CN104375050B - Electric automobile high-voltage wire harness conduction automatic testing equipment - Google Patents
Electric automobile high-voltage wire harness conduction automatic testing equipment Download PDFInfo
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- CN104375050B CN104375050B CN201410585087.3A CN201410585087A CN104375050B CN 104375050 B CN104375050 B CN 104375050B CN 201410585087 A CN201410585087 A CN 201410585087A CN 104375050 B CN104375050 B CN 104375050B
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Abstract
The invention belongs to a kind of electric automobile high-voltage wire harness conduction automatic testing equipments.Its high-voltage connector is connect with high-voltage wiring harness；High-voltage wiring harness is connected by respective switching harness with relay matrix, and relay matrix is controlled by single-chip processor i/o mouth；The voltage value of Acquisition Circuit output is read using A/D inside microcontroller, and numerical value is acquired to judge each terminal conduction of high-voltage wiring harness high-voltage connector according to A/D.The present apparatus selects time response fast, small, low in energy consumption.While meeting function, the precision of test signal ensure that, while ensure that the safety of tester.The present invention quickly, accurately, really can judge that situation is connected in high-voltage wiring harness connector, on the basis of not changing the design of test circuit plate, as long as different high-voltage wiring harness high-voltage connector conduction tests can be completed in the corresponding switching harness of design, have the high feature of versatility, successfully solves the problems, such as that high-voltage wiring harness high-voltage connector conduction test is difficult.
Description
Technical field
The invention belongs to the detection device of automobile equipment, specifically a kind of electric automobile high-voltage wire harness conduction is tested automatically
Device.
Background technology
Electric automobile high-voltage wire harness plays electric energy transmission as the connection bridge between high voltage control box and high voltage electric device
Effect.Due to high-voltage wiring harness connection high-voltage electrical apparatus component it is more, so pin define it is more, therefore detect high-voltage wiring harness it is electrical
Connection is highly desirable with the presence or absence of problem or hidden danger.
Harness should be all carried out before high-voltage wiring harness product warehousing connects each high-voltage connector conduction test, since pin is more,
Define complicated, and existing contact pin has a jack again, and reviewer is tested using multimeter, causes period testing time long, and is needed
Pin definition is familiar with.
Its conduction is examined and determine by the way of manual work always at present.Existing manual testing, every time when test
It is both needed to artificial wiring, and compares pin and defines plug wire, it is time-consuming and inconvenient.Since pin is more, cause handling time long,
Testing result depends greatly on the technical merit and working experience of personnel.
The prior art mostly uses greatly multimeter, and connecting each high-voltage connector pin according to high-voltage wiring harness defines, to high pressure
Harness carries out continuity test one by one, and test every time is both needed to artificial wiring, the line inspection, time-consuming and inconvenient, and under-enumeration, mistake easily occurs
Look into phenomenon.Even if there is conduction automatic testing equipment, but all it is special test equipment, does not have versatility, it is difficult to meets practical
Testing requirement, and test equipment cost is very high, it is difficult to it is used for actual production.
High-voltage wiring harness conduction test always exists the objective difficulties such as test point is more, time requirement is tight.Conducting resistance is anti-
The break-make relationship between circuit point is mirrored, the qualified or not reliability for directly affecting high-voltage wiring harness of the magnitude directly affects institute
Can connection high-voltage electrical apparatus component work normally.
Therefore, develop it is a set of be based on control technology, have accuracy of detection is high, easy to operate, versatility is high, human interference because
The few high-voltage wiring harness conduction automatic testing equipment of element has very high use value.
Invention content
In order to overcome the drawbacks described above of current electric automobile high-voltage wire harness conduction test, the present invention to develop a kind of electronic
Automotive high voltage line beam conduction automatic testing equipment.
