CN112213624B - Test device and method for verifying interlocking function of high-voltage loop of electric automobile - Google Patents
Test device and method for verifying interlocking function of high-voltage loop of electric automobile Download PDFInfo
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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
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/2832—Specific tests of electronic circuits not provided for elsewhere
- G01R31/2836—Fault-finding or characterising
- G01R31/2849—Environmental or reliability testing, e.g. burn-in or validation tests
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
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- 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
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
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- G—PHYSICS
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- 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
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/2832—Specific tests of electronic circuits not provided for elsewhere
- G01R31/2836—Fault-finding or characterising
- G01R31/2844—Fault-finding or characterising using test interfaces, e.g. adapters, test boxes, switches, PIN drivers
Abstract
The invention provides a test device and a method for verifying the interlocking function of a high-voltage loop of an electric automobile, which aim to add an effective test method for an automobile high-voltage safety protection test, can accurately verify whether the interlocking structure of the high-voltage loop of the whole automobile is safe and reliable, and lays a foundation for evaluating the high-voltage safety protection of the automobile. The invention discloses a test device for verifying a high-voltage loop interlocking function of an electric automobile, which comprises: a low voltage sensor for acquiring a low voltage signal in the loop interlock; the high-voltage sensor is used for acquiring a high-voltage signal of the whole vehicle and converting the high-voltage signal of the whole vehicle into a low-voltage signal in proportion; the data acquisition module is used for acquiring voltage signal values output by the low-voltage sensor and the high-voltage sensor; and the data processing module is connected with the data acquisition module and used for calculating a real voltage value and calculating the low voltage drop of the high-voltage loop interlocking circuit, namely the cut-off time from the occurrence of a fault to the reduction of the high voltage of the whole vehicle to a safe voltage, so as to judge the correct reliability of the connection of the high-voltage loop interlocking circuit.
Description
Technical Field
The invention belongs to the field of electronic test and control of electric automobiles, and particularly relates to a test device and a method for verifying a high-voltage loop interlocking function of an electric automobile.
Background
With the progress of technology, the existing automobile not only meets the function of riding instead of walk, but also is green, environment-friendly, economical and applicable, and the traditional fuel oil vehicle generates pollutants such as NO and the like due to the fact that fuel oil is compressed in an engine, so that the environment is seriously affected. Electric automobiles such as storage battery electric automobiles and hybrid electric automobiles which are researched at present not only take fuel oil as single energy, but also reduce or avoid the emission of pollutants such as tail gas and the like, have the outstanding advantages of multiple energy sources, environmental protection and the like, and are in great support for new energy automobile strategic emerging industries by the ministry of industry and government policies in various regions in China. With the push development of electric automobiles, the mileage requirement increases, the voltage of a lot of whole automobiles breaks through a high voltage value of 400V, in order to ensure the high voltage safety protection of the environments of personnel inside and outside the automobile and the automobile, a high voltage loop interlocking circuit is required in the design structure of the electric automobile and comprises accessory loop interlocking, discharge loop interlocking and charge loop interlocking, at the moment, the whole automobile needs to have the functions of detecting and verifying the electrical connection reliability of all high voltage components with the loop interlocking structure, a high voltage wire harness and a connector, and when the high voltage connector is accidentally disconnected or the high voltage components are uncovered and accessed, the high voltage connection is automatically cut off to prevent the situation that the charged components are accidentally exposed outside.
The safety performance TEST of the electric automobile in the current EV-TEST electric automobile evaluation management rule comprises five aspects of collision safety, wading electric safety, human body electromagnetic protection, electromagnetic interference resistance and battery system water prevention, the TEST method for detecting the circuit connection reliability function of the whole automobile loop interlocking structure is not described in the relevant standards of the high-voltage safety, and how to effectively evaluate and evaluate the reliability of the whole automobile electric connection needs to be determined.
In the existing patented method, no method for verifying the connection reliability function of the whole vehicle high-voltage loop interlocking structure circuit is available, and the method is generally a novel high-voltage loop interlocking system structure and a control method, or is specially used for solving the fault after the high-voltage loop has the fault.
Disclosure of Invention
The invention aims to provide a test device and a method for verifying the interlocking function of a high-voltage loop of an electric automobile, so as to add an effective test method for an automobile high-voltage safety protection test, accurately verify whether the interlocking structure of the high-voltage loop of the whole automobile is safe and reliable, and lay a foundation for evaluating the high-voltage safety protection of the automobile.
