dissipation circuit.

[0014] In some embodiments of this application, the control system is configured to acquire electrical data at a sampling rate not lower than a preset accuracy and to perform closed-loop control at a control cycle not higher than a preset period. The closed-loop control includes feedback adjustment of the operating parameters of the liquid cooling system and / or the output parameters of the energy storage converter.

[0015] In some embodiments of this application, the control system is further configured to execute fault interlock protection logic, the fault interlock protection logic including: In response to the detection of at least one of overvoltage, overcurrent, device overtemperature, or insulation fault, a graded shutdown operation is performed in the following order: First, trigger an alarm signal; Subsequently, the tested optical storage DC-DC converter is controlled to perform power lockout; Next, the first energy storage converter and the second energy storage converter are shut down. Finally, the dual-split isolation transformer is disconnected from the AC power supply.

[0016] In summary, the automated testing method and apparatus for photovoltaic-storage DC-DC converters provided in the embodiments of this application achieve complete electrical isolation between the two power circuits by using a double-split isolation transformer to power the two energy storage converters. This fundamentally cuts off the transmission path of grid interference and the crosstalk channel between circuits, thus solving the defect of test accuracy being affected by interference. By executing preset test tasks that define the overall operating conditions to coordinately control the two energy storage converters, the two power outputs on the simulated photovoltaic side and battery side can dynamically cooperate to reproduce the real scenario of dual-port interaction, thus solving the defect that a single DC source cannot simulate complex operating conditions. By integrating a liquid cooling system and dynamically adjusting its operation based on temperature monitoring, the power module is provided with heat dissipation capabilities that can be optimized in real time according to the load, ensuring the thermal stability of core components during long-term high-power testing, thus solving the defect of test interruption caused by insufficient heat dissipation. By having the control system automatically execute the entire process from task analysis, operating condition synthesis, data acquisition to thermal management, it replaces all manual operation, eliminating human error and efficiency bottlenecks, thus solving the defects of low test efficiency and poor consistency. This application establishes a high-precision, high-stability automated testing system for photovoltaic-storage DC-DC converters through the systematic integration of dual-isolation power supply, collaborative simulation, liquid-cooled temperature control, and automatic control. Attached Figure Description

[0017] The features and advantages of this application will become clearer with reference to the accompanying drawings, which are illustrative and should not be construed as limiting the application in any way. In the drawings: Figure 1 This is a schematic diagram of the main hardware structure connection of an automated testing device for optical storage DC-DC converters according to some embodiments of this application; Figure 2 This is a general flowchart of an automated testing method for a photoelectric storage DC-DC converter according to some embodiments of this application; Figure 3 This is a step-by-step flowchart of an automated testing method for an optical storage DC-DC converter according to some embodiments of this application. Detailed Implementation

[0018] In the following detailed description, numerous specific details of this application are illustrated by example to provide a thorough understanding of the relevant disclosure. However, it will be apparent to those skilled in the art that this application can be practiced without these details. It should be understood that the terms “system,” “apparatus,” “unit,” and / or “module” used in this application are one way of distinguishing different parts, elements, sections, or components at different levels in a sequential arrangement. However, these terms may be replaced with other expressions if other expressions can achieve the same purpose.

[0019] It should be understood that when a device, unit, or module is referred to as being "on," "connected to," or "coupled to" another device, unit, or module, it may be directly connected to or coupled to, or communicate with, other devices, units, or modules, or there may be intermediate devices, units, or modules present, unless the context explicitly indicates otherwise. For example, the term "and / or" as used herein includes any one and all combinations of one or more of the relevant listed items.

[0020] The terminology used in this application is for the purpose of describing specific embodiments only and is not intended to limit the scope of this application. As shown in the specification and claims of this application, unless the context clearly indicates otherwise, words such as "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural. Generally speaking, the terms "comprising" and "including" only indicate that explicitly identified features, integrals, steps, operations, elements, and / or components are included, and such expressions do not constitute an exclusive list, and other features, integrals, steps, operations, elements, and / or components may also be included.

