An offline testing device for high-voltage components

Abstract

This utility model discloses an offline testing device for high-voltage components, comprising: a high-voltage simulation unit outputting a DC voltage of 330V or higher; a discharge load resistor connected to the high-voltage output interface of the high-voltage component; a protocol playback unit with host computer software and a CAN analyzer for communication; a test box and a signal simulation unit located inside the test box, simulating CP and CC signals; a safety monitoring unit, with a pointer-type voltmeter and a digital display voltmeter connected in parallel; a low-voltage conversion unit, with a 12V switching power supply connected to the low-voltage power interface of the high-voltage component; and a temperature sensing unit, with a 10kΩ resistive element simulating the feedback temperature signal.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage component testing technology for new energy vehicles, and specifically to an offline testing device for high-voltage components. Background Technology

[0002] High-voltage components in new energy vehicles (including on-board chargers (OBC), air conditioning compressors, power battery packs, and motor controllers) are core systems for the safe operation of the entire vehicle. During maintenance or production testing, high-voltage components require functional verification to ensure their performance meets standards. However, this verification process involves reinstalling the high-voltage components back into the vehicle, which is complex and consumes significant production line resources. Large testing platforms are difficult to move and cannot support rapid deployment in remote repair shops or training scenarios. Current offline testing technologies also have the following drawbacks: traditional testing equipment cannot accurately simulate real-world operating conditions; it lacks a reliable discharge circuit design, easily leading to high-voltage accumulation under no-load conditions and posing a risk of electric shock; it lacks integrated multi-level voltage monitoring, making it unable to respond to overvoltage / overcurrent faults in real time; and the testing process cannot reproduce the dynamic charging logic of the entire vehicle. Utility Model Content

[0003] This utility model is provided to solve the above-mentioned technical problems.

[0004] An offline testing device for high-voltage components, including an on-board charger, an air conditioning compressor, a power battery pack, and a motor controller, comprising:

[0005] High voltage simulation unit: High voltage power supply, outputting DC voltage above 330V, connected to the high voltage input interface of high voltage components;

[0006] Discharge load resistor: a high-power wire-wound resistor connected to the high-voltage output interface of high-voltage components;

[0007] Protocol playback unit: host computer software and CAN analyzer, communication interface connected to high-voltage components;

[0008] Test chamber and unit modules located within the test chamber:

[0009] Signal simulation unit: includes a CP signal module composed of a PWM signal generator and a CC signal module composed of 680Ω resistors, which are only connected to the signal terminals of the on-board charger;

[0010] Safety monitoring unit: A pointer-type voltmeter and a digital display voltmeter are installed in parallel on high-voltage DC lines, low-voltage DC lines and AC mains lines;

[0011] Low-voltage conversion unit: 12V switching power supply, connecting to the low-voltage power interface of high-voltage components;

[0012] Temperature sensing unit: 10kΩ resistive element, connected only to the on-board charger.

[0013] Furthermore, when testing the air conditioner compressor, the signal simulation unit and temperature sensing unit are disabled;

[0014] When testing the power battery pack, disable the signal simulation unit, temperature sensing unit, and high voltage simulation unit.

[0015] When testing the motor controller, disable the signal simulation unit and temperature sensing unit, and enable the three bleed load resistors to be connected across the three-phase output terminals of the motor controller.

[0016] Furthermore, the discharge load resistor is a wire-wound resistor with a rated power of 5000W and a resistance of 200Ω.

[0017] Furthermore, the PWM signal generator can support independent adjustment of duty cycle, frequency, and output voltage, with a duty cycle adjustment range of 0%-97% and a frequency adjustment range of 1kHz-8kHz.

[0018] Furthermore, the protocol playback unit collects standard CAN messages through the original vehicle communication diagnostic interface and stores them in the host computer software, supporting offline playback to trigger the working program of high-voltage components.

[0019] Furthermore, the safety monitoring unit also includes circuit breakers installed on the high-voltage DC line, low-voltage DC line, and AC mains line.

[0020] Furthermore, the high-voltage power supply is model DQ-4000S-1000, the bleeder load resistor is model RX20T-5000W / 200RJ, the CAN analyzer is model CANalyst-II, the 12V switching power supply is model S-200-12, and the PWM signal generator is model STM_OSC.

[0021] This invention uses a protocol playback unit (host computer software + CAN analyzer) to pre-store and play back standard CAN messages from multiple vehicle models, breaking through the closed communication protocol barrier of car manufacturers; combined with a dynamically adjustable CP signal (duty cycle 0%-97%, frequency 1kHz-8kHz), it accurately simulates the interaction scenarios of different charging piles (vehicle charger / wall-mounted charging pile / base-mounted charging pile), solving the testing barrier caused by protocol closure.