The invention discloses a test device for verifying a high-voltage loop interlocking function of an electric automobile, which comprises:
a low voltage sensor for acquiring a low voltage signal in the loop interlock;
the high-voltage sensor is used for acquiring a high-voltage signal of the whole vehicle and converting the high-voltage signal of the whole vehicle into a low-voltage signal in proportion;
the data acquisition module is used for acquiring voltage signal values output by the low-voltage sensor and the high-voltage sensor;
and the data processing module is connected with the data acquisition module and used for calculating a real voltage value and calculating the low voltage drop of the high-voltage loop interlocking circuit, namely the cut-off time from the occurrence of a fault to the reduction of the high voltage of the whole vehicle to a safe voltage, so as to judge the correct reliability of the connection of the high-voltage loop interlocking circuit.
The test method for verifying the high-voltage loop interlocking function of the electric automobile is based on the test device, and specifically comprises a test method for the accessory loop interlocking function, a test method for the discharge loop interlocking function and a test method for the charge loop interlocking function.
The following describes the respective test methods in detail:
1. the test method of the accessory loop interlocking function comprises the following steps: after the whole vehicle control unit, the electric compressor connector, the heating system connector, the low-voltage plug-in connector of the two-in-one charger and the power distribution unit are sequentially connected in series, the power distribution unit is connected with the whole vehicle control unit, and therefore an accessory loop is formed; the method for testing the accessory loop interlocking function comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, then connecting the positive electrode of the low-voltage sensor with the low-voltage positive electrode in the low-voltage plug-in connector of the two-in-one charger, and connecting the negative electrode of the low-voltage sensor with the vehicle body electric platform; respectively connecting the positive pole and the negative pole of the high-voltage sensor with the total positive pole and the total negative pole in the power distribution unit; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. after the whole vehicle is normally electrified and stabilized for a period of time, disconnecting the low-voltage positive electrode of the low-voltage plug-in connector from the two-in-one charger;
C. the data acquisition module and the data processing module monitor whether the low voltage is disconnected and whether the high voltage in the power distribution unit is cut off, and the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage and judges the test result.
Further, before the test of the accessory loop interlock function is performed, whether the accessory loop is normal is firstly judged, and the judgment method is as follows: sending a low-voltage pulse signal from a vehicle control unit, receiving the low-voltage pulse signal by the vehicle control unit and comparing the low-voltage pulse signal with the low-voltage pulse signal sent by the vehicle control unit after passing through an electric compressor connector, a heating system connector, a low-voltage plug-in connector of a two-in-one charger, an alternating current side, a direct current side and a power distribution unit, and if the low-voltage pulse signal is inconsistent, determining a fault, sending fault information to a battery management system and an instrument control unit, and requesting to cut off a main relay and turn on a fault lamp; if there is no fault, the accessory loop interlock function can be tested.
2. The test method of the discharge loop interlocking function comprises the following steps: the whole vehicle control unit, the motor controller and the battery management system are sequentially connected to form a discharge loop, and the test method of the discharge loop interlocking function comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, then connecting the positive electrode of the low-voltage sensor with the low-voltage positive electrode in the low-voltage interface of the battery management system, and connecting the negative electrode of the low-voltage sensor with the vehicle body electric platform; respectively connecting the positive pole and the negative pole of the high-voltage sensor with the total positive pole and the total negative pole in the power distribution unit; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. after the whole vehicle is normally powered on and stabilized for a period of time, disconnecting a low-voltage positive electrode signal in a low-voltage interface of the battery management system;
C. the data acquisition module and the data processing module monitor whether the low voltage is disconnected and whether the high voltage in the power distribution unit is cut off, and the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage and judges the test result.
Further, before the test of the discharge loop interlock function is performed, it is first determined whether the discharge loop is normal, and the determination method is as follows: the whole vehicle control unit sends a low-voltage pulse signal, after the low-voltage pulse signal passes through the motor controller, the battery management system receives the low-voltage pulse signal and compares the low-voltage pulse signal with the low-voltage pulse signal sent by the whole vehicle control unit, if the low-voltage pulse signal is inconsistent with the low-voltage pulse signal, a fault is confirmed, the battery management system sends a fault instruction to the whole vehicle control unit, and the whole vehicle control unit sends a relay cut-off instruction and a fault lamp lighting instruction to the battery management system and the instrument control unit; if no fault exists, the test of the interlocking function of the discharge loop can be carried out.
