Customized Testing Equipment
Third-party testing laboratories, domestic emerging new energy automobile parts manufacturers
Application Scenario
On-board charger (OBC) is a core component in new energy vehicles, which makes it possible for new energy vehicles to use 220V mains power and still realize the charging function, expanding the usage scenarios and providing convenience for users. The product transforms the civilian 220V AC power into 350V DC power that can charge the high voltage battery through boost conversion, and controls the charging current during the process, and maintains communication with the battery management system (BMS) to protect the safety of the charging process. As the final inspection equipment in the production process, the off-line test bench must carry out functional tests for each product according to the inspection standards set by the state and enterprises to ensure that the products leaving the factory are free from defects, and the inspection data will also be uploaded to the production management data system (MES) to provide original data for product quality traceability.
Test items and realization scheme
According to the national standards and the working principle of the product, the topology logic of the off-board charger (OBC) test bench is shown in the following figure:
- Hibernation and wake-up: including hibernation quiescent current, hibernation PG signal, CP wake-up, AC wake-up control peripheral relays to make the product enter hibernation state, test current and PG output voltage for judgment Use signal generator board to output CP signal (pulse signal with certain frequency and duty cycle) to the product to test whether the product can be woken up normally Start the AC power supply, turn on the AC terminal power supply to the product, test whether the product can be woken up normally, and at the same time, test the peak current, and test whether the product can be woken up normally, and at the same time, test the peak current. Test whether the product can be woken up normally and test the peak current at the same time.
- Pre-charging characteristics: send commands to make the product enter the pre-charging state, and test the time required for the product to reach the pre-charging state.
- Low-voltage power supply compatibility test: through the command, change the size of the low-voltage power supply voltage to test whether the product's characteristics are affected in the specified power supply range, usually the test voltage varies from 9 to 16V.
- AC power supply compatibility test: through the instruction, change the AC power supply voltage size and power supply frequency, test in the national standard grid power supply quality, whether the characteristics of the product is affected, usually the test voltage (RMS) in the 170 ~ 270V changes, frequency in the 48 ~ 52Hz changes.
- Run-in test: test products in different power supply voltage and charging current characteristics, including voltage accuracy, current accuracy, power factor, efficiency, product CAN message, etc., equipment mobilization AC power supply, electronic load, power meter, oscilloscope and other instruments, to meet the test, and upload the collected results to the production management system (MES)
- Input over-voltage/under-voltage protection test: Use AC power supply to simulate the input voltage other than the normal working voltage, check the CAN message, fault signal and output voltage of the product, and test whether the product shuts down the output and enters into the protection state.
- Output over-voltage/under-voltage protection test: use DC power supply, when the product is in standby mode, output voltage out of range to the output terminal of the product, check the CAN message and fault signal of the product, and test whether the product enters into the protection state.
- Short-circuit protection: send a short-circuit command to the electronic load to see if the product can detect the output short-circuit state, and test whether the product can shut down the output within the specified time and enter the protection state without generating abnormal high current in the process.
- Over-temperature protection: send commands to make the product's highest power output and temporarily stop the product's heat dissipation facilities, monitor the product's internal test temperature and CAN message information, and when the temperature reaches the point where the test product is able to cut off the output and enter the protection state, as well as pass the fault information through the CAN message
System integration and security
- PC-based instrument communication system, command distribution execution system, data acquisition and recording system.
- PLC as auxiliary I/O control and safety control
- Safety relays combined with light curtains and online insulation testers form an emergency stop system and hardware protection system to prevent electric shock, mechanical damage and other dangers to testers.
Core parameters
- Number of test samples: 1
- AC power supply: 10 ~ 400 VAC 5 kW
- Low voltage power supply: 0 ~ 36 V 0 ~ 20 A 0 ~ 720 W
- High voltage electronic load: 10 ~ 400 V 0 ~ 20 A 0 ~ 4800 W
- CP Signal: ±9 ~ ±16 V 5% ~ 95% Duty Cycle
- Ambient Temperature: -40 ~ 120 ℃
- Cooling condition: air-cooled
- Communication Type: CAN, Ethernet, RS232, RS485
- Data Acquisition: AC-side voltage, AC-side current, DC-side voltage, DC-side current, power factor, efficiency, temperature, CAN message, etc.
- Data logging: 100 Samples/s acquisition and real-time processing, test results uploaded to MES
Software Architecture
The software has a good modular distribution design to ensure flexible and rapid development of the software.
Automated Test Interface
Manual and Test Interface