[0021] Referring to the following description and accompanying drawings, these and other features and characteristics, operating methods, functions of related structural elements, combinations of parts, and economics of manufacture of this application can be better understood, wherein the description and drawings form part of the specification. However, it is clearly understood that the drawings are for illustrative and descriptive purposes only and are not intended to limit the scope of protection of this application. It is understood that the drawings are not drawn to scale.

[0022] Various structural diagrams are used in this application to illustrate various variations of the embodiments according to this application. It should be understood that the preceding or following structures are not intended to limit this application. The scope of protection of this application is determined by the claims.

[0023] In photovoltaic energy storage systems, achieving high-precision and high-efficiency performance testing of photovoltaic-energy storage DC-DC converters is crucial to ensuring their reliable operation as core power components. Currently, typical photovoltaic-energy storage DC-DC converter testing platforms employ a scheme where the grid is supplied via a single ordinary isolation transformer, and a single programmable DC power supply or energy storage converter (PCS) is configured. This scheme can only provide a single DC input to the converter under test and cannot simultaneously and independently simulate dual-port operating conditions on both the photovoltaic and battery sides. The entire testing process relies on manual completion of wiring, parameter configuration, operating condition switching, and data recording. As described in the background section, this scheme suffers from the following drawbacks: poor anti-interference capability due to insufficient AC-side isolation; difficulty in simulating realistic dual-port operating conditions due to the single DC source architecture; insufficient stability during high-power, long-term testing due to thermal design limitations; and low automation due to the reliance on manual operation in the testing process.

[0024] To systematically address the aforementioned deficiencies, this application proposes an automated testing scheme for photovoltaic-storage DC-DC converters. The scheme aims to achieve high-precision, high-fidelity, high-stability, and high-efficiency testing through a testing system that integrates high-isolation power supply, dual-source collaborative simulation, enhanced heat dissipation, and full-process automatic control.

[0025] like Figure 1 (The schematic diagram of the main hardware structure connection of the automated testing device for the photovoltaic-storage DC-DC converter in this application) shows that this application constructs a complete integrated testing hardware platform. Its core lies in the use of a double-split isolation transformer to provide electrically isolated power supply for the dual energy storage converters (PCS1 and PCS2), and the integration of a liquid cooling system for heat dissipation, thus forming the physical basis for realizing the method of this scheme.

[0026] based on Figure 1 The hardware platform shown in this application implements the following: Figure 2 The flowchart of the automated testing method for photovoltaic-storage DC-DC converters shows a fully automated testing process. This method is automatically executed by the control system, and its core lies in: according to the preset test tasks, coordinating the output of the dual energy storage converters to dynamically synthesize the required test conditions at the dual ports of the converters, and simultaneously completing data acquisition and thermal status management during this process.

[0027] In conclusion, this application is approved. Figure 1 The hardware architecture shown is "isolated power supply, dual-source simulation, liquid cooling heat dissipation". Figure 2 The "full-process automatic control" logic shown integrates power supply, excitation, heat dissipation and management, and systematically solves the above-mentioned defects of existing technologies.

[0028] The specific embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0029] Figure 1 This is a schematic diagram of the main hardware structure of an automated testing device for a photoelectric storage DC-DC converter, as shown in some embodiments of this application. Figure 1 As shown, the hardware structure of the testing device mainly includes three functional modules: the main electrical circuit, the DC side circuit, and the cooling circuit. The control system acts as a logic scheduling module for overall coordinated management. This control system is not... Figure 1 The main hardware structure diagram is shown.

