A high and low temperature charging test system for electric vehicles

Abstract

The utility model discloses a kind of high-low temperature charging test systems of electric vehicle, including environment simulation cabin, sunlight simulator is provided in environment simulation cabin, temperature sensor, charging gun, charging pile connected with charging gun is equipped on the outside of environment simulation cabin, for real-time recording all test data, equipment state and vehicle CAN bus data notebook computer. The utility model structure is simple, and high operating convenience, it can accurately reproduce vehicle in laboratory environment under extreme conditions, such as high-low temperature, high humidity, sunlight intense irradiation, verify the reliable performance of each relevant system of vehicle by whole vehicle charging, and then provide complete experimental data, provide detailed data support for design engineer, drive the continuous optimization and iteration of product design;Integrated multiple charging guns simultaneously, can adapt to electric vehicle of different charging power, have for truck 2C, 4C, 8C even higher rate charging capacity, have good adaptability.

Description

Technical Field

[0001] This utility model relates to a high and low temperature charging test system for electric vehicles, belonging to the field of new energy vehicle charging system testing technology. Background Technology

[0002] With the global energy structure adjustment and the deepening of the "carbon peaking and carbon neutrality" initiative, electric vehicles, as the core carrier of low-carbon transformation in the transportation sector, are experiencing unprecedented market growth. Modern electric vehicles are no longer simply transportation tools, but rather "mobile intelligent terminals" and "large-scale energy storage devices" integrating power battery systems, high-voltage electric drive systems, complex thermal management systems, battery management systems (BMS), on-board chargers (OBC), and numerous electronic control units (ECUs). This fundamental change in attributes places extremely high demands on their functionality and reliability in complex and harsh environments.

[0003] Vehicle charging is one of the most direct and energy-intensive operating conditions for electric vehicles to interact with external energy networks. During this process, the coupling effects of extreme environmental conditions such as high temperature, high humidity, and strong sunlight pose a severe "stress test" to the relevant systems, specifically manifested as follows: (1) The impact of high temperature environment on power battery system: High temperature is the "enemy" of lithium-ion battery performance and life. When charging, the battery itself will generate a lot of heat. Combined with the high temperature of the environment, it is very easy to cause the battery to overheat. This will not only accelerate battery aging and capacity decay, but may also trigger the risk of thermal runaway. At the same time, the change of battery internal resistance at high temperature will affect the accurate estimation of battery state of charge (SOC) by BMS, which may lead to incomplete charging or overcharging risk. It may also lead to increased contact resistance of connector terminals and aging of insulation materials, causing local overheating, short circuit and other faults.

[0004] (2) The impact of high humidity environment on electrical safety and insulation performance: High humidity environment will significantly reduce the insulation strength of air and materials. At charging voltages of up to hundreds of volts, moisture may penetrate into the interior of high-voltage components, leading to a decrease in insulation resistance, leakage faults, and threats to personal safety. At the same time, it is also very easy to cause electrochemical corrosion in circuit boards, connectors and other parts, leading to functional failure. In addition, high humidity environment will also corrode metal parts, accelerating the corrosion rate of metal parts such as charging interfaces and body structural parts in high temperature and high humidity environment, affecting mechanical strength, conductivity and long-term reliability.

[0005] (3) The impact of strong sunlight: Strong solar radiation will cause the vehicle cabin to form a "greenhouse effect" in a short period of time, with the internal temperature rising sharply to over 70°C. This not only tests the weather resistance of the interior materials, but also forces the vehicle's air conditioning system to run at full capacity at the beginning or during charging to reduce the cabin temperature, thereby significantly increasing the vehicle's energy consumption and bringing additional burden to the thermal management and energy distribution system.

[0006] In summary, conducting vehicle charging tests under extreme conditions such as high temperature, high humidity, and strong sunlight is a crucial technical means to simulate real-world user scenarios, expose system design flaws, and verify the overall reliability and safety of vehicles. It directly relates to the safe and reliable promotion and application of electric vehicles across a wide geographical and climatic range, and is an indispensable part of the vehicle development and verification system. However, current technologies only provide a general overview of high and low temperature charging for new energy vehicles and simulate charging using battery packs. They cannot more accurately assess the reliability of various vehicle systems under extreme conditions such as high temperature, high humidity, and strong sunlight through full-vehicle charging. Especially as electric vehicles gradually evolve from the current mainstream 2C charging capacity to 4C, 8C, and even higher rates, the vehicle environment simulation chamber charging under these conditions requires continuous technological updates; current technologies cannot meet the testing needs of electric vehicles. Utility Model Content

[0007] Therefore, the purpose of this utility model is to provide a high and low temperature charging test system for electric vehicles, so as to at least solve the problems mentioned in the background art.

