Direct current charging pile detection vehicle

Abstract

The utility model discloses a direct-current charging pile detection vehicle, and mainly solves the technical problems of large human input and low detection efficiency during detection of an existing direct-current charging pile. The device comprises a vehicle body, at least one charging module which is relatively fixed on the vehicle body, and a test module which is movably embedded in the vehicle body, is correspondingly filled into a charging module cabin of a to-be-detected direct current charging pile during detection, and is correspondingly and electrically connected with the direct current charging pile. The touch screen module is arranged on the vehicle body and used for being in corresponding communication connection with a direct-current charging pile mainboard; the test modules are electrically connected with the charging modules in a one-to-one correspondence manner through test cables, and the test modules are consistent with the charging modules in outline. The direct current charging pile detection vehicle is flexible to move and convenient to operate, the detection efficiency and the detection accuracy can be greatly improved, and the adverse effect of human factors on the detection process is reduced.

Description

Technical Field

[0001] This application relates to the field of DC charging pile testing technology, specifically to a DC charging pile testing vehicle. Background Technology

[0002] A DC charging station is a device that provides fast DC charging for electric vehicles, often referred to as a "fast charging station." Unlike AC charging stations (slow charging stations), DC charging stations convert three-phase AC power into DC power through rectification, and then regulate the power output to provide a stable DC voltage and current. This eliminates the need for an onboard charger, significantly reducing charging time. The charging module is the core module of a DC charging station, responsible for converting AC power from the grid into high-voltage DC power suitable for charging the electric vehicle's battery, and controlling the charging process.

[0003] To ensure the safe and reliable operation of DC charging piles, they undergo testing before leaving the factory, including electrical performance, safety performance, communication functions, and charging functions. A common method for verifying the reliability of DC charging piles is through simulation testing. This method uses a simulated charging device to simulate the charging process of an electric vehicle, testing parameters such as the charging pile's operating voltage, current, insulation performance, grounding performance, and overload protection. Specifically, before actual testing, testers need to assemble all the charging modules onto the DC charging pile and then connect it to the simulated charging device. Furthermore, since the charging pile's power cabinet lacks a screen, a touchscreen is connected for inputting information such as IP address and pile number. After the charging pile body testing is completed, to facilitate transportation and prevent damage to the charging modules during transport, the charging modules must be removed from the DC charging pile, separately packaged, stored, and transported. Therefore, the disassembly and assembly of the relatively heavy charging modules requires a certain amount of manpower and reduces the testing efficiency of DC charging piles, which is detrimental to improving production efficiency.

[0004] The information disclosed in this background section is intended only to enhance the understanding of the background technology of this disclosure and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] In view of at least one of the above technical problems, this disclosure provides a DC charging pile testing vehicle, which mainly solves the technical problems of high manpower input and low testing efficiency in the existing DC charging pile testing.

[0006] According to one aspect of this disclosure, a DC charging pile testing vehicle is provided, comprising a vehicle body, at least one charging module relatively fixed on the vehicle body, a test module movably embedded in the vehicle body for corresponding loading into a charging module compartment of the DC charging pile to be tested during testing and electrically connected to the corresponding DC charging pile, and a touch screen module disposed on the vehicle body for corresponding communication connection with the main board of the DC charging pile; the test module and the charging module are electrically connected one-to-one via test cables and have the same outer contour as the charging module.

[0007] In some embodiments of this disclosure, the end of the test module used for insertion into the charging module compartment is provided with a test socket for electrical connection with a DC charging pile interface, the test socket including an AC input test socket and a DC output test socket.

[0008] In some embodiments of this disclosure, the test cable includes an AC cable and a DC cable; the test cable passes through the test module on the opposite side of the test socket and is electrically connected to the test socket within the test module.

[0009] In some embodiments of this disclosure, the end of the test module used for inserting into the charging module compartment is provided with a limit switch for determining the insertion position of the test module.

[0010] In some embodiments of this disclosure, the end face of the test module for insertion into the charging module compartment is provided with an anti-reverse plug for defining a specific insertion orientation of the test module and protruding from the end face of the test module along the insertion direction of the test module.

[0011] In some embodiments of this disclosure, the anti-reverse plug includes a fixed base and an L-shaped plate disposed perpendicular to the fixed base; the charging module compartment is provided with a receiving groove that matches the outline of the anti-reverse plug corresponding to the correct installation position of the test module.

[0012] In some embodiments of this disclosure, the charging module is provided with an AC input charging socket and a DC output charging socket for electrical connection with the test cable.

[0013] In some embodiments of this disclosure, the vehicle body is provided with a mounting plate corresponding to each of the charging modules. The mounting plate is provided with an input socket assembly S end and an output socket assembly S end for correspondingly engaging and electrically connecting with the AC input charging socket and DC output charging socket of the charging module.