[0022] The load discharge resistor actively consumes the output current after the high-voltage components have been working (such as the 450V current of the OBC), eliminating the accumulation of high voltage under no-load conditions; the dual-display monitoring instruments (pointer type + digital display) monitor the high-voltage input / output, low-voltage and mains lines in parallel, with a response speed of ≤50ms. The pointer meter captures transient anomalies (such as voltage drops) in real time, and the digital display meter records the values ​​accurately; four independent circuit breakers quickly disconnect fault circuits.

[0023] It can flexibly activate each unit module as needed according to different high-voltage components; some unit modules can be integrated into a portable test box to support rapid repair deployment in repair workshops / remote areas.

[0024] Therefore, this utility model has the following beneficial effects:

[0025] 1. Achieve accurate offline testing of high-voltage components across all scenarios: By combining the protocol playback unit with the dynamically adjustable CP signal, the closed limitations of automakers' communication protocols are broken, and the charging logic of the entire vehicle is accurately reproduced;

[0026] 2. Multiple safety protection mechanisms eliminate high voltage risks: The load resistor discharges the high voltage output current, and with the millisecond-level monitoring of the dual-display instrument and the trip protection, the risk of high voltage accumulation under no-load and electric shock is completely eliminated;

[0027] 3. Modular test box design improves testing efficiency and versatility: Modules are enabled according to the test object, and the test box structure is adaptable to deployment in multiple scenarios, significantly improving the efficiency of a single test. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the architecture of this utility model;

[0029] Figure 2 This is a schematic diagram of the electrical connections during the testing of the on-board charger according to this utility model;

[0030] Figure 3 This is a schematic diagram of the electrical connections during the testing of the air conditioner compressor according to this utility model;

[0031] Figure 4 This is a schematic diagram of the electrical connections during the testing of the power battery pack according to this utility model;

[0032] Figure 5 This is a schematic diagram of the electrical connection when testing the motor controller according to this utility model.

[0033] The diagram shows: 1. Test box; 2. High voltage power supply; 3. Discharge load resistor; 4. Signal simulation unit; 5. Low voltage conversion unit; 6. Safety monitoring unit. Detailed Implementation

[0034] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0035] This invention provides an offline testing device for high-voltage components, which can directly test high-voltage components individually without the need for testing the entire vehicle, and can simulate real-world operating conditions.

[0036] High-voltage components include on-board chargers, air conditioning compressors, power battery packs, and motor controllers.

[0037] The high-voltage component offline testing device of this utility model includes a high-voltage simulation unit, a discharge load resistor 3, a signal simulation unit 4, a protocol playback unit, a safety monitoring unit 6, a low-voltage conversion unit 5, and a temperature sensing unit.

[0038] Figure 1 The schematic diagram of the present invention shows the high voltage simulation unit and the discharge load resistor 3. The signal simulation unit 4, the safety monitoring unit 6, the low voltage conversion unit 5, and the temperature sensing unit are integrated and set in the test box 1. The high voltage simulation unit, the discharge load resistor 3, the test box 1, and the protocol playback unit together constitute a complete offline testing device for high voltage components.

[0039] The functional units used for testing different high-voltage components also differ, for example: Figure 2 As shown, when testing the on-board charger, all of the above functional units (i.e., high voltage simulation unit, bleed load resistor 3, signal simulation unit 4, protocol playback unit, safety monitoring unit 6, low voltage conversion unit 5, and temperature sensing unit) are required.

[0040] like Figure 3 As shown, when testing the air conditioner compressor, there is no need to use the signal analog unit and temperature sensing unit.

[0041] The high-voltage simulation unit includes an adjustable DC high-voltage power supply 2, such as... Figure 4 As shown, when testing the power battery pack, the high-voltage power supply 2 is not required.

[0042] like Figure 5 As shown, when testing the motor controller, two additional bleed load resistors 3 are required. In other words, three bleed load resistors 3 are used to connect across the three-phase output terminals (U / V / W) of the motor controller to dissipate the current between the three phases.

[0043] Therefore, this utility model integrates a high-voltage simulation unit, a discharge load resistor 3, a signal simulation unit 4, a protocol playback unit, a safety monitoring unit 6, a low-voltage conversion unit 5, and a temperature sensing unit, which enables offline testing of various high-voltage components.

[0044] The high-voltage simulation unit is an adjustable DC high-voltage power supply 2. The output terminal of the high-voltage power supply 2 is connected to the high-voltage input interface of the high-voltage component. The high-voltage power supply 2 can provide a stable DC voltage of 330V or above to simulate the voltage of the power battery pack, so that the high-voltage component can start the working program smoothly after the initial voltage signal is detected. The high-voltage power supply 2 can be a DC regulated power supply, whose input terminal is connected to the mains power, inputting AC220V±10% AC power, and inverter outputting DC power up to 1000V 4A, such as the DC regulated power supply model DQ-4000S-1000 of the brand "Dingqi".