3. The test method of the charging loop interlocking function comprises the following steps: the method comprises a test method of the interlocking function of a quick charging loop and a test method of the interlocking function of a slow charging loop, wherein the test methods comprise the following steps: wherein:
3.1, a test method of the interlocking function of the quick charging loop comprises the following steps: the quick charging pile is in butt joint with a quick charging seat of an automobile through a quick charging tool, the quick charging seat is in butt joint with a quick charging interface of a battery management system to form a quick charging loop, and the test method of the interlocking function of the quick charging loop comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, respectively butting the quick charging tool with the quick charging pile and a quick charging seat of the vehicle, and leading three signal wires of a charging connection confirmation signal, a high-voltage positive signal and a high-voltage negative signal out of a wire harness of the quick charging tool; connecting the positive pole of the low-voltage sensor with a charging connection confirmation signal, connecting the negative pole of the low-voltage sensor with a ground signal, connecting the positive pole of the high-voltage sensor with a high-voltage positive signal, and connecting the negative pole of the high-voltage sensor with a high-voltage negative signal; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. enabling the vehicle to carry out normal quick charging operation, and finishing the quick charging operation in a card swiping mode after the preset time;
C. the data acquisition module and the data processing module monitor whether the low voltage and the high voltage are disconnected, the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage, and the test result is judged.
Further, before the test of the interlock function of the fast charge charging loop is performed, whether the fast charge charging loop is normal is firstly judged, and the judging method comprises the following steps: the quick charging pile sends a low-voltage pulse signal and a high-voltage signal, the battery management system receives the low-voltage pulse signal and compares the low-voltage pulse signal with the low-voltage pulse signal sent by the quick charging pile, if the low-voltage pulse signal and the low-voltage pulse signal are inconsistent, a fault is confirmed, the battery management system sends a fault instruction to the whole vehicle control unit, and the whole vehicle control unit sends a relay cut-off instruction and a fault lamp lighting instruction to the battery management system and the instrument control unit; if no fault exists, the test of the interlocking function of the quick charging loop can be carried out.
3.2, a test method of the interlocking function of the slow charging loop comprises the following steps: the slow charging pile, the slow charging tool, the slow charging seat of the whole vehicle and the two-in-one charger are sequentially connected, and the two-in-one charger is respectively connected with the battery management system and the control unit of the whole vehicle to form a slow charging loop; the test method of the slow charging loop interlocking function comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, respectively butting the slow charging tool with the slow charging pile and a slow charging seat of the vehicle, and leading three signal wires, namely a charging connection confirmation signal, a live wire and a zero wire out of a wire harness of the slow charging tool; connecting the positive pole of the low-voltage sensor with a charging connection confirmation signal, connecting the negative pole of the low-voltage sensor with a ground signal, connecting the positive pole of the high-voltage sensor with a live wire, and connecting the negative pole of the high-voltage sensor with a zero line; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. enabling the vehicle to carry out normal slow charging operation, pulling out the slow charging tool from the slow charging pile after a preset time, and ending the slow charging operation;
C. the data acquisition module and the data processing module monitor whether the low voltage and the high voltage are disconnected, the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage, and the test result is judged.
Further, before the test of the interlock function of the slow charging loop is performed, whether the slow charging loop is normal is firstly judged, and the judging method comprises the following steps: the low-voltage pulse signal and the high-voltage signal are sent out by the slow charging pile, the awakening signal is sent out by the two-in-one charger, the whole vehicle control unit and the battery management system work normally at the same time, the low-voltage pulse signal is received by the battery management system and is compared with the low-voltage pulse signal sent by the slow charging pile, if the low-voltage pulse signal is inconsistent, the fault is confirmed, the fault instruction is sent to the whole vehicle control unit by the battery management system, the whole vehicle control unit sends the command of cutting off a relay and lighting a fault lamp to the battery management system and the instrument control unit, and if the fault does not exist, the test of the interlocking function of the slow charging loop can be carried out.