[0014] In some embodiments of this disclosure, the test cable is electrically connected to the corresponding S-end of the input socket assembly and the S-end of the output socket assembly via crimping jacks.

[0015] In some embodiments of this disclosure, the touch screen module includes a touch screen embedded in the vehicle body, a signal line with one end connected to the input port of the touch screen and the other end provided with a quick-connect terminal for connecting to the charging pile motherboard.

[0016] One or more technical solutions provided in the embodiments of this application have at least one of the following technical effects or advantages:

[0017] 1. By placing the testing module and charging module on the vehicle body, the mobility of the vehicle body is improved, which enhances the flexibility of the testing device and facilitates testing operations. Furthermore, the quick and convenient on-demand movement of the testing vehicle helps to improve testing efficiency.

[0018] 2. Set up a test module that matches the appearance of the charging module and install it in place of the charging module in the charging module compartment of the DC charging pile. Since the test module is lightweight, it can greatly reduce the manpower required in the testing process.

[0019] 3. The test module, mounting plate, and charging module can be quickly plugged in and out via sockets, which helps improve the flexibility of the testing vehicle and facilitates subsequent maintenance.

[0020] 4. The anti-reverse insertion feature ensures the correct installation of the test module and avoids the safety risks associated with reverse insertion; furthermore, the limit switch can confirm whether the test module is inserted correctly, reducing test deviations caused by human factors. Attached Figure Description

[0021] Figure 1 This is a partial structural schematic diagram of a DC charging pile testing vehicle in one embodiment of this application.

[0022] Figure 2 This is a schematic diagram of the test module in one embodiment of this application.

[0023] In the above figures, 1 is the vehicle body, 2 is the test module, 21 is the test cable, 22 is the anti-reverse plug, 23 is the AC input test socket, 24 is the DC output test socket, 25 is the limit switch, 3 is the charging module, and 31 is the mounting plate. Detailed Implementation

[0024] In the description of this application, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," "outer," "vertical," "horizontal," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "connection" and "linkage" in this application, unless otherwise specified, include both direct and indirect connections (linkages).

[0025] The programs involved or relied upon in the following embodiments are all conventional or simple programs in this technical field. Those skilled in the art can make conventional choices or adaptive adjustments according to specific application scenarios.

[0026] Unless otherwise specified, all devices and other components mentioned in the following examples are commercially available products.

[0027] To better understand the technical solution of this application, the above technical solution will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] Currently, when inspecting DC charging piles, the charging module needs to be assembled with the DC charging pile. Because the charging module is heavy and the assembly point is at a certain height, at least two people are required. Furthermore, after inspection, to facilitate transportation and avoid damage during transport, the assembled charging module needs to be removed from the DC charging pile. This results in low efficiency throughout the inspection process, and the disassembly and assembly of the charging module also poses a risk of damage. To solve these problems, this example discloses a DC charging pile inspection vehicle, see [link to relevant documentation]. Figure 1 It includes a vehicle body 1, a test module 2 mounted on the vehicle body, and a charging module 3.

[0029] Specifically, due to the presence of AC / DC conversion components within the charging module, it is quite heavy. Therefore, assembling it at the DC charging station and removing it after testing requires multiple personnel, resulting in significant manpower investment. To address this, several test modules 2 are installed on the vehicle body. The outline of these test modules 2 matches that of the charging module, allowing them to be easily installed into the charging module compartment of the DC charging station. Furthermore, the end face of the test module 2 corresponding to its insertion into the DC charging station's charging module compartment has a test socket. This test socket matches the S-end of the socket assembly inside the charging module compartment used for electrical connection to the charging module. Thus, after inserting the test module 2 into the charging module compartment, the test socket matches the S-end of the socket assembly inside the compartment, establishing a corresponding electrical connection, thereby connecting the test module 2 to the working circuit of the DC charging station. Specifically, in this embodiment, see... Figure 2 The test sockets at the end face of test module 2 include AC input test socket 23 and DC output test socket 24, which are respectively matched with the S end of the three-phase AC input socket assembly and the S end of the DC output socket assembly in the DC charging pile charging module compartment.

