CN108089056B - Insulation test equipment and method for whole-vehicle B-stage closed loop of electric vehicle - Google Patents
Insulation test equipment and method for whole-vehicle B-stage closed loop of electric vehicle Download PDFInfo
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- CN108089056B CN108089056B CN201711321044.4A CN201711321044A CN108089056B CN 108089056 B CN108089056 B CN 108089056B CN 201711321044 A CN201711321044 A CN 201711321044A CN 108089056 B CN108089056 B CN 108089056B
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- 238000009413 insulation Methods 0.000 title claims abstract description 82
- 238000012360 testing method Methods 0.000 title claims abstract description 65
- 238000000034 method Methods 0.000 title claims abstract description 12
- 238000005259 measurement Methods 0.000 claims abstract description 26
- 238000005070 sampling Methods 0.000 claims description 14
- 230000003287 optical effect Effects 0.000 claims description 10
- 238000010998 test method Methods 0.000 claims description 8
- 230000008569 process Effects 0.000 claims description 6
- 230000000087 stabilizing effect Effects 0.000 claims description 5
- 238000010348 incorporation Methods 0.000 claims description 4
- 241001089723 Metaphycus omega Species 0.000 claims description 2
- 238000013461 design Methods 0.000 abstract description 3
- 238000002955 isolation Methods 0.000 abstract description 3
- 238000010586 diagram Methods 0.000 description 8
- 238000012544 monitoring process Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000011076 safety test Methods 0.000 description 1
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R27/00—Arrangements for measuring resistance, reactance, impedance, or electric characteristics derived therefrom
- G01R27/02—Measuring real or complex resistance, reactance, impedance, or other two-pole characteristics derived therefrom, e.g. time constant
- G01R27/025—Measuring very high resistances, e.g. isolation resistances, i.e. megohm-meters
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R27/00—Arrangements for measuring resistance, reactance, impedance, or electric characteristics derived therefrom
- G01R27/02—Measuring real or complex resistance, reactance, impedance, or other two-pole characteristics derived therefrom, e.g. time constant
- G01R27/16—Measuring impedance of element or network through which a current is passing from another source, e.g. cable, power line
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/005—Testing of electric installations on transport means
- G01R31/006—Testing of electric installations on transport means on road vehicles, e.g. automobiles or trucks
Abstract
The invention provides insulation test equipment and a method for a B-stage closed loop of an electric vehicle, wherein the equipment comprises a shell, wherein a high-voltage positive electrode interface, a high-voltage negative electrode interface and an electric chassis interface are arranged on the shell and are used for measuring the voltage between a positive electrode of the loop and an electric chassis and the voltage between a negative electrode of the loop and the electric chassis; the shell is internally provided with two identical voltage test circuit boards which are connected with each other, wherein the negative electrode test circuit board is used for measuring the voltage between the negative electrode of the loop and the electric chassis, and the positive electrode test circuit board is used for measuring the voltage between the positive electrode of the loop and the electric chassis. The invention provides insulation test equipment for a B-stage closed loop of an electric vehicle, which aims at the output of a voltage source, and realizes the measurement of insulation resistance of the B-stage high-voltage loop of the vehicle under the condition of electrifying; the test equipment developed by the invention realizes the isolation design of high and low voltages of the measurement circuit, thereby ensuring the safety of testers.
Description
Technical Field
The invention belongs to the technical field of insulation safety test of electric vehicles, and particularly relates to insulation test equipment and method for a B-stage closed loop of an electric vehicle.
Background
The existing insulation monitoring of the whole vehicle mostly adopts automatic monitoring of the vehicle. The method is mainly integrated into a battery management system BMS or a vehicle control unit VCU of the vehicle, the insulation resistance is not directly calculated in most of the tests, or the insulation resistance measurement precision is not high, only the insulation safety performance is simply judged, and the vehicle-mounted self-checking equipment cannot be used as a third party approved test means; in addition, most insulation testing devices on the market are insulation resistance testing devices for class B loop loads, namely, the situation that a battery does not output voltage, which does not accord with the actual use state of a vehicle, and the insulation resistance of the class B loop of the vehicle is a result of measurement under the condition that the whole class B loop is electrified under the condition that the battery participates.
Disclosure of Invention
In view of the above, the invention aims to provide insulation test equipment for a B-stage closed loop of an electric vehicle, which solves the problem of accurate measurement of insulation resistance of the whole vehicle.