Compared with the prior art, the invention has the beneficial effects that:
1. according to three interlock circuit structures and strategies of accessory loop interlock, discharge loop interlock and charge loop interlock designed for the whole vehicle, the invention provides method guidance for verifying the circuit connection reliability function of the whole vehicle loop interlock structure, thereby accurately and effectively evaluating the reliability of the whole vehicle electrical connection, and providing a test means for the whole vehicle high-voltage safety protection technology.
Drawings
Fig. 1 is a test system diagram of a method of testing an accessory loop interlock function of the present invention.
Fig. 2 is a test system diagram of a test method of the discharge loop interlock function of the present invention.
Fig. 3 is a test system diagram of a test method of the interlock function of the fast charge circuit according to the present invention.
FIG. 4 is a system diagram of a method for testing the interlock function of a slow charge circuit according to the present invention.
In the drawings
In order to realize the interlocking structure of the high-voltage loop,
is a high-voltage interlocking signal wire, is a wire harness interface,
is an anode interface of a high-voltage component,
is a negative electrode interface of a high-voltage component,
is a slow-charge wake-up signal; the CMDC is a two-in-one charger; VCU is the control unit of the whole car, EAC is the motor-driven compressor; the PTC is a heating system; the PDU is a power supply distribution unit; BATTERY is a BATTERY in a BATTERY Management System (BMS).
Detailed Description
The following describes embodiments of the present invention, such as shapes and structures of respective members, mutual positions and connection relationships between respective portions, and actions and operation principles of the respective portions, in further detail, with reference to the accompanying drawings.
Example 1:
the embodiment provides a test device and a method for verifying the interlocking function of a high-voltage loop of an electric automobile, so that an effective test method is added for an automobile high-voltage safety protection test, whether the interlocking structure of the high-voltage loop of the whole automobile is safe and reliable can be accurately verified, and a foundation is laid for evaluating the high-voltage safety protection of the automobile.
The test device for verifying the high-voltage loop interlocking function of the electric automobile comprises:
a low voltage sensor for acquiring a low voltage signal in the loop interlock;
the high-voltage sensor is used for acquiring a high-voltage signal of the whole vehicle and converting the high-voltage signal of the whole vehicle into a low-voltage signal in proportion;
the data acquisition module is used for acquiring voltage signal values output by the low-voltage sensor and the high-voltage sensor;
and the data processing module is connected with the data acquisition module and used for calculating a real voltage value and calculating the low voltage drop of the high-voltage loop interlocking circuit, namely the cut-off time from the occurrence of a fault to the reduction of the high voltage of the whole vehicle to a safe voltage, so as to judge the correct reliability of the connection of the high-voltage loop interlocking circuit.
The following will describe in detail a method for testing the accessory loop interlock function, a method for testing the discharge loop interlock function, and a method for testing the charge loop interlock function, respectively:
1. the test method of the accessory loop interlocking function comprises the following steps:
as shown in fig. 1, after the vehicle control unit, the electric compressor connector, the heating system connector, the low-voltage plug-in connector of the two-in-one charger, and the power distribution unit are connected in series in sequence, the power distribution unit is connected with the vehicle control unit, so as to form an accessory loop. Before the test of the accessory loop interlocking function is carried out, firstly, whether the accessory loop is normal is judged, and the judgment method comprises the following steps: sending a low-voltage pulse signal from a finished automobile control unit, receiving the low-voltage pulse signal by the finished automobile control unit after passing through an electric compressor connector, a heating system connector, a low-voltage plug-in connector of a two-in-one charger, an alternating current side, a direct current side and a power distribution unit, comparing the low-voltage pulse signal with the low-voltage pulse signal sent by the finished automobile control unit, and if the low-voltage pulse signal is inconsistent with the low-voltage pulse signal, confirming a fault, sending fault information to a battery management system and an instrument control unit by the finished automobile control unit, and requesting to cut off a main relay and turn on a fault lamp; if there is no fault, the accessory loop interlock function can be tested.