The technical scheme is that：
A kind of electric automobile high-voltage wire harness conduction automatic testing equipment connects high voltage control by each high-voltage connector respectively
Box, electric air-conditioning compressor controller, Vehicular charger, DC/DC converters and PTC controllers；The high-voltage connector with
High-voltage wiring harness connects；High-voltage wiring harness is connected by respective switching harness with relay matrix, by single-chip processor i/o mouth control after
Relay matrix；The voltage value of Acquisition Circuit output is read using A/D inside microcontroller, and numerical value is acquired to judge height according to A/D
Each terminal conduction of crimping beam high-voltage connector.
Relay matrix includes continuity test input terminal relay matrix SP1 and continuity test output end relay matrix.
The test output terminal of relay matrix connects an Acquisition Circuit, the voltage value that Acquisition Circuit obtains test output terminal
A/D mouthfuls are sent to inside microcontroller, and microcontroller judges that situation is connected in internal harness according to the voltage value of acquisition, and send LCD to show and lead
Understanding and considerate condition.
Continuity test input terminal relay matrix SP1 is connect with 5V power circuits, is surveyed in continuity test input terminal application+5V
Try voltage.
The relay of relay matrix is the general normally opened PhotoMOS of 2a types, is that LED is used in input element, output member
Using the semiconductor relay of the photoelectrical coupler of MOSFET in part.
The continuity test of this test device presses key control by test.
Microcontroller, Acquisition Circuit, LCD are also powered by 5V power circuit offers+5V；The 5V power circuits and AC input
Circuit connect, it is converted and+5V power supplys.
The solution have the advantages that：
Design switching harness, establishes high-voltage wiring harness measure loop.Specifically, it is exactly installation and tested high-voltage wiring harness phase
The high-voltage connector matched, manual mode are arranged the connection relation of cable, meet the test of different connector model high-voltage wiring harness.
The PhotoMOS relays for selecting time response fast, small, low in energy consumption constitute relay array, by microcontroller I/
O directly controls relay work, realizes the selection and switching of measured point.
Test is by after key pressing, you can proper testing is connected.
Respective algorithms are designed, and develop corresponding program, the break-make that the data of acquisition accurately reflect tested cable is enable to close
System, accurately measures conducting resistance.
The chip that the present invention uses fully meets power consumption demand, and has fully considered that EMC Design and electricity safety are set
Meter, while meeting function, ensure that the precision of test signal, while ensure that the safety of tester.
Repeat circuit of the present invention all using PhotoMOS relays, is directly controlled using single-chip processor i/o mouth, eliminate after
Electrical apparatus driving circuit reduces board design size, while using PhotoMOS relays, in the premise for meeting test request
Under, substantially increase test speed.
The present invention use microcontroller control for the continuity test circuit of core, can quickly, accurately, really judge high-voltage wiring harness
Situation is connected in connector.On the basis of not changing the design of test circuit plate, situation is defined according to different high-voltage wiring harness pins, only
It designs corresponding switching harness and different high-voltage wiring harness high-voltage connector conduction tests can be completed, have the high spy of versatility
Point successfully solves the problems, such as that high-voltage wiring harness high-voltage connector conduction test is difficult.
Description of the drawings
Fig. 1 high-voltage wiring harness schematic diagrames,
Fig. 2 high-voltage wiring harness connector terminals are correspondingly connected with relational graph,
Fig. 3 high-voltage wiring harness continuity test system block diagrams,
Fig. 4 continuity test input terminal relay matrix figures,
Fig. 5 continuity test output end relay matrix figures,
Fig. 6 SP1 control relay circuit figures,
Fig. 7 SW1 control relay circuit figures,
Fig. 8 MC9S08AC12864-Pin LQFP pinouts,
The circuit of Fig. 9 power modules.
Specific implementation mode
The present invention is on the basis of fully analysis high-voltage wiring harness connected high-voltage connector, design switching harness and relay
Matrix controls relay matrix, to test point application+5V DC voltages when test, using in microcontroller by single-chip processor i/o mouth
Portion A/D reads the voltage value of Acquisition Circuit output, and acquires numerical value according to A/D to judge each terminal of high-voltage wiring harness high-voltage connector
Conduction, and LCD is sent to show.The present invention makes full use of LCD to show, as long as high pressure can be completed according to operating instruction in tester
Harness conduction test grasps pin definition inside each high-voltage connector of high-voltage wiring harness without understanding.