[0008] The objective of this utility model is achieved through the following technical solution: A high and low temperature charging test system for electric vehicles, comprising: An environmental simulation chamber, which is used to place the vehicle under test and conduct high and low temperature charging tests; A sunlight simulator is installed at the top of the environment simulation chamber for simulating strong sunlight exposure inside the chamber. Temperature sensors are arranged according to the thermal management points of the vehicle under test. The temperature sensors are connected to temperature data acquisition and analysis equipment and are used to monitor the temperature of the vehicle under test while it is charging. A charging gun is installed inside the environmental simulation chamber and corresponds to the position of the vehicle under test. The charging gun is connected to the charging pile through a charging cable that passes through the side panel of the environmental simulation chamber. A rotating hub, which is located at the bottom of the environmental simulation chamber and adapted to the vehicle under test, is used for the discharge operation of the vehicle under test. The laptop computer is equipped with a CAN data reading and analysis module for real-time recording of all test data, equipment status, and vehicle CAN bus data.

[0009] Furthermore, the environmental simulation chamber is a vehicle environment simulation test chamber that can reproduce real or extreme environments within a closed chamber by controlling parameters such as temperature, humidity, air pressure, and gas composition.

[0010] Furthermore, the sunlight simulator includes a lamp stand with height adjustment function, a lamp plate at the lower end of the lamp stand, and a sunlight simulation light source on the lamp plate.

[0011] Furthermore, the sunlight simulator includes a lamp stand with height adjustment function, a lamp plate at the lower end of the lamp stand, and a sunlight simulation light source on the lamp plate.

[0012] Furthermore, the lamp holder can be adjusted automatically or manually.

[0013] Furthermore, the sunlight simulation light source consists of several infrared lamps mounted on a lamp panel, with dozens or more infrared lamps, each with a power of 1000-1500W and a light intensity of 300-1200 W / m².

[0014] Furthermore, the surface of the simulated sunlight light source is 1000-1500mm away from the surface of the vehicle being tested.

[0015] Furthermore, the number of charging guns is configured according to the needs of the vehicle being tested.

[0016] Furthermore, the number of charging guns is configured as single gun, dual gun, four guns, six guns, or more than six guns.

[0017] Furthermore, a left charging gun placement device and a right charging gun placement device are respectively provided on the left and right sides of the environment simulation chamber. The charging gun includes a left charging gun set on the left charging gun placement device and a right charging gun set on the right charging gun placement device. The charging cable includes a left charging cable and a right charging cable corresponding to the left charging gun and the right charging gun. A charging pile is provided on one side outside the environment simulation chamber. The left charging gun and the right charging gun are connected to the charging pile through the left charging cable and the right charging cable, respectively.

[0018] Compared with the prior art, the beneficial effects of this utility model are: (1) This utility model has a simple structure and is easy to operate. It can accurately reproduce the extreme conditions of the vehicle under high and low temperature, high humidity and strong sunlight in the laboratory environment. It can verify the reliability of the vehicle's various related systems by charging the whole vehicle, thereby providing complete experimental data, providing detailed data support for design engineers, and driving the continuous optimization and iteration of product design. (2) This utility model integrates a variety of charging guns, which can be adapted to electric vehicles with different charging power, and has the ability to charge trucks at 2C, 4C, 8C or even higher rates, and has good adaptability. (3) This utility model can verify the ability of the vehicle's power battery to output electricity to the grid in reverse under various temperature, humidity and light conditions. When the vehicle is idle, the charging pile uses peak and off-peak electricity prices to charge the vehicle when the price is low (such as in the early morning), and when the price is high, it sends the electricity from the vehicle's power battery back to the grid in reverse, i.e., V2G bidirectional charging and discharging. It can not only charge new energy vehicles, but also feed the power energy from the vehicle's power battery back to the grid when the grid needs it, thereby participating in the grid's peak shaving and potentially bringing certain economic benefits to the car owner.

[0019] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description

[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the following will describe this utility model in further detail with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the structure of an electric vehicle high and low temperature charging test system provided in an embodiment of the present invention.