[0030] Electrical main circuit The main electrical circuit provides power to the entire test system and provides electrical isolation to the power supply circuit, ensuring high interference immunity. For example... Figure 1As shown, the main electrical circuit consists of the power grid, a double-split isolation transformer, the AC side of the first energy storage converter (PCS1), and the second energy storage converter (PCS2). Specifically, the power grid is connected to the primary winding of the double-split isolation transformer. The double-split isolation transformer has a secondary winding and a secondary winding that are electrically isolated from each other. The secondary winding is connected to the AC terminal of PCS1, and the secondary winding is connected to the AC terminal of PCS2. Through this double-split structure, complete electrical isolation is achieved for the two AC power supplies to PCS1 and PCS2. This design cuts off the conduction path of power grid harmonics and common-mode interference from the power supply head and eliminates electrical crosstalk between the two subsequent power circuits, thereby directly solving the defect of "poor anti-interference capability" in the prior art.

[0031] DC side circuit The DC-side loop is used to provide the device under test with independently programmable and collaboratively controllable dual-channel DC test excitation to simulate the dual-port interactive operating conditions of a real photovoltaic-storage system. For example... Figure 1 As shown, the DC-side circuit consists of the DC sides of PCS1 and PCS2 connected to the device under test. Specifically, the DC side of the first energy storage converter (PCS1) is connected to the photovoltaic input terminal (PV terminal) of the photovoltaic-energy storage DC-DC converter under test. The DC side of the second energy storage converter (PCS2) is connected to the battery terminal (BAT terminal) of the photovoltaic-energy storage DC-DC converter under test. This connection structure allows PCS1 and PCS2 to be configured to simulate the output characteristics of the photovoltaic side and the battery side, respectively. The two DC outputs are independently adjustable, thereby realistically reproducing various complex operating conditions of dynamic coupling and mutual influence between the photovoltaic side and the battery side in a real system, fundamentally solving the defect of "difficulty in simulating dual-port real operating conditions" in the prior art. Cooling circuit The cooling circuit provides active heat dissipation for the power modules within the first and second energy storage converters to ensure the thermal stability of the device under long-term, high-power testing. For example... Figure 1 As shown, this embodiment integrates a liquid cooling system, forming an independent closed-loop cooling circuit. Specifically, the cooling pipes of the liquid cooling system are connected to the coolant inlet and outlet of PCS1 and PCS2 respectively, forming a closed-loop heat dissipation circuit. This cooling circuit is thermally coupled to the power modules (such as IGBT modules) within the first and second energy storage converters, directly dissipating heat from them. This liquid cooling system can provide heat dissipation capabilities far exceeding those of traditional air cooling, ensuring that the junction temperature of the power modules remains within a safe range, thereby solving the defect of "insufficient stability during long-term high-power testing" caused by insufficient heat dissipation in the prior art.

[0032] control system The device also includes a host computer control system (as a logical function module, the control system is not included in...). Figure 1(The main hardware structure diagram is shown in the figure). The control system is connected to the first energy storage converter (PCS1), the second energy storage converter (PCS2) and the liquid cooling system through communication interfaces.

[0033] The control system is configured to acquire voltage and current data in the loop with high sampling accuracy and execute closed-loop control with high control frequency to meet the real-time and accuracy requirements of automated testing.

[0034] In addition, the control system is also configured with a fault interlock protection program, which is used to sequentially execute equipment interlock shutdown according to preset hierarchical logic when overvoltage, overcurrent, overtemperature or insulation abnormality faults are detected, so as to ensure system safety.

[0035] In some embodiments of this application, the tiered shutdown operation includes: First, trigger an alarm signal; Subsequently, the tested optical storage DC-DC converter is controlled to perform power lockout; Next, the first energy storage converter and the second energy storage converter are shut down. Finally, the dual-split isolation transformer is disconnected from the AC power supply.

[0036] This communication and control architecture provides the hardware and logic foundation for executing fully automated testing, enabling the automatic and secure scheduling of the entire process from device power-on, parameter configuration, test execution to data acquisition, thereby solving the problem of "low degree of automation" in existing technologies.

[0037] Therefore, this embodiment has fully constructed a fully automated testing hardware platform for optical-storage DC-DC converters with high isolation, high simulation, high heat dissipation, and high security.