The high-voltage wiring harness schematic diagram of the present invention is as shown in Figure 1, wherein J1 connection high voltage control boxes, J2 connection electric air-conditioning pressures
Contracting machine controller, J3 connection Vehicular chargers, J4 connection DC/DC converters, J5 connection PTC controllers.
The use of PhotoMOS relays is all this in high-voltage wiring harness conduction test mentality of designing and relay matrix
One of key technology point of invention.The present apparatus not only can guarantee high-voltage wiring harness conduction test demand, but also reduces and design and develop into
This.
Invention relay matrix is all made of Panasonic's PhotoMOS relays, is that LED is used in input element, output member
Using the semiconductor relay of the photoelectrical coupler of MOSFET in part.With traditional mechanical type relay it is maximum difference lies in：
PhotoMOS is a " photoelectrical coupler ", and contact is without mechanical opening and closing.Therefore, in reliability of contact, service life, action
There is remarkable characteristic in terms of sound, movement speed and size.
As shown in Figure 1, classify according to voltage class, high-voltage wiring harness connector terminal can be divided into two major classes：High pressure positive and negative electrode
Terminal, high-voltage interlocking terminal.Classify according to polarity of voltage, high-voltage wiring harness connector terminal can be divided into two major classes again：Positive terminal,
Negative terminal.As shown in Figure 1, there are 26 pins to define for high voltage harness connector, if harness connection error between connector, meeting
Related electric component is caused to can not work normally.
As shown in Figure 1, it is as shown in Figure 2 to be correspondingly connected with relationship for high-voltage wiring harness connector terminal.
According to fig. 2, high-voltage wiring harness connection test device is designed, design frame chart is as shown in Figure 3.The present invention is according to high-voltage line
Beam physical connection situation designs switching harness using with the matched connector of high-voltage wiring harness high-voltage connector, and designs relay
Matrix connects connector terminals connection wiring harness to be measured.After switching harness connection, after the completion of waiting system powers on, survey is pressed
Examination button can be tested.In figure 3, the high-voltage wiring harness being connect with each high-voltage connector is connected by respective switching harness
To relay matrix.
Key component of the relay matrix as the present invention comprising：Continuity test input terminal relay matrix is (see figure
4), continuity test output end relay matrix (see Fig. 5).By applying test voltage in continuity test input terminal in test process
The voltage value that test output terminal obtains is sent inside microcontroller A/D mouthfuls by+5V, Acquisition Circuit, and microcontroller is according to the voltage value of acquisition
Judge that situation is connected in internal harness, and send LCD display conducting situations.
Continuity test input terminal relay matrix SP1 selects Panasonic AQY211 Series P hotoMOS relays in Fig. 4, is used for
Control test input+5V is powered on.AQY211 continuous loads electric current up to 1.0A, when normal work LED current be 5~
10mA directly can use single-chip processor i/o mouth to drive, and control circuit design is as shown in Figure 6.LED conducting electric currents selection of the present invention
5.5mA or so ensures that LED is reliably connected, and LED forward conduction voltage drops are about 1.25V, so the resistance value of current-limiting resistance RSP1 is
680Ω。
For ease of controlling and saving circuit board space, and consider single-chip processor i/o mouth driving capability, is removed in relay matrix
Outside SP1, remaining relay selects Panasonic's AQW212EH relays, is the general normally opened PhotoMOS of 2a types.To ensure low work(
It consumes, operational amplifier circuit is designed using voltage follower in Fig. 5 Acquisition Circuits, and guarantee has higher input impedance and low-down output
Impedance ensures that U2 output voltage precision, U2 output voltages of the present invention are partial pressure value on R2.Divider resistance R1 and R2 in Acquisition Circuit
Take 3.3k Ω, in this way certain all the way continuity test when flow through the electric current of relay and be less than 1mA, it is continuous negative for AQW212EH relays
Electric current is carried up to 0.5A, fully meets testing requirement.When circuit to be tested is connected, the upper voltage drops of R2 are+2.5V, when to be tested
When circuit disconnects, the upper voltage drops of R2 are almost 0V, and microcontroller inside A/D is 2.5V or 0V according to U2 output voltages, to harness
Conduction judges.