[0021] In the diagram: 1. Environmental simulation chamber; 101. Wiring hole; 2. Sunlight simulator; 201. Lamp holder; 202. Lamp panel; 203. Sunlight simulation light source; 3. Temperature sensor; 4. Temperature data acquisition and analysis equipment; 5. Charging gun; 501. Left charging gun; 502. Right charging gun; 503. Left charging gun placement device; 504. Right charging gun placement device; 6. Charging cable; 601. Left charging cable; 602. Right charging cable; 7. Charging pile; 8. Rotary hub; 9. Laptop computer; 10. Test vehicle. Detailed Implementation

[0022] 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 scope of protection of the present utility model.

[0023] like Figure 1 As shown, the first embodiment of this utility model provides a high and low temperature charging test system for electric vehicles, comprising: Environmental simulation chamber 1, which is used to place the vehicle under test 10 and conduct high and low temperature charging tests; Sunlight Simulator 2 is located at the top of the Environment Simulation Chamber 1 and is used to simulate the strong sunlight environment inside the chamber. Temperature sensor 3 and temperature sensor 2 are arranged according to the thermal management points of the vehicle under test 10. Temperature sensor 3 is connected to temperature data acquisition and analysis equipment 4 and is used to monitor the temperature of the vehicle under test 10 during charging. The charging gun 5 is located inside the environmental simulation chamber 1 and corresponds to the position of the vehicle under test 10. The charging gun 5 is connected to the charging pile 7 through the charging cable 6 that passes through the side panel of the environmental simulation chamber 1. The rotating hub 8 is located at the bottom of the environmental simulation chamber 1 and is adapted to the vehicle under test 10 for the discharge operation of the vehicle under test 10. The laptop 9 is equipped with a CAN data reading and analysis module, which is used to record all test data, equipment status and vehicle CAN bus data in real time.

[0024] The environmental simulation chamber 1 is a common vehicle environmental simulation test chamber on the market. It can reproduce real or extreme environments within a closed chamber by controlling parameters such as temperature, humidity, air pressure, and gas composition. Specifically, the vehicle environmental simulation test chamber includes a high-insulation chamber structure, within which are configured a refrigeration system, a heating system, a humidification system, a dehumidification system, an air circulation system, and an intelligent control system connected to these systems. The high-insulation chamber structure uses high-strength, high-insulation polyurethane panels to ensure thermal insulation and airtightness. The chamber's main door must be large enough for vehicle entry and exit, and the structure includes observation windows with heating and anti-condensation functions, as well as an emergency safety door. The refrigeration system can be a cascade or two-stage compression refrigeration unit and evaporator. The heating system can be an armored electric heater unit. The humidification system can be a clean steam humidifier, and the dehumidification system can be a refrigeration dehumidification and rotary dehumidification system. The air circulation system consists of a variable frequency fan, air ducts, and air filters. The variable frequency fan provides a stable airflow to simulate the wind effect when a vehicle is driving. The air ducts ensure the uniformity of the temperature and velocity fields inside the chamber. The air filters ensure that the air entering the test chamber is clean and prevent contamination of samples or clogging of equipment.

[0025] The sunlight simulator 2 includes a lamp holder 201 with height adjustment, a lamp panel 202 at the lower end of the lamp holder 201, and a sunlight simulation light source 203 mounted on the lamp panel 202. Both the lamp holder 201 and the lamp panel 202 are made of aluminum alloy. The adjustment of the lamp holder 201 can be automatic or manual via temperature control of the vehicle surface. The sunlight simulation light source 203 consists of several infrared lamps mounted on the lamp panel. There are dozens or more infrared lamps, each with a power of 1000-1500W and a light intensity of 300-1200W / m². The distance between the light source surface and the surface of the vehicle under test is 1000-1500mm. The sunlight simulator 2 primarily conforms to standards GB / T 2423.24 "Environmental Testing Part 2-5: Test Sa: Ground Simulated Solar Radiation" and SAE J2527 "Solar Simulation Exposure Test Procedure".

[0026] The lamp holder 201 can be a manual lifting frame, an electric telescopic pole structure, an electric lifting truss, etc. The lamp holder 201 can be adjusted in height according to the height of the vehicle 10 being tested, the surface temperature of the vehicle 10 being tested, etc.

[0027] Temperature sensor 3 is arranged according to the thermal management points of the vehicle being tested 10, such as the air conditioning vent, inside the battery pack cooling pipe, etc.

[0028] The number of charging guns 5 is configured according to the overall vehicle development requirements, and can be configured as single gun, dual gun, four gun, six gun or more.

[0029] Currently, light trucks have dual-gun charging, meaning one charging port on each side of the vehicle, while heavy trucks have 4, 6, or 8 charging guns, generally evenly distributed on both sides of the heavy truck. Depending on usage requirements, the charging gun 5 includes a left charging gun 501 and a right charging gun 502, and the charging cable 6 includes a left charging cable 601 and a right charging cable 602 corresponding to the left and right charging guns 501 and 502, respectively. A charging pile 7 is located on one side of the environmental simulation chamber 1. The left charging gun 501 is connected to the charging pile 7 via the left charging cable 601, and the right charging gun 502 is connected to the charging pile 7 via the right charging cable 602. Specifically, a left charging gun placement device 503 and a right charging gun placement device 504 are respectively located on the left and right sides of the environmental simulation chamber 1. Several placement seats are provided on the upper part of the left and right charging gun placement devices 503 and 504, the number of which is arranged according to the number of charging guns. The lower part is welded to the bottom plate of the environmental simulation chamber 1, ensuring a secure and reliable connection. The left charging gun placement device 503 and the right charging gun placement device 504 are generally made of aluminum alloy.

[0030] The charging pile 7 is a common type of electric vehicle charging pile on the market, equipped with an emergency stop button, a charging status control display screen, etc. The charging status control display screen is used to display the charging status. Generally, when fully charged, the entire ring will be green. During the charging process, a portion of the green ring will be displayed according to the percentage. A fault will turn red, and the settings are defined according to the system.

[0031] The charging pile 7 is installed on the left or right side of the environmental simulation chamber 1, close to the chamber 1. Two cable holes 101 are provided on the side panel of the environmental simulation chamber 1 near the charging pile 7. The left charging cable 601 corresponding to the left charging gun 501 and the right charging cable 602 corresponding to the right charging gun 502 pass through the corresponding cable holes 101 and connect to the charging pile 7. After the left charging cable 601 and right charging cable 602 pass through the cable holes 101, they are sealed with soft soil and then hardened, providing high temperature and humidity resistance and good heat insulation performance. The left charging cable 601 and right charging cable 602 can be air-cooled or liquid-cooled charging cables, supporting megawatt flash charging. The rotating drum 8 is a test platform that simulates road resistance by rotating a drum and reproduces real driving conditions in conjunction with a loading system. The rotating drum 8 can be used for light vehicles or heavy vehicles. It can be detachably fixed in the middle of the bottom surface of the environmental simulation chamber 1, which makes it easy to configure different rotating drums according to different vehicles, thus improving adaptability.

[0032] The test method based on the above-mentioned high and low temperature charging test system for electric vehicles includes the following steps: First, the vehicle under test 10 is driven into the environmental simulation chamber 1, and the wheels of the vehicle under test 10 are connected to the rotating hub 8 to perform the discharge operation of the vehicle under test 10. Secondly, a vehicle simulation environment is set up according to the test requirements, so that the vehicle under test 10 is placed in the simulation environment for a certain period of time and then charged by the charging pile 7. The vehicle simulation environment includes one or more extreme conditions such as high temperature, high humidity, high humidity, and strong sunlight. Finally, the reliability of various vehicle systems was verified by charging the entire vehicle under extreme conditions, and various charging data of the entire vehicle were collected through the CAN communication line.

[0033] Specific verification methods include: S1. Under normal temperature conditions, the test vehicle 10 is discharged to SOC=5% using the matching rotating hub 8; S2. Adjust the temperature inside the environmental simulation chamber 1 to +10℃~+60℃, turn on the sunlight simulator 2, and adjust the light intensity of the sunlight simulator 2 (300~1200 W / m²) to 50~100% of its range, stepless adjustment; S3. In this state, the vehicle under test 10 is charged, and the thermal management capability of the cooling unit of the entire vehicle in the charging state is collected by multiple temperature sensors 3. S4. After setting the temperature inside the environmental simulation chamber 1 to normal temperature, let the vehicle under test 10 sit for a period of time, and then discharge the battery of the vehicle under test 10 to SOC=5% again through the rotating hub 8; S5. Adjust the temperature inside the environmental simulation chamber 1 to -60℃~+60℃, turn off the sunlight simulator 2 throughout the process, and leave the vehicle under test 10 stationary for a period of time. S6. In this state, the vehicle under test 10 is charged, and various charging data of the whole vehicle are collected through the CAN communication line.

[0034] In steps S1 and S4, after each test, the temperature inside the environmental simulation chamber 1 must be set to normal temperature, and the vehicle under test 10 must be left for more than 2 hours. Then, the battery of the vehicle under test 10 is discharged to SOC=5% through the rotating hub 8 before a new round of testing is conducted.