[0038] Figure 3 This is a step-by-step flowchart of an automated testing method for an optical-storage DC-DC converter according to some embodiments of this application. In this embodiment, the method is executed by a host computer control system. Figure 3 As shown, the method includes: S310, Obtain a preset test task, the test task definition includes the overall operating conditions of the converter under test.

[0039] This step marks the beginning of the automated testing process. The method acquires preset test tasks through a host computer control system. The test tasks define the overall operating conditions that the converter under test needs to simulate. These overall operating conditions include, but are not limited to, complex conditions involving dynamic coupling and mutual influence between the photovoltaic and battery sides, such as photovoltaic fluctuations, battery charging and discharging, and high / low voltage ride-through.

[0040] This step establishes the ultimate goal for all subsequent control actions, achieves standardization and programmability of the testing process, and is the primary step in solving the defect of "low degree of automation".

[0041] S320, based on the test task, generate a collaborative control command to control the first energy storage converter to simulate the photovoltaic side characteristics at the photovoltaic input terminal of the converter under test, and control the second energy storage converter to simulate the battery side characteristics at the battery terminal of the converter under test, and make the DC outputs of the two energy storage converters jointly synthesize the test electrical conditions corresponding to the overall operating condition, wherein the first energy storage converter and the second energy storage converter are powered by an electrically isolated AC power supply circuit.

[0042] This step is the core of the method, aiming to drive the hardware platform to reproduce the preset overall operating conditions. Based on the test task, the control system generates coordinated control commands for controlling the first energy storage converter (PCS1) and the second energy storage converter (PCS2). These coordinated control commands are configured to: control PCS1 to simulate the photovoltaic-side output characteristics at the photovoltaic input terminal of the converter under test, and control PCS2 to simulate the battery-side output characteristics at the battery terminal. To ensure precise execution of this control, PCS1 and PCS2 are connected by an electrically isolated AC power supply circuit (e.g., via...). Figure 1 The power supply is achieved by the double-split isolation transformer shown, to ensure that the two control circuits do not interfere with each other.

[0043] Before executing control, as a preferred safeguard, soft-start can be performed on PCS1 and PCS2 respectively to ensure smooth system power-on. Subsequently, the control system dynamically and collaboratively adjusts the output parameters of PCS1 and PCS2 by executing the aforementioned coordination instructions, so that the DC outputs of the two are precisely matched in timing and amplitude. Finally, the test electrical conditions corresponding to the overall operating conditions are synthesized at the photovoltaic input terminal and the battery terminal of the converter under test. For example, to simulate the "photovoltaic fluctuation" condition, the output voltage of PCS1 will change dynamically, and the output of PCS2 will be adjusted accordingly to simulate the battery response. This step, through the technical means of "task-driven, dual-source coordination, and dynamic synthesis," fundamentally solves the defect of "difficulty in simulating real-world dual-port operating conditions" and fully supports the core features of claim 1.

[0044] S330 automatically collects the performance data of the converter under test while synthesizing the electrical conditions for testing.

[0045] While synthesizing the test electrical conditions, the method automatically performs data acquisition. The host computer control system synchronously acquires the performance data of the converter under test. The acquisition is automated and strictly synchronized with the synthesis of the test conditions, ensuring that the acquired data accurately reflects the true response of the device under test under specific excitations.

[0046] This step seamlessly integrates test execution with result recording, forming a closed loop for automated testing and further solving the problems of inefficiency and poor consistency caused by existing technologies relying on manual recording.

[0047] S340, monitor the heating status of the first energy storage converter and / or the second energy storage converter, and dynamically adjust the operating parameters of the liquid cooling system based on the heating status.

[0048] This step is crucial and runs in parallel with the core testing process, ensuring test stability. Throughout the testing process, especially during high-power output, the method continuously monitors the thermal state of the first and / or second energy storage converters. Specifically, the monitored object is the temperature of the power modules (such as IGBTs) within the energy storage converters. The control system dynamically adjusts the operating parameters of the liquid cooling system based on the monitored thermal state (temperature). The specific adjustment logic includes comparing the monitored temperature with a preset temperature threshold and adjusting the operating parameters of the liquid cooling system based on the comparison result to control the temperature of the power modules within a safe range.