[0030] See Figure 1 In this embodiment, a test cable is threaded through the opposite end face of the test module 2 relative to the test socket. One end of the test cable establishes an electrical connection with the test socket inside the test module 2, and the other end establishes an electrical connection with the charging module. This means that an electrical connection can be established between the test module and the charging module through the test cable. Thus, the test module 2 acts as an extension module of the charging module 3, replacing the charging module 3 in its assembly at the DC charging pile to establish an electrical connection. Since the test module 2 does not contain complex electrical components, its weight primarily comes from the module housing and the test socket. This significantly reduces the weight of the test module 2 compared to the charging module 3, allowing for easy assembly and disassembly of the test module 2 at the DC charging pile by a single person with one hand, greatly facilitating the testing operation. Specifically, in this embodiment, the overall weight of the test module 2 is 2 kg, far less than the weight of the charging module. In addition, the test cables in this example include AC cables and DC cables. The AC cable ends corresponding to the AC input test socket are soldered to the AC input test socket, and the DC cable ends corresponding to the DC output test socket are soldered to the DC output test socket.

[0031] To avoid the risk of module burnout or personal injury due to incorrect orientation (upside down) of the test module during loading into the DC charging pile's charging module compartment, caused by operator error, this embodiment includes an anti-reverse plug at the end face of the test module 2 where it is inserted into the DC charging pile's charging module compartment. This anti-reverse plug protrudes perpendicularly from its end face, and a corresponding receiving groove matching the anti-reverse plug's contour is provided in the charging module compartment. Therefore, when the test module 2 is misaligned, the misalignment between the anti-reverse plug and the receiving groove restricts assembly. Furthermore, because the anti-reverse plug is perpendicular to its end face, i.e., along the insertion direction of the test module, it can limit further insertion and prevent AC / DC reversal when the test module is incorrectly assembled. For details, see [link to details]. Figure 2 In this embodiment, the anti-reverse plug-in 22 includes a fixed base and an L-shaped plate perpendicular to the fixed base. The anti-reverse plug-in has a Z-shaped structure. It is fixed to the end face of the test module 2 by bolts through the fixed base. When the test module is misaligned during assembly, its L-shaped plate structure limits the insertion depth and prevents the test module from establishing an incorrect electrical connection with the DC charging pile.

[0032] Additionally, see Figure 2 To ensure that the test module 2 can be accurately assembled into the DC charging pile's charging module compartment and to avoid inaccurate or deviated-from-actual-situation test results due to human factors (such as incomplete insertion), in this embodiment, a limit switch 25 is provided at the end face of the test module 2 corresponding to its insertion into the charging module compartment. Thus, when the test module 2 is accurately assembled, the limit switch 25 outputs a corresponding position signal. Based on this position signal, it can be determined whether the assembly of the test module meets the requirements, thereby ensuring the reliability of the test.

[0033] As an essential component for the normal operation of a DC charging pile, the charging module 3 needs to participate in the testing process. However, the test module only matches the charging module in appearance and cannot perform the corresponding functions. Therefore, in this embodiment, several charging modules 3 are installed on the vehicle body 1. Since the charging modules 3 have a certain weight and are inconvenient to transport, they are relatively fixed to the vehicle body 1, and their movement is facilitated by the vehicle's wheels. To achieve the relative installation of the charging modules 3 on the vehicle body 1, a mounting plate 31 for installing the charging modules 3 is provided on the vehicle body in this example. Specifically, the mounting plate 31 is fixedly equipped with an input socket assembly S-end and an output socket assembly S-end, which are electrically connected to the test cable 21. To facilitate the connection between the test cable 21 and the input and output socket assemblies S-ends, in this example, one end of the test cable 21 is electrically connected to the test module, and the other end is provided with a crimping hole. The crimping hole establishes the corresponding electrical connection between the test cable 21 and the socket assembly S-end on the mounting plate. This allows the test module to be easily disassembled relative to the mounting plate or charging module, and also facilitates subsequent maintenance of the test module. In this example, the AC cable in the test cable is electrically connected to the input socket assembly S-end on the mounting plate, and the DC cable is electrically connected to the output socket assembly S-end on the mounting plate.

[0034] Correspondingly, in this embodiment, the AC input charging socket and DC output charging socket of the charging module 3 are electrically connected to the socket assembly S on the mounting plate. Specifically, the AC input charging socket of the charging module is inserted into the input socket assembly S on the mounting plate, and the DC output charging socket of the charging module is inserted into the output socket assembly S on the mounting plate. Thus, a detachable connection is established between the test module and the charging module 3 through the socket assembly S on the mounting plate, thereby improving the testing flexibility of the testing vehicle.

[0035] In this embodiment, multiple charging modules and multiple testing modules are provided, and the charging modules 3 and testing modules 2 are matched one-to-one, so that the DC charging testing vehicle can simultaneously meet the testing requirements of multiple DC charging piles. In addition, in this example, each charging module is fixed relative to the mounting plate, and the vehicle body is provided with several cavities for embedding each testing module, and each testing module is slidably embedded in each cavity.

