A non-passenger car charger aging test rack

Abstract

The utility model discloses a kind of non-passenger car charger aging test racks, including ac input module and input busbar row, it is characterized by: the input busbar row is equipped with port one, port two, port three, port four and port five, the ac input module is electrically connected with the port one of the input busbar row, the port two of the input busbar row is electrically connected with ac area module, the port three and port four of the input busbar row are electrically connected with direct current area module respectively, the port five of the input busbar row is electrically connected with safety module, since using electric control module one, electric control module two, electric control module three, electric control module four and transformer, the required ac input for testing can be adapted to multiple voltage specifications, such as 220Vac, 110Vac, improve the ability of test stand to adapt to different specifications of measured product.

Description

Technical Field

[0001] This utility model relates to the field of aging test of non-passenger vehicle chargers, and in particular to an aging test rack for non-passenger vehicle chargers. Background Technology

[0002] With the widespread application of non-passenger vehicles (such as construction machinery, logistics vehicles, and special-purpose vehicles) in industries and logistics, the performance stability of their core energy supply component, the On-Board Charger (OBC), directly affects vehicle operation safety. Before leaving the factory, comprehensive aging tests are required to verify key indicators such as voltage compatibility and load tolerance. Currently, due to differences in application scenarios, non-passenger vehicle chargers have diverse requirements for test power specifications. They not only need to be compatible with 220Vac civilian AC voltage but also meet the requirements for 110Vac AC voltage testing in some special scenarios, while also covering different power type tests such as high-voltage DC load simulation and low-voltage DC power supply.

[0003] However, existing aging test benches mostly adopt a single-function design or only support fixed voltage output, lacking flexible voltage adjustment and power type switching capabilities. If different specifications of chargers need to be tested, the external transformer needs to be replaced and the wiring adjusted manually, which is cumbersome and prone to safety risks such as short circuits and power surges due to wiring errors. Some benches even require separate equipment to complete AC and DC tests, resulting in fragmented test processes, high equipment investment costs, and difficulty in adapting to the diversified test needs of non-passenger vehicle chargers. Utility Model Content

[0004] The purpose of this invention is to provide a non-passenger vehicle charger aging test fixture to solve the problem of poor adaptability mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution: An aging test fixture for a non-passenger vehicle charger includes an AC input module and an input busbar. The input busbar has ports one, two, three, four, and five. The AC input module is electrically connected to port one of the input busbar. Port two of the input busbar is electrically connected to an AC zone module. Ports three and four of the input busbar are respectively electrically connected to a DC zone module. Port five of the input busbar is electrically connected to a safety module.

[0006] Preferably, the AC zone module includes an electrical control module one, a transformer, an output busbar, an electrical control module two, and an AC output interface. The electrical control module one has a port six and a port seven. The electrical control module one is electrically connected to port two of the input busbar. The port six of the electrical control module one is electrically connected to the output busbar. The port seven of the electrical control module one, the transformer, and the output busbar are connected in series in sequence. The output busbar, the electrical control module two, and the AC output interface are connected in series in sequence.

[0007] Preferably, the DC zone module includes a load module array, an electronic control module three, a high-voltage DC interface, a switching power supply, an output branch line, an electronic control module four, and a low-voltage DC interface. The input busbar port three, the load module array, the electronic control module three, and the high-voltage DC interface are connected in series in sequence. The input busbar port four, the switching power supply, the output branch line, the electronic control module four, and the low-voltage DC interface are connected in series in sequence.

[0008] Preferably, the safety module includes a temperature control module and a safety component module, and the input busbar port five, the temperature control module and the safety component module are connected in series in sequence.

[0009] Preferably, the test fixture also includes a CAN communication module, a data acquisition module, and a central control host computer software. The data acquisition module acquires data from the AC output interface, the high-voltage DC interface, and the low-voltage DC interface. The CAN communication module enables CAN bus communication between the central control host computer software and the product under test. The central control host computer software is connected to both the CAN communication module and the data acquisition module.

