CN216485270U - Environment reliability testing device of bidirectional vehicle-mounted charger - Google Patents
Environment reliability testing device of bidirectional vehicle-mounted charger Download PDFInfo
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- CN216485270U CN216485270U CN202121183907.8U CN202121183907U CN216485270U CN 216485270 U CN216485270 U CN 216485270U CN 202121183907 U CN202121183907 U CN 202121183907U CN 216485270 U CN216485270 U CN 216485270U
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Abstract
The utility model discloses an environmental reliability testing device of a bidirectional vehicle-mounted charger, which comprises a charging power supply connecting end of a tested piece, a switching circuit, an alternating current electronic load, a high-voltage direct-current bidirectional power supply and a control computer, wherein during testing, the charging power supply connecting end of the tested piece is connected with the alternating current electronic load and the tested piece through the switching circuit, the high-voltage direct-current bidirectional power supply is connected with the tested piece, the control computer is respectively connected with the switching circuit, the alternating current electronic load, the high-voltage direct-current bidirectional power supply and the tested piece, the switching circuit is controlled to change the communication relation between the tested piece and the charging power supply connecting end and the alternating current electronic load, so that the circuit is switched to a charging or discharging connection mode, and then the alternating current electronic load, the high-voltage direct-current bidirectional power supply and the tested piece are controlled to realize that a plurality of tested pieces are simultaneously in different operation modes, And (4) automatically testing the environmental reliability under different load conditions.
Description
Technical Field
The utility model belongs to the field of test and verification of Bidirectional On-Board Charger (BOBC), and particularly relates to an environmental reliability testing device of a Bidirectional On-Board Charger.
Background
The vehicle-mounted charger is an important core part of the electric automobile, is installed in the electric automobile, is an electric energy conversion device, and can convert alternating current of a public power grid into direct current to charge a power battery pack of the electric automobile. New energy electric vehicles at home and abroad are equipped with vehicle-mounted chargers.
With the development and popularization of electric vehicles, the state promulgates a test standard of a conductive vehicle-mounted charger for an electric vehicle, namely QC/T895-2011, of the alternating current charger, and increases the running modes of a tested piece to be operated at a maximum load of 3.3 and the running modes of a minimum load of 3.4 according to the latest requirements of ISO 16750-1 standard, namely ISO 16750-1:2018Road vehicles-Environmental conditions and electronic equipment-Part 1: General.
In addition, with the development of new energy vehicles, under the background of the application of V2X (Vehicle To event) (V2L (Vehicle To Load) (Vehicle supplies power To outside, and can be used for household power outage or field camping), V2V (Vehicle To Vehicle) (Vehicle is connected with Vehicle and can be used for electric Vehicle road rescue), and V2G (Vehicle-To-grid) (Vehicle To grid and can be used for grid peak clipping and valley filling), the trend of bidirectional operation of the Vehicle-mounted charger is more and more obvious, and the output of the power battery of the new energy Vehicle is converted from direct current To alternating current (single phase) through the bidirectional Vehicle-mounted charger and is used for electric equipment outside the Vehicle.
The environmental reliability test is to evaluate the working condition of a product under environmental stress conditions (such as temperature and humidity). The environmental reliability test generally requires a plurality of tested pieces to be tested simultaneously, the test time is relatively long (up to thousands of hours), and the test working condition setting (such as temperature and humidity conversion, working mode switching, load conversion and the like) is involved. At present, aiming at the environmental reliability test of the bidirectional vehicle-mounted charger, an environmental reliability test method of the traditional vehicle-mounted charger is basically used for reference, the alternating current input end of a tested piece is directly connected to a power grid, and the direct current output end of the tested piece is connected to a fixed resistance resistor, as shown in figure 1.
The above test system has the following disadvantages:
the automatic environmental reliability test of the bidirectional vehicle-mounted charger under various operation modes (mainly including a charging mode and a discharging mode) and various load conditions cannot be realized. If the environment reliability test of the bidirectional vehicle-mounted charger in the discharging mode cannot be carried out, and the environment reliability performance can only be tested under the condition of fixed load, if the running condition needs to be changed, the software of the tested piece needs to be changed, the load needs to be replaced and the like manually.
