Testing device for simulating SHUNT current sensor of whole vehicle

Abstract

The utility model discloses a test device for simulating an SHUNT current sensor of a whole vehicle, which comprises a test circuit connected with the SHUNT current sensor, the test circuit comprises a power supply, a plectrum switch and a potentiometer, the plectrum switch and the potentiometer are connected with one side of the power supply, and the power supply is in an annular circuit with the plectrum switch and the potentiometer; the potentiometer is an adjustable potentiometer, the two ends of an adjustable resistor of the potentiometer are connected with an SHUNT positive electrode wire and an SHUNT negative electrode wire respectively, and the SHUNT positive electrode wire and the SHUNT negative electrode wire are both communicated with the SHUNT current sensor. Whether the BMS can correctly detect and send the current value or not is checked, so that the BMS performs corresponding processing or protection measures; the testing device is used for performing simulation testing, so that a large amount of cost and manpower can be saved, and the cost is reduced.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle testing technology, specifically a test device for simulating the SHUNT current sensor of a whole vehicle. Background Technology

[0002] To ensure vehicle safety, critical data such as the extreme cell voltage, total battery voltage, and battery current of the power battery system must be monitored in real time. For example, the total battery current is crucial for monitoring the battery system's operating status and predicting SOC (State of Charge, also known as remaining charge). Current sensing, as an indispensable part of the BMS system, is of paramount importance. On the one hand, the current sensor needs to provide real-time feedback of the vehicle's current to the driver or technicians to facilitate understanding of the electric vehicle's operating status. On the other hand, the accuracy of the current sensor directly affects the accuracy of the electric vehicle's SOC estimation. Abnormalities or insufficient accuracy of the current sensor will lead to significant deviations in SOC estimation, or inaccurate current measurement may trigger the vehicle's software protection strategy, resulting in the disconnection of high voltage.

[0003] A SHUNT current sensor is a detection device that senses the current being measured and transforms that information into an electrical signal or other required form of output that meets specific standards. This output fulfills requirements for information transmission, processing, storage, display, recording, and control. In electric vehicle applications, current sensors are used in motor drive control and DC-DC conversion control of motor recirculation current in electric and hybrid vehicles, as well as for battery charging and discharging current detection. They play a crucial role as a key component in the control system.

[0004] Because the verification phase is difficult, the conditions for testing complete vehicles are limited, resources are scarce, and it is impossible to provide enough complete vehicles for testing. Moreover, providing complete vehicles for testing is costly and cannot be done on a large scale. Utility Model Content

[0005] The purpose of this invention is to provide a device for testing a simulated vehicle SHUNT current sensor, in order to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solutions:

[0007] A test device for simulating a vehicle's SHUNT current sensor includes a test circuit connected to the SHUNT current sensor. The test circuit includes a power supply and a toggle switch and a potentiometer connected to one side of the power supply. The power supply and the toggle switch and potentiometer form a loop circuit.

[0008] The potentiometer is an adjustable potentiometer, and the two ends of the adjustable resistor of the potentiometer are respectively connected to the SHUNT positive terminal and the SHUNT negative terminal. Both the SHUNT positive terminal and the SHUNT negative terminal are connected to the SHUNT current sensor.

[0009] The test circuit consists of a power supply, a toggle switch, and a potentiometer. The potentiometer is connected to the SHUNT current sensor via the SHUNT positive and negative terminals. This allows the voltage to be increased to the SHUNT current sensor using the principle of series voltage division. The potentiometer is used to change the value of the increased voltage to perform different voltage tests.

[0010] As a further aspect of this invention: the power supply is a lead-acid battery, a dry cell battery, or a lithium battery. The selected power supply has a voltage specification of 1.5V to provide voltage for the test circuit.

[0011] As a further embodiment of this invention, a safety resistor is provided between the toggle switch and the potentiometer.

[0012] Setting a safety resistor can prevent power supply short circuits and improve the safety performance of the test circuit.

[0013] As a further embodiment of this utility model: the safety resistor includes a first resistor and a second resistor connected in series, the first resistor being connected to the toggle switch, and the second resistor being connected to the potentiometer.

