Aging test bench for AC single-phase and three-phase charging piles

【2】 Safety precautions

Safety signs:

In this manual, there are safety precautions and important display items when using the instrument. To prevent accidents and dangers, please be sure to follow the following dangerous, warning, and cautionary notes:

Danger: This displayed item indicates that if not followed, the operator may be injured.

Warning: This displayed item indicates that failure to comply may result in damage to the instrument.

Attention: The items displayed here indicate that they may affect the test results and quality.

[Three]Aging test bench for AC single-phase and three-phase charging pilesOverview

1.1 Equipment Introduction

This communication charging gun aging testing machine scheme adopts excellent computer control and energy feeding load, and the testing system is more intelligent, energy-saving and environmentally friendly.

1) Intelligence: The software automatically monitors aging, faults, or defects, automatically cuts off power, and prompts alarm messages

Equipment automatic short circuit fault sample, continue testing at other workstations

2) Energy saving: Using energy feeding loads to achieve energy recovery and energy conservation

3) Environmental Protection: Electric energy is fed back to the power grid without generating a large amount of heat, avoiding an increase in ambient temperature in the testing site

4) Traceability: Test data can be queried and traced in real-time

1.2 Applicable Products

Used for aging testing of single-phase AC charging gun stations to ensure product shipment meets requirements. Suitable for aging testing of electric vehicle AC charging guns/piles that comply with GB/T 18487.1-2015, IEC 62196-2-2016, SAE J1772-2017, and SAE J1772-2017. The actual product is shown in the following figure:

Standards: Single phase three-phase national standard, European standard, American standard

Load voltage: single-phase AC 0~300V, three-phase 0~420V (external input, power supply provided by the user)

Load current: 1~32A continuously adjustable

1.3 Test schematic diagram

The test schematic is shown in the following figure. KM represents the contactor, 13A represents the AC socket, black squares represent the AC charging gun holder, control guidance is the control guidance module, and M2 represents AC charging gun mode 2.

1.4 Test Control Principle

Equipment wiring schematic, using 10 products as examples, with the backend connected in series. The maximum number of tests for voltage drop is limited to the maximum allowable range. This device has 2 groups, with 10 products in each group being tested online simultaneously. Note: KMXA and KMXB are interlocked and cannot be simultaneously engaged.

Introduction to the operating principle of electrical appliances:

Station 1, insert the product, the KM contactor is closed, the M2 product is powered on, and S2 is guided to start charging through control. If the product in Station 1 is charging normally, KM1B is closed and KM1A is disconnected. If there is no charging or no product, KM1A is closed and KM1B is disconnected, and the power is directly transmitted to Station 2;

Station 2, insert the product, the KM contactor is closed, the M2 product is powered on, and S2 is guided to start charging through control. If the product in Station 2 is charging normally, KM2B is closed and KM2A is disconnected. If there is no charging or no product, KM2A is closed and KM2B is disconnected, and the power is directly transmitted to Station 3;

And so on

Workstation 12, insert product, KM contactor engages, M2 product is powered on, S2 starts charging by controlling and guiding the engagement. If workstation 2 product is charging normally, KM12B engages and KM12A disconnects. If there is no charging or no product, KM12A engages and KM12B disconnects, and the power is directly transmitted to the load contact;

The power meter measures the aging voltage and current of the tested product in a cyclic manner, and stops aging if any defects are found.

1.5 Energy Feed Load

The load adopts an energy feedback load, also known as an energy feedback electronic load. Compared with ordinary resistive loads, its working mode is to use power electronic conversion technology to recycle and reuse the output energy of the tested power source on the premise of completing the test power experiment, and to feed back the electrical energy to the grid without pollution. This not only saves energy but also does not generate a large amount of heat, avoiding the problem of rising ambient temperature in the test site.

1.6 Software

The system software has one click testing, and all test results can be recorded and queried. It has a QR code scanning function, which can trace product test data. The control panel is designed ergonomically, and the equipment can perform self inspection.

(1) The operating software adopts a Chinese interface, which is simple and easy to learn;

(2) Computerized operation, all tests completed in one go

(3) Can be connected to MES system

(4) Scan code test

(5) Test data traceability

(6) Test data can be automatically saved as EXECL or TXT documents

【4】 Whole machine picture

The pictures are for reference only and subject to the actual product (Figure 1)

【5】 Main technical parameters

1. Number of workstations: 2 layers per group, 5 workstations per layer, a total of 2 back-to-back groups, totaling 20 workstations;

2. Load requirements: Each group is connected to a 0-32A intelligent electronic control load, using a feedback type load;

3. Power sockets: Each workstation is equipped with wiring terminals;

4. Each 10 workstations is equipped with 1 load, for a total of 2 loads

5. Charging gun holder: Each workstation is equipped with single and three-phase AC charging gun holders that meet national, American, and European standards;

6. Simulated charging: Simulate the entire charging process by connecting the charging gun cluster;

7. Parameter setting: Industrial computer management system, load current, testing time and other parameters can be freely set in the computer;

8. Storage requirements: Aging data automatically corresponds to each product barcode storage and can generate electronic reports for printing and output;

9. Data upload: Integrate with MES system, data can be uploaded to our company's traceability system and accessed at any time;

10. Working power supply: AC220V/50Hz, aging power supply, AC380V/50Hz；

11. Equipment dimensions: length 1800mm X width 1200mm X height 1620mm.

【6】 Panel Description

Figure 1

Figure 2

Figure 3

Figure 4

Main power switch of the whole machine

Start Group 1

Stop Group 1

Switching between single-phase and three-phase modes in Group 1

Group 1: Connect the power supply

Start Group 2

Stop Group 2

Switching between single-phase and three-phase modes in Group 2

Group 2: Connect the power supply

USB port

scanner gun

keyboard and mouse

Keyboard and mouse bracket

American standard gun end mount

European Spear End Seat

National standard gun end socket

European standard single-phase 32A socket

Line sequence terminals L1, L2, L3, N, PE

National standard 16A socket

American standard 15A socket

European standard 16A socket

Load power switch

Control power switch

Load power input

Control power input

Instrument nameplate information

computer case

Three phase feedback load box

computer monitor

Group 1 alarm

Group 2 alarm

【7】 Instructions for use

1. Power connection: Connect the power input to the external power supply AC220V, and connect the three-phase load power input to the three-phase power supply. Press the "power main switch" on the side panel, turn on the "power switch" knob on the control panel, and the machine will start. To select the three-phase mode for testing, turn on the "single-phase, three-phase switching" switch at the same time.

2. After turning on the computer, enter the standby interface. Open the desktop testing software, enter the testing interface, manually enter the part number, scan the workstation barcode, and then press Enter to save, as shown in Figure 5.

Figure 5

3. After installing the sample, click on the upper left corner to enter the "Parameter Settings" interface, enter the corresponding "Parameter 1 Settings", set the current (A), set the testing time, check the start station 1 (i.e. the first group), turn on (check) the switch of the testing station, click save, as shown in Figure 6.

Figure 6

4. After setting the parameters in the previous step, press the "Start" button on the control panel to enter the start testing interface, browse the data, and if the current workstation displays green, it means the test is qualified, and if it displays red, it means the test is unqualified, as shown in Figure 7 and Figure 8.

Figure 7

Figure 8

Reset time: Clear the set time;

Reset alarm: Reset alarm information;

Starting: Testing begins;

Stopping: Stop testing;

5. After testing, save the data and click on "Browse Data" in the upper left corner to open Data1, as shown in Figure 9.

Figure 9

6. The test report is as follows: