DC Meter Test Bench with Split Current and Voltage Paths
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Solution Overview
Problem
Conventional test benches for high-power DC charging stations face significant challenges in meeting space, cost, and safety requirements, particularly when testing DC meters, and require substantial power electronics, making them inefficient and costly.
Innovation Solution
A compact test concept with remote access for automated testing, utilizing a hardware-in-the-loop setup with separate current and voltage paths, and a TN network configuration to reduce power source insulation requirements, allowing for efficient measurement and calibration without the need for high-power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional test benches are used for high-power DC charging stations, then measurement capability is achieved, but space requirements and safety requirements increase dramatically
Solution Approach 1:
The patent divides the test bench into separate current path and voltage path components. The current path includes a current source and current sensor, while the voltage path includes a voltage source and voltage sensor. This segmentation allows independent testing of each path without requiring full high-power capability in both paths simultaneously, reducing space and safety requirements.
Solution Approach 2:
The patent introduces a charging station under test as an intermediary component between the test bench and the measurement system. The charging station's own power electronics are utilized to provide the necessary power during testing, eliminating the need for a large dedicated high-power source in the test bench itself.
2Measurement precision
If high-power sources are provided for testing DC meters, then measurement accuracy is improved, but cost and energy requirements increase considerably
Solution Approach 1:
The charging station under test provides its own power during the testing process using its integrated power electronics. The test bench only needs to provide measurement capabilities and control functions, not the full power required for operation. This self-service approach dramatically reduces the energy requirements and cost of the test bench.
3Measurement precision
If separate current and voltage paths are implemented, then contact resistance measurement is enabled, but device complexity increases
Solution Approach 1:
The test bench is segmented into distinct current path components (current source, current sensor) and voltage path components (voltage source, voltage sensor). This segmentation enables separate measurement of contact resistance in each path while keeping the overall device complexity manageable through modular design and independent control of each path.
4Ease of repair
If automated testing with remote access is implemented, then error analysis and maintenance are simplified, but communication requirements increase
Solution Approach 1:
The test bench includes automated testing capabilities with remote access through communication interfaces that transmit test data and results. This feedback mechanism allows operators to analyze errors and perform maintenance remotely without being physically present at the test bench, simplifying operations while the communication infrastructure handles the increased data transmission requirements.
Data Source
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AI summary
The invention provides a method for testing a DC meter (11, 12) in a charging station, comprising the following features: A current source (31) and a voltage source (32) are connected to a TN system at their outputs; current is short-circuited by means of the current source (31) into a first busbar of the charging station (10) and back to the current source (31) via a charging cable (CCS2-, CCS2+) of the charging station (10); a voltage is applied in an open circuit between the first busbar and a second busbar of the charging station (10) by means of the voltage source (32); and a power measurement obtained by the DC meter (11, 12) by measuring the current and voltage is verified by means of a power meter (33). The invention further provides a corresponding test bench (30), a corresponding computer program, and a corresponding storage medium.