The method for testing the accessory loop interlocking function comprises the following specific steps:
1.1, test circuit connection: powering off the whole vehicle, then connecting the positive electrode of the low-voltage sensor with the low-voltage positive electrode in the low-voltage plug-in connector of the two-in-one charger, and connecting the negative electrode of the low-voltage sensor with the vehicle body electric platform; respectively connecting the positive pole and the negative pole of the high-voltage sensor with the total positive pole and the total negative pole in the power distribution unit; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module; the data processing module is connected with the upper computer through a network cable;
1.2, ensuring that a microswitch in a Power Distribution Unit (PDU) can be normally closed, and disconnecting the low-voltage positive electrode of the low-voltage plug-in connector from the two-in-one charger after the whole vehicle is normally electrified and stabilized for 1 minute;
1.3, the data acquisition module receives the low-voltage signal and the high-voltage signal and transmits the low-voltage signal and the high-voltage signal to the data processing module, software in the data processing module calculates the two voltage signals into a real voltage value according to a proportion, monitors whether the low voltage is disconnected and whether the high voltage in the power distribution unit is disconnected, calculates the time of the low voltage is disconnected and the high voltage is reduced to a safe voltage of 60V by the software, judges a test result, and transmits a specific curve chart and the test result to an upper computer through a network interface to display.
2. The test method of the discharge loop interlocking function comprises the following steps:
as shown in fig. 2, the vehicle control unit, the motor controller, and the battery management system are sequentially connected to form a discharge loop, and before performing a test of the discharge loop interlock function, it is first determined whether the discharge loop is normal, where the determination method is as follows: the whole vehicle control unit sends a low-voltage pulse signal, the low-voltage pulse signal passes through the motor controller, is received by the battery management system and is compared with the low-voltage pulse signal sent by the whole vehicle control unit, if the low-voltage pulse signal is inconsistent, a fault is confirmed, the battery management system sends a fault instruction to the whole vehicle control unit, and the whole vehicle control unit sends a relay cut-off instruction and a fault lamp lighting-up instruction to the battery management system and the instrument control unit; if no fault exists, the test of the interlocking function of the discharge loop can be carried out.
The test method of the discharge loop interlocking function comprises the following specific steps:
2.1, test circuit connection: powering off the whole vehicle, then connecting the positive electrode of the low-voltage sensor with the low-voltage positive electrode in the low-voltage interface of the battery management system, and connecting the negative electrode of the low-voltage sensor with the vehicle body electric platform; respectively connecting the positive pole and the negative pole of the high-voltage sensor with the total positive pole and the total negative pole in the power distribution unit; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
2.2, ensuring that a microswitch in the power distribution unit can be normally closed, and disconnecting a low-voltage positive electrode signal corresponding to an SAFETY CHAIN RETURN pin in a low-voltage interface of the battery management system after the whole vehicle is normally electrified and stabilized for 1 minute;
and 2.3, the data acquisition module receives the low-voltage and high-voltage signals and transmits the low-voltage and high-voltage signals to the data processing module, software in the data processing module calculates the two voltage signals into a real voltage value in proportion, monitors whether the low voltage in a low-voltage interface of the battery management system is disconnected and whether the high voltage in a power distribution unit is disconnected, calculates the time from the disconnection of the low voltage to the reduction of the high voltage to a safe voltage of 60V by the software, and judges a test result. And the curve graph and the test result are transmitted to an upper computer through a network port to be displayed.
3. The test method of the charging loop interlocking function comprises the following steps:
the method comprises a test method of the interlocking function of a quick charging loop and a test method of the interlocking function of a slow charging loop, wherein the test methods comprise the following steps: wherein:
3.1, a test method of the interlocking function of the quick charging loop comprises the following steps: the quick charging pile is in butt joint with a quick charging seat of an automobile through a quick charging tool, and the quick charging seat is in butt joint with a quick charging interface of a battery management system to form a quick charging loop. Before the test of the interlocking function of the quick charge charging loop, firstly, judging whether the quick charge charging loop is normal or not, wherein the judging method comprises the following steps: the quick charging pile sends a low-voltage pulse signal and a high-voltage signal, the battery management system receives the low-voltage pulse signal and compares the low-voltage pulse signal with the low-voltage pulse signal sent by the quick charging pile, if the low-voltage pulse signal and the low-voltage pulse signal are inconsistent, a fault is confirmed, the battery management system sends a fault instruction to the whole vehicle control unit, and the whole vehicle control unit sends a relay cut-off instruction and a fault lamp lighting instruction to the battery management system and the instrument control unit; if no fault exists, the test of the interlocking function of the quick charging loop can be carried out.