[0014] In this embodiment, the first and second resistors are of the same specification and are connected in series to divide the voltage, with a resistance of 655K ohms. By using two resistors, the safety performance of the circuit can be further improved; even if one of the resistors short-circuits, it will not affect the use of the test circuit.

[0015] As a further embodiment of this invention: the first resistor and the second resistor are detachably connected to a resistor mounting plate. The resistor mounting plate is made of fiberglass base material, copper, and solder resist, and is used to support and protect the resistors.

[0016] As a further embodiment of this utility model: the toggle switch is a two-position toggle switch, the toggle switch is provided with a switch toggle, the upper interface of the toggle switch is connected to the power supply, and the lower interface of the toggle switch is connected to the first resistor.

[0017] The on / off state of the test circuit is controlled by setting a toggle switch.

[0018] As a further embodiment of this utility model: the potentiometer is an adjustable resistor, the adjustable resistor is provided with a resistance adjustment knob, and the adjustable resistance value range of the adjustable resistor is 0-100K ohms.

[0019] By adjusting the actual resistance value of the adjustable resistor, the voltage between the SHUNT positive terminal and the SHUNT negative terminal can be adjusted, thereby simulating the voltage change of the SHUNT current sensor.

[0020] As a further embodiment of this utility model: the adjustable resistor is provided with a first potentiometer interface and a second potentiometer interface, the first potentiometer interface is connected to the power supply and the negative terminal of the SHUNT, and the second potentiometer interface is connected to the second resistor and the positive terminal of the SHUNT.

[0021] The positive terminal of the SHUNT and the negative terminal of the SHUNT are connected in parallel to the resistor section of the potentiometer circuit. By changing the resistance value of this section, the voltage across the resistor is adjusted, thereby regulating the voltage change between the positive and negative terminals of the SHUNT.

[0022] Compared with the prior art, the beneficial effects of the present invention are:

[0023] 1. This application uses a laboratory simulation of the vehicle's SHUNT current acquisition. When the vehicle is charging or discharging, it verifies whether the BMS can correctly detect and send out the current value, so that the BMS can perform corresponding processing or protection measures. The test device in this application is used to conduct simulation tests, which can save a lot of costs and manpower, thereby reducing costs.

[0024] 2. This application can measure charging current and discharging current through the connection of test leads. Compared with the whole vehicle system or the actual vehicle, this device can be tested repeatedly, and it is easy and convenient to operate and highly practical. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the testing device.

[0026] Figure 2 This is a circuit diagram of the test device in this embodiment;

[0027] Figure 3 This is a schematic diagram of the circuit principle used in the test device of this embodiment.

[0028] In the diagram: 1-Polypotentiometer first interface, 2-Polypotentiometer lower interface, 3-Circuit mounting plate, 4-Toggle switch upper interface, 5-Toggle switch lower interface, 6-Switch toggle, 7-First resistor, 8-Second resistor, 9-Power supply, 10-Resistance adjustment knob, 11-SHUNT positive terminal connection, 12-SHUNT negative terminal connection, 13-Polypotentiometer, 14-Toggle switch. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] Please see Figure 1-2 In this embodiment of the present invention, a test device simulating a vehicle's SHUNT current sensor includes a test circuit connected to the SHUNT current sensor. The test circuit includes a power supply 9 and a toggle switch 14 and a potentiometer 13 connected to one side of the power supply 9. The power supply 9 is a lead-acid battery, a dry cell battery, or a lithium battery. The power supply is selected with a voltage specification of 1.5V to provide voltage for the test circuit. The power supply 9, toggle switch 14, and potentiometer 13 form a loop circuit. The potentiometer 13 is an adjustable potentiometer. The two ends of the adjustable resistor of the potentiometer 13 are respectively connected to the SHUNT positive terminal 11 and the SHUNT negative terminal 12. Both the SHUNT positive terminal 11 and the SHUNT negative terminal 12 are connected to the SHUNT current sensor.