[0045] The bleed load resistor 3 is a high-power wire-wound resistor that connects to the high-voltage output interface of the high-voltage component to form a complete high-voltage current loop. For example, the wire-wound resistor with model number RX20T-5000W / 200RJ can safely consume at least 5000W of power. The bleed load resistor 3 is used to consume the bleed current of the high-voltage component, ensuring that the current is released after the high-voltage component is working, solving the problem that the high-voltage component cannot work normally due to the accumulation of high voltage under no-load, and eliminating the risk of high-voltage electric shock.

[0046] like Figure 2 As shown, the protocol playback unit consists of host computer software capable of collecting and storing standard CAN messages from multiple vehicle models and a CAN analyzer. The host computer software and the CAN analyzer are connected to the original vehicle diagnostic port via CAN-L and CAN-H lines to obtain standard working messages, breaking through the protocol closure restrictions, pre-collecting standard messages from various vehicle models and storing them in the host computer software.

[0047] When testing high-voltage components, the host computer software and CAN analyzer are connected to the communication interface of the low-voltage interface of the high-voltage component via CAN-L and CAN-H lines to send corresponding messages, triggering the working program of the high-voltage component and realizing offline playback of messages to trigger the operation of the high-voltage component.

[0048] Currently, there are various host computer software and CAN analyzers on the market that can achieve the above functions. For example, the CAN analyzer with the model CANalyst-II from the brand "Zhuhai Chuangxin" and the corresponding "CANPro Protocol Analysis Platform" host computer software.

[0049] Low-voltage conversion unit 5 is a 12V switching power supply that provides 12V low-voltage DC power to high-voltage components. Its input terminal is connected to the mains power, and its output terminal is connected to the low-voltage power interface of the high-voltage components. Low-voltage conversion unit 5 can invert the input AC220V AC power to output DC12V DC power, such as the "Hongming" brand model S-200-12 switching power supply.

[0050] The signal simulation unit 4 is only connected and used when testing the on-board charger. It includes a CP signal module and a CC signal module. The CP signal module simulates the wake-up and handshake signal interaction between the charging gun and the on-board charger, and the CC signal module simulates the connection confirmation of the charging gun, so that the on-board charger can properly recognize the charging gun.

[0051] The CP signal module consists of a PWM signal generator, which is provided with a 12V operating voltage by the low-voltage conversion unit 5. The output of the CP signal module is connected to the signal terminal of the low-voltage interface of the vehicle charger. The PWM signal generator can output a square wave signal and supports independent adjustment of duty cycle, frequency, and output voltage. It can cover the entire charging scenario from slow charging to fast charging and accurately reproduce the interactive scenarios of different charging piles (vehicle charger / wall pile / station pile). The PWM signal generator can be a device that can generate square waves that is currently available on the market, such as the STM_OSC oscilloscope from the brand "Aiersai", which has a duty cycle adjustment range of 0%-97% and a frequency adjustment range of 1kHz-8kHz.

[0052] The CC signal module is a 680Ω resistor. One end of it is connected to the corresponding signal terminal of the low-voltage interface of the on-board charger, and the other end can be connected to the ground of the on-board charger's casing. It is used to simulate and detect the resistance of the charging cable to confirm that the charging gun is properly connected to the vehicle.

[0053] The temperature sensing unit is only connected and used when testing the on-board charger. It is a 10kΩ resistor. One end of the resistor is connected to the corresponding terminal of the low-voltage interface of the on-board charger, and the other end can be connected to the ground of the on-board charger's casing. It simulates the NTC temperature of the charging socket contact and the feedback signal of the on-board charger detecting the charging environment temperature.

[0054] Safety monitoring unit 6 integrates multi-level voltage monitoring and responds in real time to overvoltage / overcurrent faults; pointer-type voltmeters and digital voltmeters for measuring high voltage DC are installed on the high voltage DC lines of high voltage power supply 2 and bleed load resistor 3; pointer-type voltmeters and digital voltmeters for measuring low voltage DC are installed on the low voltage DC line of low voltage conversion unit 5; and pointer-type voltmeters and digital voltmeters for measuring 220V AC are installed on the AC 220V AC mains power line.

[0055] The pointer-type and digital voltmeters on the above four lines constitute safety monitoring unit 6, capable of real-time monitoring of key voltage points with a response time of ≤50ms. The digital voltmeters provide a clear and intuitive display of voltage values ​​for easy monitoring, while the pointer-type voltmeters offer zero latency and can respond in real-time in certain testing scenarios, instantly identifying abnormal fluctuations such as sudden voltage drops or large waveform changes. Furthermore, each of these four lines is equipped with a circuit breaker to ensure testing safety and proper operational procedures.