[0049] This closed-loop thermal management mechanism works in conjunction with the liquid cooling circuit in the aforementioned hardware embodiment to ensure the thermal stability of the test device under long-term, high-power output, thereby solving the defect of "insufficient stability of high-power long-term testing" caused by insufficient heat dissipation in the prior art.

[0050] The automated testing solution of this application will be further described in detail below with a specific application scenario. This embodiment takes a photovoltaic-storage integrated converter testing system with a rated power of 150kW as an example to demonstrate the specific implementation and excellent effect of the aforementioned system architecture and method.

[0051] 1. Specific implementation of the hardware platform The testing device constructed in this application embodiment is Figure 1 The system architecture shown is a specific example, and its core equipment selection and parameters are as follows: Device under test: A photovoltaic-side unidirectional DC-DC converter with a rated power of 150kW is adopted, with a photovoltaic input voltage range of 500-1000Vdc and a DC bus output voltage stability range of 700-1200Vdc.

[0052] Dual energy storage converter (PCS): It is equipped with two energy storage converters (PCS1 and PCS2) with a rated power of 150kW. The AC side grid connection voltage is 400V three-phase, and the DC side bus is adapted to 450-1000Vdc, with four-quadrant grid connection control function.

[0053] Power supply and isolation unit: A dry-type isolation transformer of model SGG with a rated capacity of 350kVA is used. Its primary side is connected to a 400V / 800V three-phase AC power grid, and the secondary side provides two fully electrically isolated 690V / 800V AC outputs, dedicated to PCS1 and PCS2 respectively, realizing complete electrical isolation, harmonic suppression and surge protection on the power grid side.

[0054] Thermal protection unit: An integrated energy storage liquid-cooled thermal management unit, model BTMS-80-ES, with a rated cooling capacity of 80kW, is used. Its cooling pipes are connected to the power modules of PCS1 and PCS2 respectively, forming a closed-loop liquid-cooled heat dissipation circuit.

[0055] Measurement and control unit: It is equipped with a high-precision measurement and control acquisition system with a voltage sampling accuracy of 0.01%FS, a current sampling accuracy of 0.02%FS, and a closed-loop control cycle of ≤1ms, providing a performance foundation for high-precision automated testing.

[0056] 2. Full-process automated test execution Based on the aforementioned hardware platform, the host computer control system automatically executes... Figure 2 The test procedure shown below has the following specific steps: System safety self-test and power-on: After the system is closed, the SGG-350kVA isolation transformer is energized under no-load to complete insulation testing and self-testing. Subsequently, the power circuits of PCS1, PCS2, and the tested DC-DC converter are unlocked sequentially, and the BTMS-80-ES liquid-cooled unit is started. Once all modules report no faults, the system enters standby mode.

[0057] Grid energy isolation access and platform readiness: The grid power, after being isolated and transformed by the isolation transformer, provides clean power to PCS1 and PCS2. The control system configures PCS1 to operate as a DC voltage source simulating photovoltaic side characteristics and PCS2 to operate as a DC voltage source simulating battery side characteristics, and performs soft start on both to bring the test platform to a stable output state. Subsequently, the 150kW DC-DC converter under test is powered on.

[0058] Automated test task execution: The control system acquires a preset test task (such as "photovoltaic fluctuation test"). Based on the task, it generates coordinated control commands to dynamically and collaboratively adjust the output of PCS1 to simulate photovoltaic fluctuations, while simultaneously adjusting the output of PCS2 to simulate the corresponding behavior at the battery end, thereby synthesizing a realistic dynamic test condition at the PV end and BAT end of the DC-DC converter.

