Electric vehicle controller reliability test circuit and tool
By designing a reliability test circuit for an electric vehicle controller, and using a combination of a microcontroller and a switching module, precise control over the number of times and duration of power-on and power-off of the electric vehicle controller was achieved, solving the inconvenience problem of existing test devices and reducing test costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- WUXI JINGHUI ELECTRONICS
- Filing Date
- 2025-07-24
- Publication Date
- 2026-07-03
AI Technical Summary
Existing electric vehicle controller power-on/off testing devices cannot accurately adjust the duration and number of power-on/off cycles, making testing inconvenient.
A reliability test circuit for an electric vehicle controller was designed. It utilizes a microcontroller, a selection button module, an up button module, an down button module, and a switch module to generate enable signals to control the number and duration of power-on and power-off cycles of the electric vehicle controller. A combination of transistors and MOSFETs is used to replace relays to achieve accurate power-on and power-off tests.
It enables precise adjustment of the number of power-on and power-off cycles and duration, improving the convenience of testing, reducing testing costs, and avoiding problems caused by relay damage due to mechanical structure.
Smart Images
Figure CN224457266U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric vehicle controller testing technology, and in particular to an electric vehicle controller reliability testing circuit and tool. Background Technology
[0002] Power-on / off testing of electric vehicle controllers is a crucial aspect of their reliability testing. Current power-on / off testing methods typically rely on relay operation, where manual control of the relay coil's on / off state controls the relay's switching terminals connected to the electric vehicle controller. During these tests, it may be necessary to analyze the impact of the number and duration of power-on / off cycles on reliability. Existing testing equipment lacks the capability for precise adjustment of test parameters such as power-on / off duration based on specific circumstances. Utility Model Content
[0003] To solve the above-mentioned technical problems, this utility model provides a reliability testing circuit and tool for electric vehicle controllers.
[0004] This utility model provides a reliability test circuit for an electric vehicle controller, used to test the reliability of the electric vehicle controller after multiple consecutive power-on and power-off cycles. It includes a microcontroller, a selection button module, an increase button module, an decrease button module, a switch module, and a display module.
[0005] The first input terminal of the microcontroller is electrically connected to the output terminal of the selection button module, its second input terminal is electrically connected to the output terminal of the up button module, its third input terminal is electrically connected to the output terminal of the down button module, its first output terminal is electrically connected to the enable control terminal of the switch module, and its second output terminal is electrically connected to the input terminal of the display module.
[0006] The input terminal of the switch module is used to connect to the working power supply, and its output terminal is used to provide test power to the electric vehicle controller.
[0007] The microcontroller is used to generate an enable signal based on the number of power-on / off cycles and the power-on and power-off durations set by the selection button module, the up button module, and the down button module. The switch module is used to control the number of on / off cycles and the on / off durations between its input and output terminals based on the enable signal.
[0008] In one possible implementation, the switching module includes a transistor control unit and a MOSFET switching unit;
[0009] The control terminal of the transistor control unit serves as the enable control terminal of the switching module. Its input terminal is electrically connected to the control terminal of the MOS transistor switching unit, and its output terminal is electrically connected to ground.
[0010] The input terminal of the MOS transistor switching unit serves as the input terminal of the switching module, and its output terminal serves as the output terminal of the switching module.
[0011] In one possible implementation, the transistor control unit includes a first resistor, a diode, a second resistor, and an NPN transistor;
[0012] The first end of the first resistor serves as the control terminal of the transistor control unit, and its second end is electrically connected to the positive terminal of the diode.
[0013] The negative terminal of the diode is electrically connected to the first terminal of the second resistor and the base of the NPN transistor, respectively.
[0014] The second terminal of the second resistor is electrically connected to the emitter of the NPN transistor and grounded;
[0015] The collector of the NPN transistor serves as the input terminal of the transistor control unit.
[0016] In one possible implementation, the MOS transistor switching unit includes a PMOS transistor, a third resistor, and a fourth resistor;
[0017] The drain of the PMOS transistor serves as the output terminal of the MOS transistor switching unit, its source is electrically connected to the first terminal of the third resistor and serves as the input terminal of the MOS transistor switching unit, and its gate is electrically connected to the second terminal of the third resistor and the first terminal of the fourth resistor, respectively.
[0018] The second end of the fourth resistor serves as the control terminal of the MOS transistor switching unit.