LED current is 5~10mA when AQW212EH normal works simultaneously, directly single-chip processor i/o mouth can be used to drive.
AQW212EH output end conducting resistance average values are 0.83 Ω, the resistance value and switching harness self-resistance value and R1 and R2 phases
Than negligible.
By taking SW1 as an example, AQW212EH control circuits are as shown in Figure 7.LED conducting electric currents selection 5.5mA of the present invention or so, is protected
Card LED is reliably connected, and LED forward conduction voltage drops are about 1.25V, so the resistance value of current-limiting resistance RSW1 and RSW2 are 680 Ω,
The control circuit design principle and parameter of SW2~SW7 relays and SN1~SN7 relays are and SW1 control circuits keep one
It causes, to ensure the consistency and debugging convenience of relay matrix design.
Microcontroller of the present invention is encapsulated as 64-Pin LQFP, such as Fig. 8 institutes using Freescale MC9S08AC128 series
Show.Bus frequency with 128Kb flash memories, 16 channel 10 ADC and up to 20MHz, I/O is up to 54, and the monolithic
Machine use+5V power supplies ensure that entire low-voltage system power source design is unified, it is not necessary to be further added by power conversion module.
The present invention directly drives PhotoMOS relays using single-chip processor i/o mouth, wherein the single-chip processor i/o of driving relay
Mouth needs 29, and LCD data lines occupy 8 I/O mouthfuls, so MC9S08AC128I/O mouthfuls of quantity fully meet design requirement, and
There is surplus.Acquisition Circuit output voltage of the present invention is 0V or 2.5V, voltage fluctuation very little, it is contemplated that this test system is for A/D
Precision do not do excessive demand, so carrying out data acquisition using A/D inside MC9S08AC128, do not increase additional A/D chips,
Design requirement can be met.
Circuit feeder ear is all made of+5V power supplys in the present invention, and power module circuitry is as shown in Figure 9.Power module uses
DAS5-DC5-N isolated form AC/DC power modules ,+5V is provided for microcontroller, relay matrix, Acquisition Circuit, LCD.DAS5-
DC5-N input voltage ranges are AC165~265V, and output voltage is 5V DC, and output current much meets design need up to 1A
It asks.Working frequency 100kHz, efficiency>75%, input over voltage is protected, long-term self- recoverage, and isolation voltage Vin-Vo is reachable
2500V AC, the type of cooling are natural cooling.Power module has high power density, ultrathin design, small, multiple protective work(
The advantages that energy, integrated encapsulation strengthens anti-corrosion, moisture-proof, shockproof properties, while integrated encapsulation also adds thermal conductivity, to
Strengthen product reliability.
Under the premise of ensureing power module normal work, the Electro Magnetic Compatibility for considering power module emphatically is set the present invention
It counts, F1 (fuse), RV1 (varistor), C1 (X capacitances), L1 (differential mode inductance), L2 (differential mode electricity is increased in power circuit
Sense), C3 (high-frequency filter capacitor), C4 (low frequency filtering capacitance) design, ensure power module normal work under the premise of, examine simultaneously
The safe design and electromagnetic Compatibility Design for having considered power module, to ensure that the electricity safety and output 5V of test equipment
The quality of power supply, to ensure that the integrality of entire test circuit signal.
Mechanical relay may be selected in PhotoMOS relays in relay matrix, but compared with PhotoMOS relays,
Mechanical relay in reliability of contact, service life, movement speed, in terms of size do not have advantage.Microcontroller is also optional
Other microcontrollers are selected, individual A/D chips may be selected in Acquisition Circuit, if selecting individual A/D chips, and can increase test circuit
The size of plate.The resistance of other resistance values also may be selected in acquisition resistance.