SUMMERY OF THE UTILITY MODEL
The utility model aims to provide a device for realizing automatic test of the environmental reliability of a bidirectional vehicle-mounted charger.
The utility model aims to be realized by the following technical scheme: an environment reliability testing device of a bidirectional vehicle-mounted charger comprises N testing branch circuits, wherein N is more than or equal to 2, each testing branch circuit comprises an alternating current electronic load and a high-voltage direct current bidirectional power supply, the alternating current electronic load and the high-voltage direct current bidirectional power supply are respectively connected with the bidirectional vehicle-mounted charger during testing, the testing device also comprises a testing computer, the testing computer is respectively connected with the alternating current electronic load, the high-voltage direct current bidirectional power supply and a tested piece during testing, the impedance of the alternating current electronic load is adjusted, the high-voltage direct current bidirectional power supply is set to work in a power supply mode or a load mode, the impedance of the high-voltage direct current bidirectional power supply under the load mode is adjusted, the output of the tested piece is controlled, the testing device also comprises a switching circuit, a charging power supply connecting end of the tested piece and the alternating current electronic load are respectively connected with the tested piece through the switching circuit, the switching circuit is also connected with the test computer and used for switching the communication relation between the tested piece and the charging power supply connecting end thereof as well as the alternating current electronic load and awakening the tested piece under the control of the test computer.
When the charging mode is tested, under the instruction of a testing computer, the switching circuit controls the charging power supply, the tested piece and the high-voltage direct-current bidirectional power supply to be communicated, meanwhile, the testing computer sets the high-voltage direct-current bidirectional power supply to work in a load mode, a charging mode testing circuit of the tested piece is built, and testing of the charging mode under various load conditions is achieved by setting the high-voltage direct-current bidirectional power supply as impedance when the load is loaded.
When the discharge mode test is needed, under the instruction of a test computer, the switching circuit disconnects the charging power supply from the tested piece, and then the high-voltage direct-current bidirectional power supply, the tested piece and the alternating-current electronic load are communicated.
When the charging and discharging mode is tested, the testing computer can also adjust the output of the piece to be tested according to the set condition.
The switching circuit is provided with a working power supply input end, a communication control end, a three-phase four-wire input end compatible with single-phase and three-phase AC charging power supply input, N groups of three-phase four-wire output ends compatible with single-phase and three-phase AC output, N groups of single-phase output ends and N Wakeup output ends, the three-phase four-wire input ends are parallelly output to each group of three-phase four-wire output ends, a switch is connected in each parallel circuit in series, each group of the N groups of three-phase four-wire output ends is connected to the N groups of single-phase output ends in a parallel mode, and a switch is also connected in each parallel circuit in series.
During testing, the working power supply input end of the switching circuit is externally connected with a low-voltage direct-current power supply, the communication control end is connected with a testing computer, each Wakeup output end can be respectively connected with a tested piece, the three-phase four-wire input end is connected with a single-phase or three-phase AC charging power supply, N groups of single-phase output ends are respectively connected with N alternating-current electronic loads, and each group of three-phase four-wire output ends can be respectively connected with a tested piece.
The switching circuit can receive the unidirectional input of AC220V or the three-phase input of AC380V, and the unidirectional input and the three-phase input are parallelly switched to each group of three-phase four-wire output ends, so that a plurality of vehicle-mounted chargers can be simultaneously connected, two different alternating current input specifications are provided for the vehicle-mounted chargers, and the requirements of a part 2 alternating current charging interface of a connecting device for conducting charging of GB/T20234.2-2015 electric vehicles on the alternating current charging interface of the vehicle-mounted chargers are met. The switching circuit realizes one-to-many conversion in the charging mode and many-to-many conversion in the discharging mode, meets the requirement of simultaneously testing a plurality of tested pieces in the environment reliability test, and has simple and clear circuit topology.