In order to achieve the above purpose, the technical scheme of the invention is realized as follows:
the insulation test equipment for the whole-vehicle B-stage closed loop of the electric vehicle comprises a shell, wherein a high-voltage positive electrode interface, a high-voltage negative electrode interface and an electric chassis interface are arranged on the shell, and are respectively connected with a high-voltage positive electrode, a high-voltage negative electrode and an electric chassis of measurement equipment and used for measuring the voltage between the positive electrode of the loop and the electric chassis and the voltage between the negative electrode of the loop and the electric chassis;
two identical voltage test circuit boards which are connected with each other are arranged in the shell, wherein the negative electrode test circuit board is used for measuring the voltages of a loop negative electrode and the electric chassis, and the positive electrode test circuit board is used for measuring the voltages of a loop positive electrode and the electric chassis;
the voltage test circuit board comprises a power supply module, a singlechip, an accessory equipment module and an insulation resistance measurement module, wherein the power supply module is used for supplying power to the singlechip and the accessory equipment module, the singlechip is communicated with equipment in the accessory equipment module to control and complete corresponding functions, and the singlechip is also used for controlling the insulation resistance measurement module to select parallel resistance branches with different resistance values so as to realize the incorporation of resistors with different resistance values into a circuit;
the insulation test equipment is also connected with an upper computer display through a singlechip.
Furthermore, the power supply module is connected with an external power supply through a power interface, is connected with the voltage stabilizing module through the rectifying module, and is connected with the two DC-DC modules, and the DC-DC modules are used for isolating the power supply and forming different reference grounds.
Further, the insulation resistance measurement module comprises a parallel resistance branch, a sampling branch and an insulation resistance branch.
Further, the accessory equipment module comprises a CAN bus, an optical relay and an AD collector, wherein the CAN bus is used for transmitting voltage acquisition data in a circuit board, the optical relay is used as a switch to control the conduction of different resistance branches in the insulation resistance measurement module so as to realize the parallel connection of resistors with different resistance values, the optical relay is also connected with a reference resistor to control the attraction of the reference resistor, so that whether the reference resistor is connected into a circuit or not is controlled, and the AD collector is used for collecting the voltage at the sampling resistor in the sampling branch.
Furthermore, the high-voltage positive electrode interface, the high-voltage negative electrode interface and the electric chassis interface are all connected with the singlechip.
Compared with the prior art, the insulation test equipment for the B-stage closed loop of the whole electric vehicle has the following advantages:
(1) The invention provides insulation test equipment for a B-stage closed loop of an electric vehicle, which aims at the output of a voltage source, and realizes the measurement of insulation resistance of the B-stage high-voltage loop of the vehicle under the condition of electrifying;
(2) The test equipment developed by the invention realizes the isolation design of high and low voltages of the measurement circuit, thereby ensuring the safety of testers;
(3) The invention designs a plurality of groups of test processes, and carries out redundant processing on the test results to obtain accurate test results.
The invention further aims to provide an insulation test method for the B-stage closed loop of the whole electric vehicle, which solves the problem of accurate measurement of the insulation resistance of the whole electric vehicle.
In order to achieve the above purpose, the technical scheme of the invention is realized as follows:
a test method of insulation test equipment of a B-stage closed loop of an electric vehicle specifically comprises the following steps:
(1) Electrifying the tested vehicle to a running state, and ensuring that all electric power and electronic switches on the vehicle are in an activated state;
(2) The positive electrode, the negative electrode and the electric chassis of the B-level high-voltage loop of the vehicle are respectively connected to a high-voltage positive electrode interface, a high-voltage negative electrode interface and an electric chassis interface of insulation test equipment through connecting wires;
(3) Measuring the voltage between the positive and negative terminals of the B-stage loop of the whole vehicle and the electric chassis by using an AD collector of insulation test equipment;
(4) Selecting a reference resistor on insulation test equipment, and measuring the voltage between the positive and negative terminals of the B-stage loop of the whole vehicle and the electric chassis again by using an AD collector of the insulation test equipment;
(5) And (3) calculating the insulation resistance value of the vehicle by using the values obtained in the step (3) and the step (4).
Further, the voltage values obtained in the step (3) are denoted as U1_0 and U1_1, and the voltage values obtained in the step (4) are denoted as U2_0 and U2_1, so that
R p ＝R n =r formula (3)
Wherein R is p 、R n For incorporating the original resistances at both ends of the insulation resistances R1, R2, respectively, in the insulation test equipment circuit, R a Is a reference resistance;
the simultaneous formulas (1), (2) and (3) can be obtained
R 1 And R is R 2 The smaller insulation resistance is the insulation resistance of the whole vehicle, the calculation process is integrated into the singlechip, and finally the calculated insulation resistance value is sent to an upper computer display.