[0035] After discharging the battery of the vehicle under test to SOC=5%, repeat steps S2-S3 to conduct charging tests on the whole vehicle under conditions of 10℃, 25℃, 45℃ and 60℃, while simultaneously turning on the Sunshine Simulator 2.

[0036] After discharging the battery of the vehicle under test to SOC=5%, repeat steps S5-S6 to conduct whole vehicle charging tests under conditions of -60℃, -40℃, -20℃, 25℃, 45℃, and 60℃, while keeping the Sunshine Simulator 2 completely off.

[0037] In steps S5-S6, the temperature inside the environmental simulation chamber 1 is adjusted to the corresponding simulated temperature, the sunlight simulator 2 is turned off throughout the process, and the vehicle under test 10 is left to stand still for more than 12 hours. Under this state, the vehicle under test 10 is charged, and various charging data of the whole vehicle are collected through the CAN communication line.

[0038] The above description is merely a preferred embodiment of the present utility model and is not intended to restrict the present utility model in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments without departing from the technical solution of the present utility model and based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A high and low temperature charging test system for electric vehicles, characterized in that, include: An environmental simulation chamber (1) is used to place the vehicle under test (10) and conduct high and low temperature charging tests. A sunlight simulator (2) is installed at the top of the environment simulation chamber (1) for simulating the strong sunlight environment inside the chamber. Temperature sensor (3), the temperature sensor (3) is arranged according to the thermal management points of the vehicle under test (10), the temperature sensor (3) is connected to the temperature data acquisition and analysis device (4) and is used to monitor the temperature of the vehicle under test (10) in the charging state. Charging gun (5), the charging gun (5) is set inside the environmental simulation chamber (1) and corresponds to the position of the vehicle under test (10). The charging gun (5) is connected to the charging pile (7) through the charging cable (6) that passes through the side plate of the environmental simulation chamber (1). Rotating hub (8), which is located at the bottom of the environmental simulation chamber (1) and adapted to the vehicle under test (10), is used for the discharge operation of the vehicle under test (10); The laptop (9) is equipped with a CAN data reading and analysis module for real-time recording of all test data, equipment status and vehicle CAN bus data.

2. The electric vehicle high and low temperature charging test system according to claim 1, characterized in that, The environmental simulation chamber (1) is a vehicle environment simulation test chamber that can reproduce real or extreme environments in a closed chamber by controlling temperature, humidity, air pressure and gas composition parameters.

3. The electric vehicle high and low temperature charging test system according to claim 1, characterized in that, The sunlight simulator (2) includes a lamp stand (201) with height adjustment function, and a lamp plate (202) is provided at the lower end of the lamp stand (201). A sunlight simulation light source (203) is provided on the lamp plate (202).

4. The electric vehicle high and low temperature charging test system according to claim 3, characterized in that, The lamp holder (201) can be adjusted automatically or manually.

5. The electric vehicle high and low temperature charging test system according to claim 3, characterized in that, The sunlight simulation light source (203) consists of several infrared lamps set on the lamp panel. The number of infrared lamps is more than dozens, and each infrared lamp is 1000-1500W with a light intensity of 300-1200 W / m².

6. The electric vehicle high and low temperature charging test system according to claim 5, characterized in that, The surface of the simulated sunlight light source (203) is 1000-1500mm away from the surface of the vehicle under test (10).

7. The electric vehicle high and low temperature charging test system according to claim 1, characterized in that, The number of charging guns (5) is configured according to the needs of the vehicle under test (10).

8. The electric vehicle high and low temperature charging test system according to claim 7, characterized in that, The number of charging guns (5) is configured as single gun, double gun, four guns, six guns or more.

9. The electric vehicle high and low temperature charging test system according to claim 8, characterized in that, A left charging gun placement device (503) and a right charging gun placement device (504) are respectively provided on the left and right sides of the environment simulation chamber (1). The charging gun (5) includes a left charging gun (501) on the left charging gun placement device (503) and a right charging gun (502) on the right charging gun placement device (504). The charging cable (6) includes a left charging cable (601) and a right charging cable (602) corresponding to the left charging gun (501) and the right charging gun (502). A charging pile (7) is provided on one side outside the environment simulation chamber (1). The left charging gun (501) and the right charging gun (502) are connected to the charging pile (7) through the left charging cable (601) and the right charging cable (602) respectively.

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