The control circuit of each switch in the switching circuit is composed as follows:
it includes MCU, high limit drive circuit, low limit drive circuit and CAN bus circuit, and high limit drive circuit's signal amplitude is greater than low limit drive circuit, MCU with high limit drive circuit, low limit drive circuit and CAN bus circuit link to each other respectively, control high limit drive circuit output wakeup signal, control low limit drive circuit output switch control signal, and pass through CAN bus circuit input/output CAN communication control signal.
The wakeup signal is highly active, requiring the use of a high-side driver chip. The automobile control chip is imported abroad, and the output of the designed high-end driving chip is generally below four paths. Because the switching signals can be controlled by the low-end driving chip, and the number of output circuits of the switching signals is large, the number of output circuits of the low-end driving chip is generally high in selectivity and low in cost compared with the high-end driving chip. Therefore, the wakeup signal is output only through the high-end driving chip, so that the cost is saved.
During testing, a tested piece is placed in the environment test box, and the alternating current electronic load, the high-voltage direct current bidirectional power supply and the test computer are all placed outside the environment test box.
The switching circuit is fixedly sealed in a box body to form an independent unit which completes the set function, and the independent unit is called a switching box in the following, and the switching box is placed in the environment test box during testing. The length of a connecting circuit between the adapter box and the piece to be tested is shortened while the connection relation of the circuits is simplified.
Compared with the prior art, the utility model has the following beneficial effects:
the testing device can meet the automatic test of the environmental reliability of the bidirectional vehicle-mounted charger under different load conditions and in different operation modes (charging mode and discharging mode) so as to achieve the aims of verifying the product quality and improving the testing efficiency.
Drawings
FIG. 1 is a block diagram of a conventional vehicle-mounted charger for testing environmental reliability;
FIG. 2 is a circuit connection block diagram of the bi-directional vehicle charger when the testing device of the preferred embodiment of the utility model is used for testing the environmental reliability of the bi-directional vehicle charger;
FIG. 3 is an internal electrical diagram of the adapter box;
FIG. 4 is a diagram of an internal control circuit of the adapter box;
FIG. 5 is a schematic diagram of a sleep mode;
FIG. 6 is a schematic view of a charging mode;
fig. 7 is a schematic diagram of a discharge mode.
Detailed Description
Fig. 2 is a circuit connection block diagram of the testing device according to the preferred embodiment of the utility model when the testing device is used for testing the environmental reliability of the bidirectional vehicle-mounted charger. The testing device of the embodiment mainly comprises a switching box, an alternating current electronic load, a high-voltage direct current bidirectional power supply and a water chiller. The switching circuit is fixedly sealed in the box body to form an independent unit which completes the setting function, namely the switching box in the embodiment.
The low-voltage side of the tested piece of the bidirectional vehicle-mounted charger in the figure and the working power supply input end of the adapter box are connected with a low-voltage direct-current power supply, and the working power supply is provided by the low-voltage direct-current power supply. And a single-phase or three-phase alternating current network outside the environmental test box is connected to the three-phase four-wire input end of the junction box through the circuit breaker. Three-phase four-wire output ends of the adapter box are respectively connected to the high-voltage input end of the three-group bidirectional vehicle-mounted charger, and the other three single-phase output ends of the adapter box are respectively connected to three alternating-current electronic loads outside the environmental test box. And the direct-current high-voltage end of the bidirectional vehicle-mounted charger is connected to a high-voltage direct-current bidirectional power supply outside the environment test box.
Three groups of water inlets and water outlets of the water cooler are respectively connected to corresponding bidirectional vehicle-mounted chargers to cool the bidirectional vehicle-mounted chargers during working. CAN communication control lines of the bidirectional vehicle-mounted charger and the adapter box are connected to a CAN card outside the environmental test box, and are converted into USB interfaces to be connected to a test computer. The AC electronic load and the high-voltage DC bidirectional power supply are respectively connected to the switch through network ports and then are switched to a test computer, a tested piece and external equipment (mainly comprising the AC electronic load, the high-voltage DC bidirectional power supply and the switching box) are networked through a CAN (controller area network) and a LAN (local area network), the switching box is controlled to change the communication relation between the tested piece and a charging power supply connecting end and the AC electronic load, so that a circuit is switched to a charging or discharging connection mode, and then the AC electronic load, the high-voltage DC bidirectional power supply and the tested piece are controlled to realize the automatic test of the environmental reliability under different operation modes and different load conditions. In the figure, the Wakeup 1-3 signals are the bidirectional vehicle-mounted charger Wakeup signals controlled by the tested computer respectively.