Further, the R p 、R n The resistance values were 10.05 M.OMEGA.
The beneficial effects of the testing method of the insulation testing equipment of the whole B-stage closed loop of the electric vehicle are the same as those of the insulation testing equipment of the whole B-stage closed loop of the electric vehicle, and are not repeated here.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention. In the drawings:
FIG. 1 is a schematic diagram illustrating connection between insulation test equipment and a vehicle under test according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating connection between insulation test equipment and a tested vehicle after a reference resistor is connected according to an embodiment of the present invention;
FIG. 3 is a basic circuit diagram of a system under test according to an embodiment of the present invention;
FIG. 4 is a circuit diagram of a voltage test circuit board according to an embodiment of the invention;
fig. 5 is a schematic structural diagram of a positive electrode test circuit board according to an embodiment of the invention.
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first", "a second", etc. may explicitly or implicitly include one or more such feature. In the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art in a specific case.
The invention will be described in detail below with reference to the drawings in connection with embodiments.
1-5, the invention provides insulation test equipment for a B-stage closed loop of an electric vehicle, which comprises a shell, wherein a high-voltage positive electrode interface, a high-voltage negative electrode interface and an electric chassis interface are arranged on the shell, and are respectively connected with a high-voltage positive electrode, a high-voltage negative electrode and an electric chassis of measurement equipment, and are used for measuring the voltage between the positive electrode of the loop and the electric chassis and the voltage between the negative electrode of the loop and the electric chassis;
two identical voltage test circuit boards which are connected with each other are arranged in the shell, wherein the negative electrode test circuit board is used for measuring the voltages of a loop negative electrode and the electric chassis, and the positive electrode test circuit board is used for measuring the voltages of a loop positive electrode and the electric chassis;
the voltage test circuit board comprises a power supply module, a singlechip, an accessory equipment module and an insulation resistance measurement module, wherein the power supply module is used for supplying power to the singlechip and the accessory equipment module, the singlechip is communicated with equipment in the accessory equipment module to control and complete corresponding functions, and the singlechip is also used for controlling the insulation resistance measurement module to select parallel resistance branches with different resistance values so as to realize the incorporation of resistors with different resistance values into a circuit;
the insulation test equipment is also connected with an upper computer display through a singlechip.
The specific structure of the positive electrode test circuit board is shown in fig. 5, and mainly comprises a power supply module, a singlechip, an accessory equipment module and an insulation resistance measurement module, wherein
1) Power supply module
The device is connected with a 12V power supply externally and then passes through a rectifying device, and the rectifying device can realize positive and negative connection at the position of the external power supply. The rectifying module is connected with a voltage stabilizing module to stabilize the voltage. The voltage stabilizing module is connected with two DC-DC modules, namely a CAN module DC-DC and a battery anode DC-DC. The DC-DC module functions to isolate the power supply and form different references to ground. After power isolation, the battery positive module generates the ground gnd_1 and the can module generates the ground gnd_3. The voltage measurement requires forming a potential difference between a high potential point and a low potential point, wherein in the positive circuit board, the battery positive electrode input B+ can be used as the high potential point, the GND_1 generated by the vehicle ground GND_vehicle connected with the battery positive electrode DC-DC is used as the low potential point, and the formed DeltaU=B + GND_1 > 0, which can be normally used in the positive electrode circuit board. In the negative electrode circuit board, if gnd_car is continuously used as a low potential point, the battery negative electrode is input B-as a high potential point, and Δu=b is formed - -GND Vehicle with a frame And < 0, can not be normally used in the negative electrode circuit board. For this purpose, the negative electrode circuit board is provided with a negative electrode DC-DC circuit boardGenerating an isolated ground gnd_2, taking the battery cathode B-access gnd_2 as a low potential point, thereby forming Δu=gnd Vehicle with a frame -GND 2 > 0. And an isolated power supply after passing through the battery anode DC-DC is connected with the voltage stabilizing module to respectively supply power to the singlechip, the optical relay and the AD collector.