[0010] The beneficial effects of this utility model are: 1. By employing control modules one, two, three, and four, along with a transformer, the test bench can adapt to multiple voltage specifications of the AC input required for testing, such as 220Vac and 110Vac. This improves the bench's ability to adapt to different specifications of tested products. Furthermore, due to the use of control modules one, two, three, and four, the bench can independently control the AC output, high-voltage DC input, and low-voltage DC output of 12 channels. This allows for simultaneous testing of 12 tested products, or arbitrary combinations of any number of products (less than 12). In case of an anomaly during testing, the testing of any product can be stopped independently, ensuring both testing safety and flexibility while improving testing efficiency. 2. Because the CAN communication module has 12 channels and supports bidirectional communication on the CAN bus, it can simultaneously test and control multiple products.

[0011] 3. A data acquisition module integrating AC and DC electrical parameter acquisition functions was implemented. It can acquire various AC and DC electrical parameters with high precision and high frequency, and transmit them to the host computer software in real time. Therefore, it can obtain the dynamic changes of electrical parameters in real time and accurately during the test process, providing comprehensive and accurate data support for test analysis. This facilitates the timely detection of electrical parameter anomalies, ensures the accuracy and reliability of the test, and provides strong data basis for subsequent optimization of test plans and evaluation of the performance of the equipment under test.

[0012] 4. Due to the design of the input busbar and load module array structure, and the selection of regenerative load modules, the peak power consumption only occurs during startup testing. As the product starts operating, the feedback loop is established, and the power consumption instantly drops to below 10% of the nominal power consumption. This significantly reduces energy consumption for aging tests, saves costs, and reduces the impact of grid fluctuations.

[0013] 5. Thanks to the central control host computer software, the rack lines and various devices can be flexibly controlled. During testing, the test plan is run automatically throughout the entire process, and the data acquisition and operation status are monitored in real time. Anomalies can be detected in a timely manner, test parameters can be adjusted, and data can be automatically collected and recorded to ensure stable test operation and reliable test results. Attached Figure Description

[0014] Figure 1 This is a circuit diagram of an embodiment of the present invention. Detailed Implementation

[0015] 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.

[0016] See Figure 1 This utility model provides an aging test rack for a non-passenger vehicle charger, including an AC input module and an input busbar. The input busbar has port one, port two, port three, port four and port five. The AC input module is electrically connected to port one of the input busbar. Port two of the input busbar is electrically connected to an AC zone module. Ports three and four of the input busbar are respectively electrically connected to a DC zone module. Port five of the input busbar is electrically connected to a safety module.

[0017] The AC input module, which includes an air plug, an AC circuit breaker, and a surge protector, is the power input of the entire test bench. It is responsible for introducing external AC power and ensuring the safety and stability of the power input through surge protection and other measures.

[0018] The input busbar serves as the core carrier for power distribution. It receives power from the mains and transmits it to various power-consuming parts, such as the AC and DC zones, thus playing a role in centralized power distribution. At the same time, it receives feedback output from the load module array, forming a complete internal power loop within the test bench.

[0019] Specifically, the AC zone module includes an electrical control module one, a transformer, an output busbar, an electrical control module two, and an AC output interface. The electrical control module one has a port six and a port seven. The electrical control module one is electrically connected to port two of the input busbar. The port six of the electrical control module one is electrically connected to the output busbar. The port seven of the electrical control module one, the transformer, and the output busbar are connected in series in sequence. The output busbar, the electrical control module two, and the AC output interface are connected in series in sequence.

[0020] The first electrical control module is connected to the input busbar. After receiving the input power, it performs preliminary electrical control processing on the power to form two-way line outputs: one outputs 220V voltage directly, and the other outputs 110V voltage through a transformer, so that the voltage transmitted to the output busbar can be selected in two levels.

[0021] The transformer is connected to the output busbar and is used to change the AC voltage level to meet the different voltage requirements of subsequent tests.