The test method for the interlocking function of the quick charging loop comprises the following specific steps:
3.1.1, test circuit connection: powering off the whole vehicle, respectively butting the quick charging tool with the quick charging pile and a quick charging seat of the vehicle, and leading three signal wires of a charging connection confirmation signal, a high-voltage positive signal and a high-voltage negative signal out of a wire harness of the quick charging tool; connecting the positive pole of the low-voltage sensor with a charging connection confirmation signal, connecting the negative pole of the low-voltage sensor with a ground signal, connecting the positive pole of the high-voltage sensor with a high-voltage positive signal, and connecting the negative pole of the high-voltage sensor with a high-voltage negative signal; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
3.1.2, enabling the vehicle to carry out normal quick charging operation, and finishing the quick charging operation in a card swiping mode after the preset time;
3.1.3, the data acquisition module receives the low-voltage signal and the high-voltage signal and transmits the signals to the data processing module, software in the data processing module calculates the two voltage signals into a real voltage value in proportion, monitors whether the low voltage and the high voltage led out by the quick-charging tooling wire harness are cut off or not, calculates the time from the low voltage disconnection to the high voltage reduction to the safe voltage of 60V, and judges a test result. And the curve graph and the test result are transmitted to an upper computer through a network port to be displayed.
3.2, a method for testing the interlocking function of the slow charging loop: the slow charging pile, the slow charging tool, the slow charging seat of the whole vehicle and the two-in-one charger are sequentially connected, and the two-in-one charger is respectively connected with the battery management system and the control unit of the whole vehicle to form a slow charging loop. Before the test of the interlocking function of the slow charging loop is carried out, firstly, whether the slow charging loop is normal is judged, and the judging method comprises the following steps: the low-voltage pulse signal and the high-voltage signal are sent out by the slow charging pile, the awakening signal is sent out by a two-in-one charger, the whole vehicle control unit and the battery management system work normally at the same time, the low-voltage pulse signal is received by the battery management system and is compared with the low-voltage pulse signal sent by the slow charging pile, if the low-voltage pulse signal is inconsistent, the fault is confirmed, the fault instruction is sent to the whole vehicle control unit by the battery management system, the command of cutting off a relay and lighting a fault lamp is sent to the battery management system and the instrument control unit by the whole vehicle control unit, and if the fault does not exist, the test of the interlocking function of the slow charging loop can be carried out.
The test method of the slow charging loop interlocking function comprises the following specific steps:
3.2.1, test circuit connection: powering off the whole vehicle, respectively butting the slow charging tool with the slow charging pile and a slow charging seat of the vehicle, and leading three signal wires, namely a charging connection confirmation signal, a live wire and a zero wire out of a wire harness of the slow charging tool; connecting the positive pole of the low-voltage sensor with a charging connection confirmation signal, connecting the negative pole of the low-voltage sensor with a ground signal, connecting the positive pole of the high-voltage sensor with a live wire, and connecting the negative pole of the high-voltage sensor with a zero line; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
3.2.2, enabling the vehicle to carry out normal slow charging operation, pulling out the slow charging tool from the slow charging pile after 5 minutes, and finishing the slow charging operation;
3.2.3, the data acquisition module receives the low-voltage signal and the high-voltage signal and transmits the low-voltage signal and the high-voltage signal to the data processing module, software in the data processing module calculates the two voltage signals into a real voltage value in proportion, monitors whether the low voltage and the high voltage led out by the slow-charging tooling wire harness are cut off or not, calculates the time from the low voltage disconnection to the high voltage reduction to the safe voltage of 30V, and judges a test result. And the curve graph and the test result are transmitted to an upper computer through a network port to be displayed.
In summary, the test method and the test device for verifying the interlock function of the high-voltage loop of the electric vehicle according to the embodiment have the advantages of simple and understandable principle, reliable test method, convenience in operation, strong operability, low test cost and short test period, can correctly simulate the disconnection condition of the high-voltage interlock loop and detect whether the high-voltage interlock loop is normally connected, and provide an effective and reliable test method for the high-voltage safety protection test of the electric vehicle.