Fig. 3 is an internal electrical diagram of the adapter box.
As shown in fig. 3, the internal electrical connections of the junction box are that ac high-voltage inputs (L1, L2, L3, N) pass through a short-circuit protector (current-limiting protection), and then are connected in parallel to 4 contacts corresponding to the contactors T1 to T3, 2 contacts corresponding to the contactors T1 to T3 are connected to contacts corresponding to the contactors T4 to T5, and G11, G21, G31, G12, G22, and G32 are coil control terminals corresponding to the contactors T1 to T6, respectively. G01-G06 are coil control ends of relays D1-D6 respectively, and control logic relations of contactors T1-T6 are as follows:
TABLE 1 contactor T1, T4 control logic table (corresponding to "tested piece _ 1")
TABLE 2 contactor T2, T5 control logic table (corresponding to "tested piece _ 2")
TABLE 3 contactor T3, T6 control logic table (corresponding to "tested piece _ 3")
As can be seen from table 1, when Wakeup1 is invalid (floating), the device under test is in sleep mode; when the Wakeup1 is effective (12V), the tested piece is awakened to normally work, and when the tested piece is in a charging mode, three-phase or single-phase alternating current input is connected to the high-voltage alternating current input end of the sample through the control of G01 and G04; when the tested piece is in a discharge mode, the high-voltage alternating-current single-phase output of the sample is connected to an alternating-current electronic load outside the darkroom through the adapter box.
Table 2 and table 3 work the same.
An internal control circuit of the adapter box is shown in fig. 4, a low-voltage direct-current power supply outputs 12V to a power supply circuit and a high-side drive circuit, the power supply circuit converts 12V into 5V to respectively supply power to a single chip Microcomputer (MCU), a low-side drive chip and a CAN bus circuit, pins PTC0, PTC1 and PTC2 of the single chip microcomputer are connected to the input end of the high-side drive circuit to control Wakeup 1-Wakeup 3 to output, and a CAN Module (MSCAN) of the single chip microcomputer is connected to a CAN card outside an environmental test box through the CAN bus circuit and is connected with a test computer after being converted into USB. And an SPI bus module of the singlechip is connected to the low-end driving chip and controls the outputs of G01-G06.
The wakeup signal is highly active, requiring the use of a high-side driver chip. The automobile control chip is imported abroad, and the output of the designed high-end driving chip is generally below four paths. Because the switching signals can be controlled by the low-end driving chip, and the number of output circuits of the switching signals is large, the number of output circuits of the low-end driving chip is generally high in selectivity and low in cost compared with the high-end driving chip. Therefore, the wakeup signal is output only through the high-end driving chip, so that the cost is saved.
The core chip of the internal control circuit of the adapter box is selected as follows:
a single chip microcomputer chip: MC9S08DZ128 high side driver chip: VNQ5E050K-E
A low-end driving chip: TLE6240
A CAN bus chip: TJA1051T
Power supply circuit chip: TLE6389-3 GV 50.
As can be seen from fig. 2, fig. 3, and tables 1 to 3, when the tested object is in the sleep state, the high-voltage ac input is disconnected, the connection with the ac electronic load is disconnected, and the low-voltage part and the high-voltage part of the tested object do not work, and the schematic diagram is shown in fig. 5.
When the tested piece works in a charging mode, the high-voltage alternating-current end of the tested piece is provided with input and is disconnected with the alternating-current electronic load, the direct-current high-voltage end of the tested piece outputs voltage to the high-voltage direct-current bidirectional power supply outside the environment test box, and the direct-current high-voltage bidirectional power supply works in an inversion mode (direct current inversion is alternating current, and electric energy is fed back to an alternating-current power grid) at the moment, and is equivalent to a high-voltage direct-current load.