[0022] Among them, the second electrical control module performs 12 independent electrical control adjustments and finally outputs AC power that meets the test requirements through the AC output interface for testing 12 related devices.

[0023] The output busbar serves as a power transfer and transmission hub within the AC zone, connecting the power control module one, the transformer, and the power control module two, thereby enabling the orderly transmission of power among the various components within the AC zone.

[0024] Specifically, the DC zone module includes a load module array, an electronic control module three, a high-voltage DC interface, a switching power supply, an output branch line, an electronic control module four, and a low-voltage DC interface. The input busbar port three, the load module array, the electronic control module three, and the high-voltage DC interface are connected in series in sequence. The input busbar port four, the switching power supply, the output branch line, the electronic control module four, and the low-voltage DC interface are connected in series in sequence.

[0025] Among them, the third electrical control module is connected to 12 high-voltage DC input interfaces. Through electrical control processing, it transmits DC power to the load module of the corresponding channel, providing high-voltage DC power input to the load module array for load simulation on the high-voltage DC side of the test product.

[0026] The load module array receives high-voltage DC power from the electronic control module three, and can simulate different load conditions to perform high-voltage DC load testing on the device under test.

[0027] The switching power supply is connected to the input busbar and converts the input AC power into low-voltage DC power (24 / 12VDC).

[0028] The fourth electrical control module receives low-voltage DC power converted by the switching power supply, performs electrical control adjustment, transmits power through the output branch line, and finally outputs it through the low-voltage DC interface for testing products that require low-voltage DC power supply.

[0029] The output branch line is responsible for power transmission in the low-voltage DC branch, connecting the switching power supply, the electronic control module four, and the low-voltage DC interface, and is used to divide the low-voltage DC into 12 outputs.

[0030] Specifically, the safety module includes a temperature control module and a safety component module, and the input busbar port five, the temperature control module and the safety component module are connected in series in sequence.

[0031] The safety component module includes an emergency stop switch, audible and visual warning devices, and is associated with the power control module and other systems of the entire test bench. In case of an emergency, the emergency stop switch can quickly cut off the relevant power supply, and the audible and visual warning devices will issue an alarm to ensure the safety of the testing process.

[0032] The temperature control module consists of a temperature controller and a fan. It monitors the internal heat circulation of the test bench. When the internal temperature of the test bench is too high, the temperature controller controls the fan and other equipment to work, adjust the internal temperature of the test bench, and ensure that the test bench equipment operates in a suitable temperature environment.

[0033] Specifically, the test fixture also includes a CAN communication module, a data acquisition module, and a central control host computer software. The data acquisition module acquires data from the AC output interface, the high-voltage DC interface, and the low-voltage DC interface. The CAN communication module enables CAN bus communication between the central control host computer software and the product under test. The central control host computer software is connected to both the CAN communication module and the data acquisition module.

[0034] The CAN communication module is connected to the central control host computer software via a communication line and is also connected to the CAN bus of the product under test. This module enables CAN bus communication between the central control host computer software and the product under test, simulating communication between the BMS and the product, transmitting control commands, product status, and other information. With 12 independent CAN communication channels, it can meet the needs of simultaneous CAN communication testing or control of multiple products.

[0035] The data acquisition module is connected to the AC output interface of the AC zone, the high-voltage DC interface and the low-voltage DC interface of the DC zone, respectively. It is used to collect AC electrical parameters (such as voltage, current, frequency, power, etc.) output by the AC output interface and DC electrical parameters (such as voltage, current, power, etc.) output by the high-voltage DC interface and the low-voltage DC interface. At the same time, this module is connected to the host computer software of the central control through a communication line to transmit the collected electrical parameter data to the host computer software of the central control for data recording, analysis and monitoring.

[0036] The main control host computer software serves as the control core of the entire test bench. It is connected to the various electrical control modules and load module arrays in the AC and DC areas via communication lines, enabling functions such as parameter setting, status monitoring, and test process control for each module.