[0036] In addition, to enable real-time monitoring of test data during the inspection process, this embodiment of the DC charging pile inspection vehicle also includes a touch screen module for real-time display of DC charging pile operating data. Specifically, in this example, the touch screen module includes a touch screen embedded in the vehicle body, and the input port of the touch screen is connected to a signal line. The other end of the signal line is equipped with a quick-connect terminal block, thereby quickly establishing a communication connection between the touch screen and the charging pile motherboard. This allows inspection personnel to monitor the charging pile's voltage, current, and other information parameters in real time, and to set data such as the charging pile's IP address and pile code through the touch screen.

[0037] In this example, the DC charging pile testing vehicle is moved to the vicinity of the DC charging pile to be tested. The test module is then inserted into the charging module compartment of the DC charging pile, and an electrical connection is established between the charging gun and the simulated charging equipment. After the DC charging pile and the simulated charging equipment complete protocol calibration, current and voltage matching, and handshake operations, three-phase power flows through the molded case circuit breaker to the AC contactor. The three-phase AC power then enters the charging module via the S-terminal of the charging module compartment's socket assembly, the test module, the AC cable, the S-terminal of the input socket assembly on the mounting plate, and the AC input charging socket of the charging module. After processing by the charging module, DC power is sequentially output to the DC charging pile via the charging module's DC output charging socket, the S-terminal of the output socket assembly on the mounting plate, the DC cable, the test module, and the S-terminal of the charging module compartment's socket assembly, supplying power to the charging gun. During this process, voltage and current data are monitored in real time via a touchscreen module to ensure that the DC charging pile operates in accordance with relevant standards and specifications. In addition, after the test module is inserted into the charging module compartment of the DC charging pile, the 24V switching power supply from the charging pile can be introduced to the test vehicle to power the touch screen and limit switch. After the limit switch is powered on, it will detect the position of the test module to ensure that the test module is fully inserted into the charging module compartment and avoid test errors caused by poor contact due to incomplete insertion.

[0038] Although some preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0039] Obviously, those skilled in the art can make various modifications and variations to this disclosure without departing from the spirit and scope of its inventive concept. Therefore, if such modifications and variations to this disclosure fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A DC charging pile testing vehicle, characterized in that, The device includes a vehicle body, at least one charging module relatively fixed on the vehicle body, a test module movably embedded in the vehicle body for corresponding loading into the charging module compartment of the DC charging pile to be tested during testing and electrically connected to the corresponding DC charging pile, and a touch screen module disposed on the vehicle body for corresponding communication connection with the DC charging pile motherboard; the test module and the charging module are electrically connected one-to-one through test cables and have the same outer contour as the charging module.

2. The DC charging pile testing vehicle according to claim 1, characterized in that, The test module is provided with a test socket on the end side for insertion into the charging module compartment, which is used for electrical connection with the DC charging pile interface. The test socket includes an AC input test socket and a DC output test socket.

3. The DC charging pile testing vehicle according to claim 2, characterized in that, The test cable includes AC cable and DC cable; the test cable passes through the test module on the opposite side of the test socket, and is electrically connected to the test socket within the test module.

4. The DC charging pile testing vehicle according to claim 1, characterized in that, The end of the test module that is inserted into the charging module compartment is equipped with a limit switch for determining the insertion position of the test module.

5. The DC charging pile testing vehicle according to claim 1 or 4, characterized in that, The end face of the test module used for insertion into the charging module compartment is provided with an anti-reverse plug that limits the specific insertion orientation of the test module and protrudes from the end face of the test module along the insertion direction of the test module.

6. The DC charging pile testing vehicle according to claim 5, characterized in that, The anti-reverse plug includes a fixed base and an L-shaped plate perpendicular to the fixed base; the charging module compartment is provided with a receiving groove that matches the outline of the anti-reverse plug corresponding to the correct installation position of the test module.

7. The DC charging pile testing vehicle according to claim 1, characterized in that, The charging module is provided with an AC input charging socket and a DC output charging socket on the corresponding side for electrical connection with the test cable.

8. The DC charging pile testing vehicle according to claim 7, characterized in that, The vehicle body is provided with a mounting plate corresponding to each of the charging modules. The mounting plate is provided with an input socket assembly S end and an output socket assembly S end for correspondingly engaging and electrically connecting with the AC input charging socket and DC output charging socket of the charging module.

9. The DC charging pile testing vehicle according to claim 8, characterized in that, The test cable is electrically connected to the corresponding S-end of the input socket assembly and the S-end of the output socket assembly via crimping holes.

10. The DC charging pile testing vehicle according to claim 1, characterized in that, The touch screen module includes a touch screen embedded in the vehicle body, a signal line with one end connected to the input port of the touch screen and the other end provided with a quick-connect terminal for connecting to the charging pile motherboard.

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