[0019] In one possible implementation, the MOS transistor switching unit further includes a Zener diode;
[0020] The positive terminal of the Zener diode is electrically connected to the gate of the PMOS transistor, and its negative terminal is electrically connected to the source of the PMOS transistor.
[0021] In one possible implementation, the display module includes a count display unit and a duration display unit.
[0022] This utility model also provides an electric vehicle controller reliability testing tool, including a PCB board and the electric vehicle controller reliability testing circuit as described above;
[0023] The electric vehicle controller reliability test circuit is located on the PCB board.
[0024] The technical solution provided by this utility model has at least the following beneficial effects:
[0025] By selecting, increasing, or decreasing the button module, users can manually set the number of power-on / off cycles and the duration of power-on and power-off cycles for the microcontroller. This allows for precise adjustment of test parameters such as the number of power-on / off cycles and the duration of power-on and power-off cycles, improving the convenience of testing. Attached Figure Description
[0026] Figure 1 A schematic diagram of a reliability test circuit for an electric vehicle controller provided in an embodiment of this utility model;
[0027] Figure 2 The circuit diagram of the switching module provided in this embodiment of the utility model;
[0028] Figure 3 This is a schematic diagram of an application scenario of the display module provided in an embodiment of the present utility model. Detailed Implementation
[0029] To enhance understanding of this utility model, it will be described in further detail below with reference to the accompanying drawings and embodiments. These embodiments are only used to explain this utility model and do not limit the scope of protection of this utility model.
[0030] Please refer to Figures 1 to 3 This utility model provides a reliability test circuit for an electric vehicle controller, used to test the reliability of the electric vehicle controller after multiple consecutive power-on and power-off cycles. It includes a microcontroller, a selection button module, an increase button module, an decrease button module, a switch module, and a display module.
[0031] The first input terminal of the microcontroller is electrically connected to the output terminal of the selection button module, its second input terminal is electrically connected to the output terminal of the up button module, its third input terminal is electrically connected to the output terminal of the down button module, its first output terminal is electrically connected to the enable control terminal of the switch module, and its second output terminal is electrically connected to the input terminal of the display module.
[0032] The input terminal of the switch module is used to connect to the working power supply, and its output terminal is used to provide test power to the electric vehicle controller.
[0033] The microcontroller is used to generate an enable signal based on the number of power-on / off cycles and the power-on and power-off durations set by the selection button module, the up button module, and the down button module. The switch module is used to control the number of on / off cycles and the on / off durations between its input and output terminals based on the enable signal.
[0034] In this embodiment, the microcontroller can be a conventional model, used to set the power-on and power-off duration and number of cycles of the electric vehicle controller via selection button module, adjustment button module, and adjustment button module, and can count the number of power-on and power-off cycles during actual testing. The selection button module, adjustment button module, and adjustment button module can all be implemented based on conventional buttons. The switch module can be implemented based on a combination of conventional MOSFETs and transistors, used to turn the power on and off. The display module can be implemented based on a conventional OLED screen, used in display mode to display the real-time count of power-on and power-off cycles, as well as the power-on and power-off durations; in setting mode, it serves as the display interface for setting the power-on and power-off duration and number of cycles of the electric vehicle controller, facilitating intuitive testing. The enable signal can be a conventional PWM signal, with the period of the PWM signal corresponding to the set number of power-on and power-off cycles, the high-level time in the PWM signal corresponding to the power-on duration, and the low-level time in the PWM signal corresponding to the power-off duration. It should be noted that, to improve testing convenience, input interface J1 can be connected to the input terminal of the switch module, and output interface J2 can be connected to the output terminal of the switch module. Input interface J1 can be directly connected to a power supply, such as a 72V power supply. Output interface J2 can be directly connected to the electric vehicle controller that needs to be tested.
[0035] In one possible implementation, the switching module includes a transistor control unit and a MOSFET switching unit;
[0036] The control terminal of the transistor control unit serves as the enable control terminal of the switching module. Its input terminal is electrically connected to the control terminal of the MOS transistor switching unit, and its output terminal is electrically connected to ground.
[0037] The input terminal of the MOS transistor switching unit serves as the input terminal of the switching module, and its output terminal serves as the output terminal of the switching module.