[0037] Working principle of this utility model: 1. Start the test bench. External AC power is connected through the AC input module and distributed through the input busbar.

[0038] 2. Provide low-voltage DC power supply. Power enters the low-voltage DC branch of the DC zone, is converted into low-voltage DC by the switching power supply, and then processed by the output branch and the electronic control module before being output from the low-voltage DC interface to provide low-voltage DC power supply to the product under test.

[0039] 3. Perform CAN communication with the product. The host computer software simulates BMS communication signals, establishes a communication connection with the product under test through the CAN communication module, sends instructions to the product, and receives feedback signals from the product.

[0040] 3. If a 220V AC test is performed, power enters the AC zone and, after a series of processes by control module one, the output busbar, and control module two, AC power is output from the AC output interface to power the product under test. If a test of other AC voltages (such as 110V) is performed, power enters the AC zone and, after a series of processes by control module one, the transformer, the output busbar, and control module two, AC power is output from the AC output interface to power the product under test.

[0041] 4. Conduct a high-voltage DC load test. Power enters the high-voltage DC branch in the DC zone, is transmitted to the load module array via the three-phase control module, and is converted into AC power and transmitted again to the input busbar for use by other block equipment.

[0042] 5. During testing, the data acquisition module continuously collects AC parameters (voltage, current, frequency, etc.) from the AC output interface and DC parameters (voltage, current, etc.) from the high-voltage DC interface and low-voltage DC interface, and transmits the collected data to the central control host computer software in real time. The central control host computer software displays and records this data in real time. If abnormal electrical parameters are detected, it can promptly issue an alarm or adjust the test parameters. The safety component module monitors in real time and triggers emergency stop and warning in case of emergency; the temperature control module monitors and adjusts the test bench temperature; the central control host computer software monitors the status of each module throughout the process, controls the test procedure, and records test data.

[0043] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A non-passenger vehicle charger aging test fixture, comprising an AC input module and an input busbar, characterized in that: The input busbar has ports one, two, three, four and five. The AC input module is electrically connected to port one of the input busbar. Port two of the input busbar is electrically connected to the AC zone module. Ports three and four of the input busbar are respectively electrically connected to the DC zone module. Port five of the input busbar is electrically connected to the safety module.

2. The aging test fixture for a non-passenger vehicle charger according to claim 1, characterized in that: The AC zone module includes an electrical control module one, a transformer, an output busbar, an electrical control module two, and an AC output interface. The electrical control module one has a port six and a port seven. The electrical control module one is electrically connected to port two of the input busbar. The port six of the electrical control module one is electrically connected to the output busbar. The port seven of the electrical control module one, the transformer, and the output busbar are connected in series in sequence. The output busbar, the electrical control module two, and the AC output interface are connected in series in sequence.

3. The aging test fixture for a non-passenger vehicle charger according to claim 2, characterized in that: The DC zone module includes a load module array, an electronic control module three, a high-voltage DC interface, a switching power supply, an output branch line, an electronic control module four, and a low-voltage DC interface. The input busbar port three, the load module array, the electronic control module three, and the high-voltage DC interface are connected in series in sequence. The input busbar port four, the switching power supply, the output branch line, the electronic control module four, and the low-voltage DC interface are connected in series in sequence.

4. The aging test fixture for a non-passenger vehicle charger according to claim 3, characterized in that: The safety module includes a temperature control module and a safety component module, and the input busbar port five, the temperature control module and the safety component module are connected in series in sequence.

5. The aging test fixture for a non-passenger vehicle charger according to claim 1, characterized in that: The test fixture also includes a CAN communication module, a data acquisition module, and a central control host computer software. The data acquisition module acquires data from the AC output interface, the high-voltage DC interface, and the low-voltage DC interface. The CAN communication module enables CAN bus communication between the central control host computer software and the product under test. The central control host computer software is connected to both the CAN communication module and the data acquisition module.

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