The automatic testing procedure of electric automobile high-voltage wire harness conduction is：
1, switching connector connects AC input after installation is complete, and 5V voltages are exported after power module, and microcontroller powers on,
It is in running order；
2, after pressing test button, after System self-test 5s clocks, test is proceeded by, SP1 relays are first closed in test process
Device thus turns on test adaptor input terminal relay matrix load upper end electrification；
3, the output end that single-chip processor i/o mouth control SN1 relays are connected with J4-B is closed, and then single-chip processor i/o mouth controls
The output end that SW1 relays are connected with J1-A is closed, and after waiting for 2s clocks, ensures that SN1 and SW1 output ends are reliably closed, if at this time
Chip Microcomputer A/D collects+2.5V voltages, illustrates that the harness conduction that the road is connected is normal, if it is 0V left to collect voltage value
The right side illustrates that the harness that the road is connected is not turned on or is nearly at off-state, after test waits for 2s, drive test test result storage
To microcontroller built-in storage；Control disconnects the output end being connected with J1-A in SW1 relays, and then control disconnects SN1 relays
The output end being connected with J4-B；
4, according to step 3, to remaining connection wiring harness in Fig. 2, by detection ordering from left to right, harness conducting is completed one by one
Property test；
5, after step 4 completes 5s clocks, SP1 relays are disconnected；
6, step 2-5 testing process is repeated, second of test of high-voltage wiring harness conduction is completed；
7, scm software analyzes flash storage mesohigh harness conduction test data twice, and obtains high-voltage line
Each terminal conduction test of beam judges result；
8, each terminal conduction test judgement result of the high voltage control box is shown on LCD.
Claims (6)
1. electric automobile high-voltage wire harness conduction automatic testing equipment, respectively by each high-voltage connector connection high voltage control box, electricity
Move air conditioner compressed machine controller, Vehicular charger, DC/DC converters and PTC controllers；The high-voltage connector and high-voltage line
Beam connects；It is characterized in that：
High-voltage wiring harness is connected by respective switching harness with relay matrix, and relay matrix is controlled by single-chip processor i/o mouth；
The voltage value of Acquisition Circuit output is read using A/D inside microcontroller, and numerical value is acquired to judge high-voltage wiring harness high pressure according to A/D
Each terminal conduction of connector；
Relay matrix includes continuity test input terminal relay matrix and continuity test output end relay matrix, relay square
The test input of battle array passes through a relay SP1 connection power circuits；
Wherein, in electric automobile high-voltage wire harness conduction automatic testing process, first closing relay SP1 is so that continuity test is defeated
Enter to hold relay matrix load upper end electrification, when testing a high-voltage wiring harness to be measured, be closed continuity test output successively
It is waited for this in the relay and continuity test input terminal relay matrix that are connected with the high-voltage wiring harness to be measured in the relay matrix of end
The connected relay of high-voltage wiring harness is surveyed, obtains test result after waiting for preset time, and the test result is stored in the list
Piece machine built-in storage, and then the relay being connected with the high-voltage wiring harness to be measured in continuity test input terminal relay matrix is disconnected successively
The relay being connected with the high-voltage wiring harness to be measured in device and continuity test output end relay matrix, wherein the preset time
For 2s.
2. automatic testing equipment according to claim 1, it is characterised in that：The test output terminal connection one of relay matrix
The voltage value that test output terminal obtains is sent to inside microcontroller A/D mouthfuls by Acquisition Circuit, Acquisition Circuit, and microcontroller is according to acquisition
Voltage value judges that situation is connected in internal harness, and send LCD display conducting situations.
3. automatic testing equipment according to claim 1, it is characterised in that：Continuity test input terminal relay matrix passes through
Relay SP1 is connect with 5V power circuits, in continuity test input terminal application+5V test voltages.