The invention has been described in connection with the accompanying drawings, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description, as long as the invention is capable of being practiced without modification in any way whatsoever, and is capable of other applications without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (8)
1. An experimental method for verifying a high-voltage loop interlock function of an electric vehicle, characterized in that the experimental method comprises the following test devices:
a low voltage sensor for acquiring a low voltage signal in the loop interlock;
the high-voltage sensor is used for acquiring a high-voltage signal of the whole vehicle and converting the high-voltage signal of the whole vehicle into a low-voltage signal in proportion;
the data acquisition module is used for acquiring voltage signal values output by the low-voltage sensor and the high-voltage sensor;
the data processing module is connected with the data acquisition module and used for calculating a real voltage value and calculating the low voltage drop of the high-voltage loop interlocking circuit, namely the cut-off time from the occurrence of a fault to the reduction of the high voltage of the whole vehicle to a safe voltage, so as to judge the reliability of the correct connection of the high-voltage loop interlocking circuit;
the test method comprises a test method of the accessory loop interlocking function, a test method of the discharge loop interlocking function and a test method of the charge loop interlocking function, wherein after a vehicle control unit, an electric compressor connector, a heating system connector, a low-voltage plug-in connector of a two-in-one charger and a power distribution unit are sequentially connected in series, the power distribution unit is connected with the vehicle control unit, so that an accessory loop is formed; the method for testing the accessory loop interlocking function comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, then connecting the positive electrode of the low-voltage sensor with the low-voltage positive electrode in the low-voltage plug-in connector of the two-in-one charger, and connecting the negative electrode of the low-voltage sensor with the vehicle body electric platform; respectively connecting the positive pole and the negative pole of the high-voltage sensor with the total positive pole and the total negative pole in the power distribution unit; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. after the whole vehicle is normally electrified and stabilized for a period of time, disconnecting the low-voltage positive electrode of the low-voltage plug-in connector from the two-in-one charger;
C. the data acquisition module and the data processing module monitor whether the low voltage is disconnected and whether the high voltage in the power distribution unit is cut off, and the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage and judges the test result.
2. The experimental method for verifying the high-voltage loop interlock function of the electric vehicle as set forth in claim 1, wherein before the test of the accessory loop interlock function, it is first determined whether the accessory loop is normal, by the following method:
sending a low-voltage pulse signal from a finished automobile control unit, receiving the low-voltage pulse signal by the finished automobile control unit after passing through an electric compressor connector, a heating system connector, a low-voltage plug-in connector of a two-in-one charger, an alternating current side, a direct current side and a power distribution unit, comparing the low-voltage pulse signal with the low-voltage pulse signal sent by the finished automobile control unit, if the low-voltage pulse signal is inconsistent with the low-voltage pulse signal, sending fault information to a battery management system and an instrument control unit, and requesting to cut off a main relay and light a fault lamp; if there is no fault, the accessory loop interlock function can be tested.
3. The experimental method for verifying the high-voltage loop interlocking function of the electric automobile as claimed in claim 1, wherein a complete automobile control unit, a motor controller and a battery management system are sequentially connected to form a discharge loop, and the test method for the discharge loop interlocking function comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, then connecting the positive electrode of the low-voltage sensor with the low-voltage positive electrode in the low-voltage interface of the battery management system, and connecting the negative electrode of the low-voltage sensor with the vehicle body electric platform; respectively connecting the positive pole and the negative pole of the high-voltage sensor with the total positive pole and the total negative pole in the power distribution unit; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. after the whole vehicle is normally powered on and stabilized for a period of time, disconnecting a low-voltage positive electrode signal in a low-voltage interface of the battery management system;
C. the data acquisition module and the data processing module monitor whether the low voltage is disconnected and whether the high voltage in the power distribution unit is cut off, and the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage and judges the test result.
4. An experimental method for verifying the high-voltage loop interlocking function of an electric vehicle as claimed in claim 3, wherein before the test of the discharge loop interlocking function, it is first determined whether the discharge loop is normal, and the determination method is as follows:
the whole vehicle control unit sends a low-voltage pulse signal, the low-voltage pulse signal passes through the motor controller, is received by the battery management system and is compared with the low-voltage pulse signal sent by the whole vehicle control unit, if the low-voltage pulse signal is inconsistent, a fault is determined, the battery management system sends a fault instruction to the whole vehicle control unit, and the whole vehicle control unit sends a relay cut-off instruction and a fault lamp lighting instruction to the battery management system and the instrument control unit; if no fault exists, the test of the interlocking function of the discharge loop can be carried out.