[0038] In this embodiment, the relay is replaced by a combination of a transistor control unit and a MOSFET switching unit, solving the problem of relays being prone to damage and having a short lifespan during frequent testing due to their mechanical structure, thus reducing testing costs. In specific implementation, the microcontroller generates a periodic PWM signal as an enable signal based on the set number of power-on / off cycles and the duration of power-on and power-off cycles. When the enable signal is high, the transistor control unit controls the conduction between the input and output terminals of the MOSFET switching unit, allowing the operating power supply to provide test power to the electric vehicle controller, thus powering on the electric vehicle controller. When the enable signal is low, the transistor control unit controls the cutoff between the input and output terminals of the MOSFET switching unit, preventing the operating power supply from providing test power to the electric vehicle controller, thus powering off the electric vehicle controller.
[0039] In one possible implementation, the transistor control unit includes a first resistor R1, a diode D1, a second resistor R2, and an NPN transistor Q1;
[0040] The first end of the first resistor R1 serves as the control terminal of the transistor control unit, and its second end is electrically connected to the positive terminal of the diode D1.
[0041] The negative terminal of the diode D1 is electrically connected to the first terminal of the second resistor R2 and the base of the NPN transistor Q1, respectively.
[0042] The second terminal of the second resistor R2 is electrically connected to the emitter of the NPN transistor Q1 and grounded;
[0043] The collector of the NPN transistor Q1 serves as the input terminal of the transistor control unit.
[0044] In this embodiment, both the first resistor R1 and the second resistor R2 are conventional resistors. Both diode D1 and NPN transistor Q1 are standard models. Diode D1 protects the microcontroller from reverse current. In specific implementation, the microcontroller's first output pin outputs an enable signal. When the enable signal is high, NPN transistor Q1 is turned on, thereby controlling the conduction between the input and output of the MOSFET switching unit. When the enable signal is low, NPN transistor Q1 is turned off, thereby controlling the cutoff between the input and output of the MOSFET switching unit.
[0045] In one possible implementation, the MOS transistor switching unit includes a PMOS transistor V1, a third resistor R3, and a fourth resistor R4;
[0046] The drain of the PMOS transistor V1 serves as the output terminal of the MOS transistor switching unit, its source is electrically connected to the first terminal of the third resistor R3 and serves as the input terminal of the MOS transistor switching unit, and its gate is electrically connected to the second terminal of the third resistor R3 and the first terminal of the fourth resistor R4, respectively.
[0047] The second terminal of the fourth resistor R4 serves as the control terminal of the MOS transistor switching unit.
[0048] In this embodiment, PMOS transistor V1 is a standard model. The third resistor R3 and the fourth resistor R4 are also standard resistors. In specific implementation, it is assumed that the operating power supply is 72V. The microcontroller's first output terminal outputs an enable signal. When the enable signal is high, the input and output terminals of the transistor control unit are connected. The third resistor R3 and the fourth resistor R4 divide the 72V voltage, creating a conduction voltage drop between the gate and source of PMOS transistor V1, thus turning on PMOS transistor V1. The 72V voltage is supplied to the electric vehicle controller through PMOS transistor V1. When the enable signal is low, the input and output terminals of the transistor control unit are cut off. The circuit containing the third resistor R3 and the fourth resistor R4 cannot form a current loop, and the third resistor R3 and the fourth resistor R4 cannot perform the voltage division function. Therefore, no conduction voltage drop is obtained between the gate and source of PMOS transistor V1, causing PMOS transistor V1 to turn off, and the electric vehicle controller is powered down.
[0049] In one possible implementation, the MOS transistor switching unit further includes a Zener diode D2;
[0050] The positive terminal of the Zener diode D2 is electrically connected to the gate of the PMOS transistor V1, and its negative terminal is electrically connected to the source of the PMOS transistor V1.
[0051] In this embodiment, the Zener diode D2 can be a conventional type. By adding the Zener diode D2 between the gate and source of the PMOS transistor V1, the voltage between the gate and source of the PMOS transistor V1 can be prevented from becoming too high due to static electricity or other reasons, which could damage the MOS transistor.
[0052] In one possible implementation, such as Figure 3 The display module includes a count display unit and a duration display unit.