2) Accessory equipment module
The auxiliary equipment mainly comprises a CAN bus, an optical relay and an AD collector. The CAN bus is responsible for transmitting voltage acquisition data in the circuit board; the optical relay is used as a switch to control the conduction of different branches in the insulation resistance measurement module so as to realize the parallel connection of resistors with different resistance values, and is also connected with a reference resistor to control the attraction of the reference resistor, thereby controlling whether the reference resistor is connected with a circuit or not; the AD collector is used for collecting the voltage at the sampling resistor and obtaining the total voltage of the branch through the proportionality coefficient of the sampling resistor and the total resistor of the branch.
3) MCU singlechip module
The MC9S12DP256 singlechip is adopted as a control element, and the singlechip is communicated with equipment in an accessory module to control the equipment to complete corresponding functions.
4) Insulation resistance measuring module
The insulation resistance measurement module comprises a parallel resistance branch, a sampling branch and an insulation resistance branch. The singlechip can control and select parallel resistor branches with different resistance values through the optical relay, so that resistors with different resistance values are integrated into a circuit, and reference resistors with the precision of 50KΩ,100KΩ,1MΩ,2MΩ and 5MΩ reaching 1%. In the sampling branch, the voltage at the sampling resistor is obtained through the AD collector, and the total voltage of the sampling branch, namely the voltage value of the high-voltage positive stage and the electric chassis, is obtained through the proportionality coefficient of the sampling resistor and the total resistance of the sampling branch.
In the test, fig. 1 is a schematic diagram of a step-B high-voltage loop of a vehicle to be tested, then, finding out the positive pole of the loop and the negative pole of the loop, and an electric chassis connected with the high-voltage positive pole, the high-voltage negative pole and the electric chassis of a measuring device respectively, and measuring the voltage of the positive pole of the loop and the electric chassis and the voltage of the negative pole of the loop and the electric chassis respectively, wherein the rees is an energy-storable power supply, and the electric vehicle generally represents a battery.
FIG. 2 is a schematic diagram of a vehicle with an optional reference resistor R connected in parallel between the high voltage positive pole of the B-stage circuit of the vehicle and the electrical chassis based on the wiring of FIG. 1 0 After (50 kΩ,100kΩ,1mΩ,2mΩ,5mΩ), the voltages at the positive pole of the loop and the electrical chassis and the voltages at the negative pole of the loop and the electrical chassis were measured, respectively.
Fig. 3 is a measurement process diagram showing a vehicle class B loop including an storable power source. R is R 1 、R 2 Represents insulation resistance between positive and negative stages of B-stage loop and electric chassis, R p 、R n Representing the additional resistance of the measuring resistance device, R a Representing the reference resistor to be connected in parallel, U1_0, U1_1 representing the voltage between the positive and negative terminals of the high-voltage loop and the electrical chassis, U2_0, U2_1 representing the incorporation of the reference resistor R a The voltage between the positive and negative terminals of the rear high-voltage loop and the electric chassis.
The specific test procedure is as follows
(1) Electrifying the tested vehicle to a running state, and ensuring that all electric power and electronic switches on the vehicle are in an activated state;
(2) And respectively connecting the anode, the cathode and the electric chassis of the B-level high-voltage loop of the vehicle to a high-voltage anode interface, a high-voltage cathode interface and an electric chassis interface of the insulation test equipment.
(3) The voltage between the positive and negative terminals of the B-stage loop of the whole vehicle and the electric chassis is measured by two AD collectors of insulation test equipment and is recorded as U1_0 and U1_1.
(4) Selecting a known reference resistance R on insulation test equipment a Then, simultaneously measuring the voltage between two terminals (high voltage positive and high voltage negative) of the B-stage loop and the electric chassis by using two AD acquisition circuit modules of the equipment, and recording as U2-0 and U2-1;
(5) Calculating insulation resistance R i The method comprises the following steps: wherein R is p 、R n Incorporating insulation resistance R into test equipment circuit 1 、R 2 The original resistance at both ends (the resistance is connected in parallel with the vehicle insulation resistance and is used for pulling the vehicle insulation resistance low so that the AD collector can collect the resistance). Its resistance valueAre all 10.05mΩ.
In the measurement process, R is measured first 1 、R 2 The voltages at both ends are denoted as U1_0 and U1_1. According to the following equation that the left and right paths of currents are equal:
thereafter, at R 1 Resistor side parallel resistor R a And measure R 1 、R 2 The voltages at the two ends are denoted as U2_0 and U2_1. Similarly, the following equation can be used:
R p ＝R n =r formula (3)
The combination of the three equation sets finally obtains the insulation resistance of the vehicle:
R 1 and R is R 2 The smaller insulating resistance is the insulating resistance of the whole vehicle, the calculation process is integrated into the singlechip, finally, the calculated insulating resistance value is sent to an upper computer display, and the equipment can store 500 test results.