5. The experimental method for verifying the interlocking function of the high-voltage loop of the electric vehicle as claimed in claim 1, wherein the experimental method comprises a test method for the interlocking function of a fast-charging loop and a test method for the interlocking function of a slow-charging loop, the fast-charging pile is in butt joint with a fast-charging seat of the vehicle through a fast-charging tool, the fast-charging seat is in butt joint with a fast-charging interface of a battery management system to form the fast-charging loop, and the test method for the interlocking function of the fast-charging loop comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, respectively butting the quick charging tool with the quick charging pile and a quick charging seat of the vehicle, and leading three signal wires of a charging connection confirmation signal, a high-voltage positive signal and a high-voltage negative signal out of a wire harness of the quick charging tool; connecting the positive electrode of the low-voltage sensor with a charging connection confirmation signal, connecting the negative electrode of the low-voltage sensor with a ground signal, connecting the positive electrode of the high-voltage sensor with a high-voltage positive signal, and connecting the negative electrode of the high-voltage sensor with a high-voltage negative signal; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. enabling the vehicle to carry out normal quick charging operation, and finishing the quick charging operation in a card swiping mode after the preset time;
C. the data acquisition module and the data processing module monitor whether the low voltage and the high voltage are disconnected, the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage, and the test result is judged.
6. The experimental method for verifying the interlocking function of the high-voltage loop of the electric vehicle as claimed in claim 5, wherein before the test of the interlocking function of the quick-charge loop, it is first determined whether the quick-charge loop is normal, and the determination method is as follows: the quick charging pile sends out a low-voltage pulse signal and a high-voltage signal, the battery management system receives the low-voltage pulse signal and compares the low-voltage pulse signal with the low-voltage pulse signal sent by the quick charging pile, if the low-voltage pulse signal and the low-voltage pulse signal are inconsistent, a fault is confirmed, the battery management system sends a fault instruction to the whole vehicle control unit, and the whole vehicle control unit sends a relay cut-off instruction and a fault lamp lighting instruction to the battery management system and the instrument control unit; if no fault exists, the test of the interlocking function of the quick charging loop can be carried out.
7. The experimental method for verifying the interlocking function of the high-voltage loop of the electric vehicle as claimed in claim 5, wherein the slow charging pile, the slow charging tool, the slow charging seat of the whole vehicle and the two-in-one charger are sequentially connected, and the two-in-one charger is respectively connected with the battery management system and the control unit of the whole vehicle to form the slow charging loop; the test method of the slow charging loop interlocking function comprises the following specific steps:
A. and (3) test circuit connection: powering off the whole vehicle, respectively butting the slow charging tool with the slow charging pile and a slow charging seat of the vehicle, and leading three signal wires, namely a charging connection confirmation signal, a live wire and a zero wire out of a wire harness of the slow charging tool; connecting the positive pole of the low-voltage sensor with a charging connection confirmation signal, connecting the negative pole of the low-voltage sensor with a ground signal, connecting the positive pole of the high-voltage sensor with a live wire, and connecting the negative pole of the high-voltage sensor with a zero line; the data output ends of the low-voltage sensor and the high-voltage sensor are respectively connected with a data acquisition module, and the data acquisition module is connected with a data processing module;
B. enabling the vehicle to carry out normal slow charging operation, pulling out the slow charging tool from the slow charging pile after a preset time, and finishing the slow charging operation;
C. the data acquisition module and the data processing module monitor whether the low voltage and the high voltage are disconnected, the data processing module calculates the time from the disconnection of the low voltage to the reduction of the high voltage to the safe voltage, and the test result is judged.
8. The experimental method for verifying the interlocking function of the high-voltage loop of the electric vehicle as claimed in claim 7, wherein before the test of the interlocking function of the slow charge charging loop, it is first determined whether the slow charge charging loop is normal, and the determination method is as follows: the low-voltage pulse signal and the high-voltage signal are sent out by the slow charging pile, the awakening signal is sent out by the two-in-one charger, the whole vehicle control unit and the battery management system work normally at the same time, the low-voltage pulse signal is received by the battery management system and is compared with the low-voltage pulse signal sent by the slow charging pile, if the low-voltage pulse signal is inconsistent, the fault is confirmed, the fault instruction is sent to the whole vehicle control unit by the battery management system, the whole vehicle control unit sends the command of cutting off a relay and lighting a fault lamp to the battery management system and the instrument control unit, and if the fault does not exist, the test of the interlocking function of the slow charging loop can be carried out.
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