[0031] The test circuit consists of power supply 9, toggle switch 14, and potentiometer 13. The potentiometer is connected to the SHUNT current sensor through SHUNT positive terminal 11 and SHUNT negative terminal 12. The voltage required to increase the SHUNT current sensor can be increased through the principle of series voltage division. The value of the increased voltage can be changed by potentiometer 13 to perform different voltage tests.

[0032] In this embodiment, a safety resistor is provided between the toggle switch 14 and the potentiometer 13. The safety resistor includes a first resistor 7 and a second resistor 8 connected in series. The first resistor 7 and the second resistor 8 are detachably connected to the resistor mounting plate 3. The resistor mounting plate 3 is made of fiberglass base material, copper, and solder resist, and is used to support and protect the resistors. The first resistor 7 is connected to the toggle switch 14, and the second resistor 8 is connected to the potentiometer 13. The first resistor 7 and the second resistor 8 have the same specifications and are connected in series to divide the voltage, with a resistance of 655K ohms. By setting the safety resistor, the power supply 9 can be prevented from short-circuiting, improving the safety performance of the test circuit. Even if one of the resistors short-circuits, it will not affect the use of the test circuit.

[0033] The toggle switch 14 is a two-position toggle switch with a switch toggle 6. The upper interface 4 of the toggle switch 14 is connected to the power supply 9, and the lower interface 5 of the toggle switch 14 is connected to the first resistor 7. The on / off state of the test circuit is controlled by setting the toggle switch.

[0034] Potentiometer 13 is an adjustable resistor with a resistance adjustment knob 10. The adjustable resistor's resistance range is 0-100K ohms. By adjusting the actual resistance value of the adjustable resistor, the voltage between the SHUNT positive terminal 11 and the SHUNT negative terminal 12 can be adjusted, thus simulating the voltage change of the SHUNT current sensor. The adjustable resistor has a potentiometer first interface 1 and a potentiometer second interface 2. The first potentiometer interface 1 is connected to the power supply 9 and the SHUNT negative terminal 12, while the second potentiometer interface 2 is connected to the second resistor 8 and the SHUNT positive terminal 11. The SHUNT positive terminal 11 and the SHUNT negative terminal 12 are connected in parallel to the resistor section of the potentiometer's input circuit. By changing the resistance value of this section, the voltage change across the input resistor is adjusted, thereby adjusting the voltage change between the SHUNT positive terminal 11 and the SHUNT negative terminal 12.

[0035] In use, after connecting the testing device of this embodiment, connect the SHUNT positive terminal 11 and SHUNT negative terminal 12 to the SHUNT current sensor. The circuit can be kept open by manually setting the two-position toggle switch. Then, connect the SHUNT+ and SHUNT- detection lines used for current detection on the vehicle to the SHUNT positive terminal 11 and SHUNT negative terminal 12. A corresponding positive voltage value will be detected between the SHUNT+ and SHUNT- detection points. The detected positive voltage value can then be changed by adjusting the resistance of the adjustable resistor. The BMS and other relevant vehicle controllers will calculate the actual collected positive current value based on the voltage value, which is generally the discharge current, such as 1MV = 1A; 10MV = 10A; 500MV = 500A; 1000MV = 1000A; and so on. If the SHUANT+ and SHUANT- detection lines used for current detection on the vehicle are connected to the SHUANT positive terminal 11 and the SHUANT negative terminal 12 at this time, a corresponding negative voltage value will be detected between the detection points SHUANT+ and SHUANT-. Then, by adjusting the resistance value of the adjustable resistor, the detected negative voltage value can be changed. The BMS and other related controllers of the vehicle will calculate the actual collected negative current value based on the voltage value, which is generally the charging current. For example, -1mV voltage corresponds to a collected negative current value of -1A; -10mV voltage corresponds to a collected negative current value of -10A; -500mV voltage corresponds to a collected negative current value of -500A; and -1000mV voltage corresponds to a collected negative current value of -1000A.

[0036] Example 1

[0037] The SHUNT shunt selected in this embodiment is model SH-S 350A 35mA 0.2P-006. The voltage-current conversion relationship is: 35mV corresponds to 350A, that is, 1mV corresponds to 10A, that is, a specification of 100uR, that is, 1mV / 100uR equals 10A.