[0059] Synchronous data acquisition and thermal management: While conducting the synthetic test, the measurement and control system simultaneously acquires the input and output voltage and current, conversion efficiency, and device temperature rise of the DC-DC converter with high sampling accuracy. Throughout the test, the system monitors the temperature of the PCS1 and PCS2 power modules in real time and dynamically adjusts the operating parameters of the liquid cooling system according to preset thresholds to ensure that the IGBT junction temperature is controlled within a safe range, guaranteeing stable operation during long-term full-load testing.

[0060] Tiered fault protection and automatic archiving: If the system detects overvoltage, overcurrent, overtemperature, or insulation faults, it will immediately trigger the graded interlocking protection logic, which will execute the following sequentially within <2ms: liquid cooling system alarm, DC-DC converter power lockout, PCS1 and PCS2 shutdown, and isolation transformer no-load disconnection.

[0061] After the test, the host computer automatically analyzes the collected data and generates efficiency reports, loss analysis reports and fault tracing records, completing the entire closed loop process.

[0062] 3. Quantitative Explanation of Application Effects Through the specific implementation of this application embodiment, quantifiable results have been achieved: Testing efficiency has been greatly improved: Compared to the traditional manual testing method that requires 24 hours for full-condition verification of a single set of equipment, this automated testing platform reduces the testing time to 9.5 hours, improving testing efficiency by 60.4%. It also supports unattended operation and multi-batch rotation testing, greatly reducing the R&D and factory inspection cycle.

[0063] Testing costs have been significantly reduced: Automated operation reduced testing manpower by 82%; tiered interlocking and soft start / stop protection reduced equipment damage risk by 78%. Overall, the total testing cost per set of equipment was reduced by 71%.

[0064] Enhanced reliability: The dedicated isolated power supply and liquid cooling design ensure high accuracy of test data and high stability of the testing process, improving the versatility and engineering safety of the test platform.

[0065] In summary, the automated testing method and apparatus for photovoltaic-storage DC-DC converters provided in the embodiments of this application achieve complete electrical isolation between the two power circuits by using a double-split isolation transformer to power the two energy storage converters. This fundamentally cuts off the transmission path of grid interference and the crosstalk channel between circuits, thus solving the defect of test accuracy being affected by interference. By executing preset test tasks that define the overall operating conditions to coordinately control the two energy storage converters, the two power outputs on the simulated photovoltaic side and battery side can dynamically cooperate to reproduce the real scenario of dual-port interaction, thus solving the defect that a single DC source cannot simulate complex operating conditions. By integrating a liquid cooling system and dynamically adjusting its operation based on temperature monitoring, the power module is provided with heat dissipation capabilities that can be optimized in real time according to the load, ensuring the thermal stability of core components during long-term high-power testing, thus solving the defect of test interruption caused by insufficient heat dissipation. By having the control system automatically execute the entire process from task analysis, operating condition synthesis, data acquisition to thermal management, it replaces all manual operation, eliminating human error and efficiency bottlenecks, thus solving the defects of low test efficiency and poor consistency. This application establishes a high-precision, high-stability automated testing system for photovoltaic-storage DC-DC converters through the systematic integration of dual-isolation power supply, collaborative simulation, liquid-cooled temperature control, and automatic control.

[0066] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the devices and modules described above can be referred to the corresponding descriptions in the foregoing device embodiments, and will not be repeated here.

[0067] Although the subject matter described herein is provided in the general context of execution on a computer system in conjunction with an operating system and applications, those skilled in the art will recognize that other implementations can also be executed in conjunction with other types of program modules. Generally, program modules include routines, programs, components, data structures, and other types of structures that perform specific tasks or implement specific abstract data types. Those skilled in the art will understand that the subject matter described herein can be practiced using other computer system configurations, including handheld devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframes, etc., and can also be used in distributed computing environments where tasks are performed by remote processing devices connected via a communication network. In a distributed computing environment, program modules may reside on both local and remote memory storage devices.