[0056] High-voltage component testing procedures:

[0057] First, prepare for message transmission. Connect the CAN analyzer to the corresponding communication diagnostic interface of the original vehicle via CAN-H and CAN-L cables. Insert the charging gun and check if the instrument panel indicates normal charging. If normal, use the host computer software to directly collect messages, save the collected messages, and name and label them.

[0058] Then, the various lines are connected, and after collecting the original vehicle messages, the host computer software and CAN analyzer are connected to the low-voltage communication interface of the high-voltage component via CAN-H and CAN-L lines, waiting to send messages to start the working program of the high-voltage component; the low-voltage conversion unit 5 is connected to AC220V mains power and connected to the low-voltage power interface of the high-voltage component to provide 12V DC power to the high-voltage component; depending on the high-voltage component under test, the high-voltage power supply 2 and the discharge load resistor 3 in the high-voltage simulation unit are selectively added or removed from the high-voltage interface of the high-voltage component to simulate the high-voltage current loop; if testing the OBC, the signal simulation unit and the temperature sensing unit are both connected to the low-voltage interface.

[0059] Finally, the test begins. Taking the OBC test as an example, a low-voltage 12V DC power supply is first supplied, and the low-voltage voltmeter is observed to ensure it displays normally. The high-voltage power supply switch is then turned on and adjusted to a stable 330V DC high voltage. After the DC / DC converter starts working, the low-voltage DC voltmeter displays a voltage of 11.3V-13V. The signal simulation unit and temperature sensing unit are then activated to simulate the CP, CC, and temperature signals. The host computer software is opened, and the baud rate, frame rate, and time are set. The message is then sent to start the high-voltage component. The voltmeter value set on the high-voltage power supply line 2 is observed. If the displayed voltage value fluctuates between 330V and 450V, it indicates that the corresponding high-voltage component has successfully started and is running. Then, the duty cycle, frequency, and output voltage are independently adjusted through the CP signal module to simulate and restore various charging scenarios and states. The safety monitoring unit 6 is used to observe the values, the host computer software reads and monitors the data, and the working status of the high-voltage component to test whether the high-voltage component is working normally.

[0060] This utility model is not limited to the above-described preferred embodiments. Any other products that are the same as or similar to this utility model and derived by anyone under the guidance of this utility model shall fall within the protection scope of this utility model.

Claims

1. An off-line testing device for high-voltage components, including an on-board charger, an air-conditioning compressor, a power battery pack, a motor controller, characterized in that, include: High voltage simulation unit: High voltage power supply, outputting DC voltage above 330V, connected to the high voltage input interface of high voltage components; Discharge load resistor: a high-power wire-wound resistor connected to the high-voltage output interface of high-voltage components; Protocol playback unit: host computer software and CAN analyzer, communication interface connected to high-voltage components; Test chamber and unit modules located within the test chamber: Signal simulation unit: includes a CP signal module composed of a PWM signal generator and a CC signal module composed of 680Ω resistors, which are only connected to the signal terminals of the on-board charger; Safety monitoring unit: A pointer-type voltmeter and a digital display voltmeter are installed in parallel on high-voltage DC lines, low-voltage DC lines and AC mains lines; Low-voltage conversion unit: 12V switching power supply, connecting to the low-voltage power interface of high-voltage components; Temperature sensing unit: 10kΩ resistive element, connected only to the on-board charger.

2. The high-voltage component offline testing device according to claim 1, characterized in that: When testing the air conditioner compressor, disable the signal simulation unit and the temperature sensing unit. When testing the power battery pack, disable the signal simulation unit, temperature sensing unit, and high voltage simulation unit. When testing the motor controller, disable the signal simulation unit and temperature sensing unit, and enable the three bleed load resistors to be connected across the three-phase output terminals of the motor controller.

3. The high voltage component off-line testing device of claim 1, wherein: The discharge load resistor is a wire-wound resistor with a rated power of 5000W and a resistance of 200Ω.

4. The high voltage component off-line testing device of claim 1, wherein: The PWM signal generator can support independent adjustment of duty cycle, frequency, and output voltage. Its duty cycle adjustment range is 0%-97%, and its frequency adjustment range is 1kHz-8kHz.

5. The high-voltage component offline testing device according to claim 1, characterized in that: The protocol playback unit collects standard CAN messages through the original vehicle communication diagnostic interface and stores them in the host computer software, supporting offline playback to trigger the working program of high-voltage components.

6. The high voltage component off-line testing device of claim 1, wherein: The safety monitoring unit also includes circuit breakers installed on high-voltage DC lines, low-voltage DC lines, and AC mains lines.

7. The high voltage component off-line testing device of claim 1, wherein: The high-voltage power supply is model DQ-4000S-1000, the bleeder load resistor is model RX20T-5000W / 200RJ, the CAN analyzer is model CANalyst-II, the 12V switching power supply is model S-200-12, and the PWM signal generator is model STM_OSC.

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