4. automatic testing equipment according to claim 1, it is characterised in that：The relay of relay matrix is general 2a types
Normally opened Photo MOS are that LED is used in input element, using the semiconductor of the photoelectrical coupler of MOSFET in output element
Relay.
5. automatic testing equipment according to claim 1, it is characterised in that：The continuity test of this test device is pressed by testing
Key control.
6. according to the automatic testing equipment described in claim 1-5 any one, it is characterised in that：Microcontroller, Acquisition Circuit,
LCD is also powered by 5V power circuit offers+5V；The 5V power circuits are connect with AC input circuit, it is converted and+5V electricity
Source.
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| CN201410585087.3A CN104375050B (en) | 2014-10-27 | 2014-10-27 | Electric automobile high-voltage wire harness conduction automatic testing equipment |
Applications Claiming Priority (1)
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|---|---|---|---|
| CN201410585087.3A CN104375050B (en) | 2014-10-27 | 2014-10-27 | Electric automobile high-voltage wire harness conduction automatic testing equipment |
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| CN104375050B true CN104375050B (en) | 2018-09-11 |
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| CN105870895A (en) * | 2016-05-13 | 2016-08-17 | 广州金升阳科技有限公司 | Protection circuit for lightning surge |
| CN106324441A (en) * | 2016-11-08 | 2017-01-11 | 骆香山 | Cable detection system based on single chip |
| CN107102234B (en) * | 2017-05-25 | 2020-09-22 | 宁德时代新能源科技股份有限公司 | Detection device and method for voltage sampling wire harness of battery module |
| CN109030977B (en) * | 2018-06-01 | 2021-01-26 | 北京新能源汽车股份有限公司 | High-voltage wire breaking box and control method and control device thereof |
| CN108766089B (en) * | 2018-06-04 | 2020-10-30 | 浙江大学 | System and method for diagnosing wiring faults of electric circuit |
| CN111722613A (en) * | 2020-06-08 | 2020-09-29 | 江苏协和电子股份有限公司 | Automation equipment for burning and detecting PTC (positive temperature coefficient) controller of new energy automobile |
| CN113899756B (en) * | 2021-09-09 | 2024-03-22 | 东风柳州汽车有限公司 | High-voltage wire harness grouping test method, device, equipment and storage medium |
| CN114325482A (en) * | 2021-12-31 | 2022-04-12 | 江苏华凯比克希线束有限公司 | Method for efficiently detecting automobile wire harness conduction |
| CN115754892A (en) * | 2023-01-06 | 2023-03-07 | 山东计保电气有限公司 | Electric energy metering line checking and error correcting method and device |
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| JPH07159474A (en) * | 1993-12-08 | 1995-06-23 | Nissan Diesel Motor Co Ltd | Device for diagnosing electrical wiring of vehicle |
| CN2599595Y (en) * | 2003-01-16 | 2004-01-14 | 中国航空工业第一集团公司航空动力控制系统研究所 | Line pencil detector |
| CN1614440A (en) * | 2003-11-07 | 2005-05-11 | 上海燃料电池汽车动力系统有限公司 | Voltage measuring circuit of single accumulator |
| CN101937038B (en) * | 2009-07-02 | 2013-12-25 | 中国第一汽车集团公司无锡油泵油嘴研究所 | Intelligent multi-core cable harness detection device |
| CN201740832U (en) * | 2010-04-23 | 2011-02-09 | 武汉理工大学 | Integrated detection device of cab electrical appliance |
| CN201740833U (en) * | 2010-05-13 | 2011-02-09 | 三一重机有限公司 | Wiring harness detection table |
| CN103852666B (en) * | 2014-02-28 | 2017-01-04 | 成都蓉盛达系统工程技术有限公司 | A kind of wire harness tester |
| CN104090216A (en) * | 2014-07-10 | 2014-10-08 | 苏州福瑞互感器有限公司 | Device and method for detecting wiring harness high-voltage insulation |
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