[0038] like Figure 3 As shown, the shunt is fixedly placed on the negative circuit of the high-voltage circuit. The SHUNT+ and SHUNT- of the shunt are connected to the SHUNT+ and SHUNT- pins of the BMS host acquisition port X201, respectively. The acquisition chip inside the BMS converts the acquired voltage value into a current value. At the same time, the SHUNT positive terminal 11 and SHUNT negative terminal 12 in this embodiment are connected to the SHUNT current sensor, and then the test can be started.

[0039] Manually set the two-position toggle switch to open to ensure the circuit is conducting. Then adjust potentiometer 13 and the resistance connected to the circuit in potentiometer 13. This will adjust the voltage between the SHUNT positive terminal 11 and the SHUNT negative terminal 12 of this detection device. Furthermore, it will adjust the voltage entering the SHUNT shunt, and thus the positive voltage value between the SCU detection points SHUNT+ and SHUNT-.

[0040] By adjusting the resistance of potentiometer 13, the detected positive voltage value is changed. The BMS and other related controllers of the vehicle will calculate the actual positive current value based on the voltage value. In this embodiment, through multiple measurements, the detected voltages are -1.5mV, -5mV, -11mV, -32mV, and 65mV, respectively. The corresponding currents are -15A, -50A, -110A, -320A, and -650A.

[0041] In summary, a set voltage can be input to the SHUNT shunt using the testing device of this application. This input voltage simulates the voltage of the entire vehicle and can be used to detect whether the SHUNT shunt is functioning properly.

[0042] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0043] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A test device for simulating a vehicle's SHUNT current sensor, characterized in that, The test circuit includes a test circuit connected to a SHUNT current sensor. The test circuit includes a power supply (9) and a toggle switch (14) and a potentiometer (13) connected to one side of the power supply (9). The power supply (9) and the toggle switch (14) and potentiometer (13) form a loop circuit. The potentiometer (13) is an adjustable potentiometer (13). The two ends of the adjustable resistor of the potentiometer (13) are respectively connected to the SHUNT positive terminal (11) and the SHUNT negative terminal (12). The SHUNT positive terminal (11) and the SHUNT negative terminal (12) are both connected to the SHUNT current sensor.

2. The simulated vehicle SHUNT current sensor testing device according to claim 1, characterized in that, The power source (9) is a lead-acid battery, a dry cell battery, or a lithium battery.

3. The simulated vehicle SHUNT current sensor testing device according to claim 1, characterized in that, A safety resistor is provided between the toggle switch (14) and the potentiometer (13).

4. The simulated vehicle SHUNT current sensor testing device according to claim 3, characterized in that, The safety resistor includes a first resistor (7) and a second resistor (8) connected in series. The first resistor (7) is connected to the toggle switch (14), and the second resistor (8) is connected to the potentiometer (13).

5. The simulated vehicle SHUNT current sensor testing device according to claim 4, characterized in that, The first resistor (7) and the second resistor (8) are detachably connected to the resistor mounting plate (3).

6. The simulated vehicle SHUNT current sensor testing device according to claim 4, characterized in that, The toggle switch (14) is a two-position toggle switch with a switch toggle (6) on it. The upper interface (4) of the toggle switch (14) is connected to the power supply (9), and the lower interface (5) of the toggle switch (14) is connected to the first resistor (7).

7. The simulated vehicle SHUNT current sensor testing device according to claim 4, characterized in that, The potentiometer (13) is an adjustable resistor, and the adjustable resistor is provided with a resistance adjustment knob (10). The adjustable resistance value range of the adjustable resistor is 0-100K ohms.

8. The simulated vehicle SHUNT current sensor testing device according to claim 7, characterized in that, The adjustable resistor is provided with a potentiometer first interface (1) and a potentiometer second interface (2). The potentiometer first interface (1) is connected to the power supply (9) and the SHUNT negative terminal connection (12). The potentiometer second interface (2) is connected to the second resistor (8) and the SHUNT positive terminal connection (11).

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