The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, alternatives, and improvements that fall within the spirit and scope of the invention.
Claims (3)
1. The insulation test method of the whole B-stage closed loop of the electric vehicle comprises a shell and is characterized in that: the shell is provided with a high-voltage positive electrode interface, a high-voltage negative electrode interface and an electric chassis interface, wherein the high-voltage positive electrode interface, the high-voltage negative electrode interface and the electric chassis interface are respectively connected with a high-voltage positive electrode, a high-voltage negative electrode and an electric chassis of the measuring equipment and are used for measuring the voltage between a loop positive electrode and the electric chassis and the voltage between a loop negative electrode and the electric chassis;
two identical voltage test circuit boards which are connected with each other are arranged in the shell, wherein the negative electrode test circuit board is used for measuring the voltages of a loop negative electrode and the electric chassis, and the positive electrode test circuit board is used for measuring the voltages of a loop positive electrode and the electric chassis;
the voltage test circuit board comprises a power supply module, a singlechip, an accessory equipment module and an insulation resistance measurement module, wherein the power supply module is used for supplying power to the singlechip and the accessory equipment module, the singlechip is communicated with equipment in the accessory equipment module to control and complete corresponding functions, and the singlechip is also used for controlling the insulation resistance measurement module to select parallel resistance branches with different resistance values so as to realize the incorporation of resistors with different resistance values into a circuit;
the insulation test equipment is also connected with an upper computer display through a singlechip;
the power supply module is connected with an external power supply through a power supply interface, is connected with the voltage stabilizing module through the rectifying module, and is connected with two DC-DC modules, wherein the DC-DC modules are used for isolating the power supply and forming different reference grounds;
the insulation resistance measurement module comprises a parallel resistance branch, a sampling branch and an insulation resistance branch;
the auxiliary equipment module comprises a CAN bus, an optical relay and an AD collector, wherein the CAN bus is used for transmitting voltage acquisition data in a circuit board, the optical relay is used as a switch to control the conduction of different resistance branches in the insulation resistance measurement module so as to realize parallel connection of resistors with different resistance values, the optical relay is also connected with a reference resistor to control the attraction of the reference resistor, so that whether the reference resistor is connected with a circuit or not is controlled, and the AD collector is used for acquiring the voltage at the sampling resistor in the sampling branch;
the high-voltage positive electrode interface, the high-voltage negative electrode interface and the electric chassis interface are all connected with the singlechip;
the testing method specifically comprises the following steps:
(1) Electrifying the tested vehicle to a running state, and ensuring that all electric power and electronic switches on the vehicle are in an activated state;
(2) The positive electrode, the negative electrode and the electric chassis of the B-level high-voltage loop of the vehicle are respectively connected to a high-voltage positive electrode interface, a high-voltage negative electrode interface and an electric chassis interface of insulation test equipment through connecting wires;
(3) Simultaneously measuring the voltage between the positive and negative terminals of the B-stage loop of the whole vehicle and the electric chassis by using an AD collector of insulation test equipment;
(4) Selecting a reference resistor on insulation test equipment, and simultaneously measuring the voltage between the positive and negative terminals of the B-stage loop of the whole vehicle and the electric chassis again by using an AD collector of the insulation test equipment;
(5) And (3) calculating the insulation resistance value of the vehicle by using the values obtained in the step (3) and the step (4).
2. The insulation test method for the whole-vehicle B-stage closed loop of the electric vehicle according to claim 1, wherein the insulation test method comprises the following steps of: the voltage values obtained in the step (3) are denoted as U1_0 and U1_1, and the voltage values obtained in the step (4) are denoted as U2_0 and U2_1, so that the voltage values are obtained
R p ＝R n =r formula (3)
Wherein R is p 、R n Incorporating insulation resistors R into insulation test equipment circuits, respectively 1 、R 2 Original resistance at both ends, R a Is a reference resistance;
the simultaneous formulas (1), (2) and (3) can be obtained
R 1 And R is R 2 The smaller insulation resistance is the insulation resistance of the whole vehicle, the calculation process is integrated into the singlechip, and finally the calculated insulation resistance value is sent to an upper computer display.
3. The insulation test method for the whole-vehicle B-stage closed loop of the electric vehicle according to claim 2, wherein the insulation test method comprises the following steps of: the R is p 、R n The resistance values were 10.05 M.OMEGA.
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