[0068] Those skilled in the art will recognize that the units and method steps of the various examples described in conjunction with the embodiments disclosed in this application can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0069] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of this application and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of this application should be included within the protection scope of this application. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A method of automated testing of a light storage DC-DC converter, characterized in that, include: Obtain a preset test task, the test task definition of which includes the overall operating conditions of the converter under test; Based on the test task, a collaborative control command is generated to control the first energy storage converter to simulate the photovoltaic side characteristics at the photovoltaic input terminal of the converter under test, and to control the second energy storage converter to simulate the battery side characteristics at the battery terminal of the converter under test. The DC outputs of the two energy storage converters are combined to form the test electrical conditions corresponding to the overall operating condition. The first energy storage converter and the second energy storage converter are powered by an electrically isolated AC power supply circuit. While synthesizing the electrical conditions for testing, the performance data of the converter under test is automatically collected; Monitor the heating status of the first energy storage converter and / or the second energy storage converter, and dynamically adjust the operating parameters of the liquid cooling system based on the heating status.

2. The method of claim 1, wherein, The acquisition of the preset test task includes: The test task is defined by at least one of the following overall operating conditions: photovoltaic fluctuation, battery charge and discharge, and high and low voltage ride-through.

3. The method of claim 1, wherein, Before controlling the first energy storage converter to simulate photovoltaic-side characteristics at the photovoltaic input terminal of the converter under test, and controlling the second energy storage converter to simulate battery-side characteristics at the battery terminal of the converter under test, the method further includes: Soft start is performed on the first energy storage converter and the second energy storage converter respectively.

4. The method of claim 1, wherein, The monitoring of the thermal state of the first energy storage converter and / or the second energy storage converter includes: Monitor the temperature of the power modules within the first energy storage converter and / or the second energy storage converter.

5. The method of claim 4, wherein, The dynamic adjustment of the liquid cooling system operating parameters based on the heating state includes: The heating state is compared with a preset temperature threshold, and the operating parameters of the liquid cooling system are adjusted based on the comparison result to control the temperature of the power module within a safe range.

6. An optical storage DC-DC converter automated test apparatus, characterized by, include: A double-split isolation transformer, in which the primary side is used to connect to an AC power source, and the first secondary winding and the second secondary winding are electrically isolated from each other; The first energy storage converter has its AC side connected to the first secondary winding of the double-split isolation transformer, and its DC side is used to connect to the photovoltaic input terminal of the photovoltaic-storage DC-DC converter under test. The second energy storage converter has its AC side connected to the second secondary winding of the double-split isolation transformer, and its DC side is used to connect to the battery terminal of the photovoltaic-storage DC-DC converter under test. The liquid cooling system has its cooling circuit thermally coupled to the power modules in the first energy storage converter and the second energy storage converter. The control system is communicatively connected to the first energy storage converter, the second energy storage converter, and the liquid cooling system. The control system is configured to perform the automated testing method for the optical-storage DC-DC converter according to any one of claims 1-5.

7. The apparatus according to claim 6, characterized in that: The AC power source is the power grid.

8. The apparatus according to claim 6, characterized in that: The cooling pipes of the liquid cooling system are respectively connected to the coolant inlet and outlet of the first energy storage converter and the second energy storage converter, forming a closed-loop heat dissipation circuit.

9. The apparatus according to claim 6, characterized in that: The control system is configured to acquire electrical data at a sampling rate of not less than a preset accuracy and to perform closed-loop control at a control cycle of not more than a preset period. The closed-loop control includes feedback adjustment of the operating parameters of the liquid cooling system and / or the output parameters of the energy storage converter.

10. The apparatus of claim 6, wherein, The control system is also configured to execute fault interlock protection logic, which includes: In response to the detection of at least one of overvoltage, overcurrent, device overtemperature, or insulation fault, a graded shutdown operation is performed in the following order: First, trigger an alarm signal; Subsequently, the tested optical storage DC-DC converter is controlled to perform power lockout; Next, the first energy storage converter and the second energy storage converter are shut down. Finally, the dual-split isolation transformer is disconnected from the AC power supply.

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