When the tested piece works in a discharge mode, the input port of the high-voltage alternating current end of the tested piece is disconnected, the alternating current electronic load input is connected to the tested piece, and the high-voltage direct current bidirectional power supply outside the environmental test box works in a rectification mode (alternating current of a power grid is rectified into high-voltage direct current output, and electric energy is transmitted to the tested piece through an alternating current power grid).
The testing device can realize the automatic environmental reliability test of a plurality of samples under the conditions of realizing different running modes and different loads of the bidirectional vehicle-mounted charger, the power of a piece to be tested is not required to be cut off midway, the power supply and the load of the piece to be tested are not required to be replaced, the testing efficiency of a product can be improved, and the quality of the product can be better verified simultaneously. The testing device realizes automatic switching of alternating current input of a power grid and alternating current output of a tested piece through the adapter box, is safe and reliable, meets the requirements of a bidirectional vehicle-mounted charger with three-phase alternating current input and single-phase alternating current input, is compatible with the three-phase alternating current input and single-phase alternating current output states of the bidirectional vehicle-mounted charger, and is convenient and reliable in wiring, high in universality and wide in application.
Claims (5)
1. The environment reliability testing device of the bidirectional vehicle-mounted charger is characterized by comprising N testing branch circuits, wherein N is more than or equal to 2, each testing branch circuit comprises an alternating current electronic load and a high-voltage direct current bidirectional power supply, the alternating current electronic load and the high-voltage direct current bidirectional power supply are respectively connected with the bidirectional vehicle-mounted charger during testing, the testing device further comprises a testing computer, the testing computer is respectively connected with the alternating current electronic load, the high-voltage direct current bidirectional power supply and a tested piece during testing, the impedance of the alternating current electronic load is adjusted, the high-voltage direct current bidirectional power supply is set to work in a power mode or a load mode, the impedance of the high-voltage direct current bidirectional power supply under the load mode is adjusted, the output of the tested piece is controlled, the testing device further comprises a switching circuit, the charging power supply connecting end of the tested piece and the alternating current electronic load are respectively connected with the tested piece through the switching circuit, the switching circuit is also connected with the test computer and used for switching the communication relation between the tested piece and the charging power supply connecting end thereof as well as the alternating current electronic load and awakening the tested piece under the control of the test computer.
2. The test apparatus as claimed in claim 1, wherein the switching circuit is provided with an operating power input terminal, a communication control terminal, a three-phase four-wire input terminal compatible with single-phase and three-phase AC charging power inputs, N sets of three-phase four-wire output terminals compatible with single-phase and three-phase AC outputs, and N sets of single-phase output terminals and N Wakeup output terminals, the three-phase four-wire input terminals are output in parallel to each set of three-phase four-wire output terminals thereof, and a switch is connected in series in each parallel line, each set of N sets of the three-phase four-wire output terminals is connected in parallel to each set of N sets of the single-phase output terminals, and a switch is also connected in series in each parallel line.
3. The test apparatus according to claim 2, wherein the control circuit of each switch in the switching circuit is configured as follows:
it includes MCU, high limit drive circuit, low limit drive circuit and CAN bus circuit, and high limit drive circuit's signal amplitude is greater than low limit drive circuit, MCU with high limit drive circuit, low limit drive circuit and CAN bus circuit link to each other respectively, control high limit drive circuit output wakeup signal, control low limit drive circuit output switch control signal, and pass through CAN bus circuit input/output CAN communication control signal.
4. The testing device of claim 3, wherein during testing, the tested piece is placed in an environmental test chamber, and the alternating current electronic load, the high-voltage direct current bidirectional power supply and the testing computer are all placed outside the environmental test chamber.
5. A test device as claimed in claim 4, wherein the switching circuit is enclosed in a case to form an independent unit performing a predetermined function, hereinafter referred to as a patch box, which is placed in the environmental test chamber during the test.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114720809A (en) * | 2022-06-09 | 2022-07-08 | 深圳市明珞锋科技有限责任公司 | Vehicle-mounted bidirectional charger test system and control method thereof |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114720809A (en) * | 2022-06-09 | 2022-07-08 | 深圳市明珞锋科技有限责任公司 | Vehicle-mounted bidirectional charger test system and control method thereof |
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