[0053] In this embodiment, the count display unit and the duration display unit can be implemented using OLED screens. The selection button module, the increase button module, and the decrease button module are implemented based on the selection button, the increase button, and the decrease button, respectively. In one specific implementation, assuming the microcontroller's initial state is setting mode, the default selection is the number of power-on / off cycles, with an initial value of 10 cycles, an initial power-on duration of 10 seconds, and an initial power-off duration of 5 seconds. If the initial values meet the test requirements, the display mode can be switched by using the selection button (e.g., double-clicking). The microcontroller outputs an enable signal according to the settings, and automatically re-enters setting mode after completion. If the initial values do not meet the test requirements, in setting mode, any one of the power-on / off cycles, power-on duration, and power-off duration can be selected by using the selection button (e.g., single-clicking). The value is increased by using the increase button and decreased by using the decrease button until the set value meets the test requirements. Then, the display mode is switched by using the selection button (e.g., double-clicking). The microcontroller outputs an enable signal according to the settings, and automatically re-enters setting mode after completion. In display mode, the count unit can display the number of power-on / off cycles in real time, and the duration display unit can display the set power-on and power-off durations in real time. In setting mode, the count unit can display the set number of power-on / off cycles, and the duration display unit can display the set power-on and power-off durations.
[0054] This utility model also provides an electric vehicle controller reliability testing tool, including a PCB board and the electric vehicle controller reliability testing circuit as described above;
[0055] The electric vehicle controller reliability test circuit is located on the PCB board.
[0056] The above embodiments should not limit the present invention in any way. All technical solutions obtained by equivalent substitution or equivalent conversion fall within the protection scope of the present invention.
Claims
1. An electric vehicle controller reliability test circuit for testing the reliability of an electric vehicle controller for continuous power on and power off for a plurality of times, characterized by, It includes a microcontroller, a selection button module, a high-increase button module, a low-increase button module, a switch module, and a display module; The first input terminal of the microcontroller is electrically connected to the output terminal of the selection button module, its second input terminal is electrically connected to the output terminal of the up button module, its third input terminal is electrically connected to the output terminal of the down button module, its first output terminal is electrically connected to the enable control terminal of the switch module, and its second output terminal is electrically connected to the input terminal of the display module. The input terminal of the switch module is used to connect to the working power supply, and its output terminal is used to provide test power to the electric vehicle controller. The microcontroller is used to generate an enable signal based on the number of power-on / off cycles and the power-on and power-off durations set by the selection button module, the up button module, and the down button module. The switch module is used to control the number of on / off cycles and the on / off durations between its input and output terminals based on the enable signal.
2. The electric vehicle controller reliability test circuit of claim 1, wherein, The switching module includes a transistor control unit and a MOSFET switching unit; The control terminal of the transistor control unit serves as the enable control terminal of the switching module. Its input terminal is electrically connected to the control terminal of the MOS transistor switching unit, and its output terminal is electrically connected to ground. The input terminal of the MOS transistor switching unit serves as the input terminal of the switching module, and its output terminal serves as the output terminal of the switching module.
3. The electric vehicle controller reliability test circuit of claim 2, wherein, The transistor control unit includes a first resistor, a diode, a second resistor, and an NPN transistor; The first end of the first resistor serves as the control terminal of the transistor control unit, and its second end is electrically connected to the positive terminal of the diode. The negative terminal of the diode is electrically connected to the first terminal of the second resistor and the base of the NPN transistor, respectively. The second terminal of the second resistor is electrically connected to the emitter of the NPN transistor and grounded; The collector of the NPN transistor serves as the input terminal of the transistor control unit.
4. The electric vehicle controller reliability test circuit according to claim 2, characterized in that, The MOS transistor switching unit includes a PMOS transistor, a third resistor, and a fourth resistor; The drain of the PMOS transistor serves as the output terminal of the MOS transistor switching unit, its source is electrically connected to the first terminal of the third resistor and serves as the input terminal of the MOS transistor switching unit, and its gate is electrically connected to the second terminal of the third resistor and the first terminal of the fourth resistor, respectively. The second end of the fourth resistor serves as the control terminal of the MOS transistor switching unit.
5. The electric vehicle controller reliability test circuit of claim 4, wherein, The MOS transistor switching unit also includes a Zener diode; The positive terminal of the Zener diode is electrically connected to the gate of the PMOS transistor, and its negative terminal is electrically connected to the source of the PMOS transistor.
6. The electric vehicle controller reliability test circuit of claim 1, wherein, The display module includes a count display unit and a duration display unit.
7. An electric vehicle controller reliability test tool, characterized by, Includes a PCB board and an electric vehicle controller reliability test circuit as described in any one of claims 1 to 6; The electric vehicle controller reliability test circuit is located on the PCB board.