Prosedur Pagsusi sa Field alang sa mga Charging Piles sa Electric Vehicle

Isipagtrabaho isip teknisyan nga nahimutang sa unang linya sa pag-test sa charging pile, ang akong pangadag-um nga trabaho nagpakita og usa ka bagay nga malinaw: samtang ang standard sa kinabuhi sa mga tawo mogamay, ang demand sa mga sasakyan nagsugyot. Tungod sa kasikatan sa konsepto sa proteksyon sa kalibutan, ang industriya sa electric vehicle (EV) kasagaran mobuto. Ang mga charging pile, isip “lifeline” sa mga EV, direkta nagpahayag kung makapila ug maayo ang mga EV mokonduktar. Sa simple, ang amua trabaho sa pag-test mao ang “diagnose” sa mga charging pile, siguradohon ang ilang performance nga dili matog. Kini nga trabaho nagkinahanglan og atensyon ug presisyon.

1. Overview sa Electric Vehicle Charging Piles: Pagbutok sa Industria ug Kahalagahan sa Pag-test

Ang global na industriya sa paggama naka-set sa high gear, nakakonsumo og resources sa astunhante nga rate. Ang mga mahimong resources sama sa petroleum gititikloan sa iba't ibang sektor, ug ang mga reserve kasagaran mobuto. Isip derivative sa petroleum, ang demand sa gasoline ug diesel mobuto ngadto sa mas daghan nga sasakyan. Gikan sa perspektibo sa kalibutan ug sustainable development, ang mga fuel-powered vehicles destinahe nga mobag-o. Kasagaran, ang hybrid ug pure electric vehicles kasagaran mobuto tungod sa ilang low o zero fuel consumption, ug ang industriya sa charging equipment “taking off” sa parehas, uban ang mga bag-ong teknolohiya ug devices nga mobuto sa regular basis.

Gikan sa perspektibo sa pag-test, adunay daghang key classifications para sa charging equipment:

• Batasan sa Electrical Input: AC charging piles (depende sa on-board charger para sa power conversion) ug DC chargers (direkta mag-supply og power sa battery);

• Batasan sa Installation Method: Floor-mounted ug wall-mounted, gipili batasan sa site conditions;

• Batasan sa Equipment Structure: Split-type ug integrated, naapektuhan ang installation ug maintenance difficulty;

• Batasan sa Accuracy Level: Class 1 ug Class 2, nagpahayag sa precision sa energy measurement. Kini nga mga classification form the “baseline knowledge” nga kinahanglan ko master bago ang bawat test.

Ang AC charging piles nagserbi isip “intermediaries” nga mag-supply og AC power sa on-board charging system: ang single-phase piles angkop sa small vehicles, karaniha molihok 3–8 oras aron mopuno; ang three-phase piles nag-enable sa fast charging sa medium-to-large buses, molihok 80% charge sa katugbang sa usa ka oras. Tungod sa tuig-tuig nga pag-test, nakakita ko nga ang pag-test sa charging pile kinahanglan “comprehensive” — ang mga parameters sama sa output voltage, current, ug frequency direkta nagpahayag sa pile's control, data acquisition, ug processing capabilities. Mas pa, ang seguridad sa charging piles “a matter of life and death”; bisan unsa nga malfunction makapailoy sa EV nga dili mokonduktar.

Subong, ang kasagaran nga mga metodo sa pag-test adunay limitasyon. Ang environmental testing method, nga gigamit og physical batteries, dili maka-simulate sa real-world charging conditions, resulta sa large errors ug low efficiency. Kini nagpilit sa amua frontline testers nga mobuto uban sa R & D sa new energy vehicles, pag-improve sa standards sa pag-test aron makapagtubag sa industry progress.

2. On-Site Testing Methods para sa Electric Vehicle Charging Piles: Practical Insights gikan sa Frontline
2.1 Configuration sa On-Site Testing Platform
2.1.1 Hardware Platform

Ang automatic testing platform nga gigamit nato kinahanglan kompatibel sa AC pile testing ug support interoperability. Puli, sa panahon sa pag-test sa three-phase 63A pile, ang AC power supply set sa 60kVA, nag-output 0VAC–300VAC aron minimizaha ang harmonic current ug avoid grid interference. Single-phase independent loading, tungod kay ang bawat phase nag-operate separately, simula sa loading conditions sa nonlinear charging modules ug chargers, generating an impact force twice the rated current. Kini nga mga parameter settings mao ang “battle-tested” insights nakuhado gikan sa countless tests.

Ang charging piles depende sa AC power supplies ug kinahanglan simulate “disruptions” sama sa harmonics ug voltage sags sa mains supply, siguradohon ang pile's data meets national standards sa extreme conditions. Pure resistive loads programmed for single-phase control, meeting testing requirements for both single-phase ug three-phase piles.

Gamiton ang AC charging test interface aron simulate ground faults ug switch logic, combined with power supplies ug loads, makakita kita sa compatibility sa pagitan sa pile ug EV, verifying the effectiveness of protective actions. High-precision power meters collect voltage ug current data; a 6.5-digit digital multimeter installed in the data acquisition card with 20 channels for simultaneous measurement. Signal gating devices work with oscilloscopes to capture switching signals, ug serial servers connect to industrial computers for real-time data exchange ug reporting. Kini nga hardware setup mao ang “backbone” sa testing accuracy.

2.1.2 Testing Software

Ang software kinahanglan open, integrating various test data to centrally manage devices, programs, ug reports while ensuring data security. Ang software nga gamiton ko features a secondary programming interface, facilitating frontline testers to adjust programs ug process data.

Ang human-machine interface (HMI) highly functional: parameter detection, dynamic display, operation control, ug report generation, with online customization of interface effects. The client module communicates via data interfaces ug control commands; the control command module receives, executes, ug verifies commands, unifiedly managing device interfaces. If hardware changes, configurations updated to simplify upgrades. The data module responsible for data collection, storage, ug processing, separating parameter ug result verification, ug defining hardware configurations.

Maayo ko ang software operation process: log in, select test items, adjust program commands in real-time, ug send instructions to the control cabinet. After executing a project, view edit commands on the left ug variables/reports on the right. Online monitoring allows adjustment of oscilloscopes ug power analyzers; start testing, collect data, ug save to a folder. This streamlined process significantly boosts testing efficiency.

2.2 Testing Items: Key Checkpoints for Frontline Testing
2.2.1 Inspection of Appearance ug Structure

Sa bawat test, ang una nga hakbang mao ang inspection sa charging pile's casing ug nameplate. Ang nameplate kinahanglan clear ug complete, with proper safety protections in place, ug free from rust or dust. “Hidden aspects” sama sa power supply, operating environment, electric shock protection, ug electrical clearance must strictly comply with standards. The pile body must be clean, free of cracks ug burrs, ug have neatly arranged wiring. An emergency stop button mandatory, allowing for immediate power cutoff in case of faults. The pile body must be durable, resistant to corrosion ug high temperatures, ug its internal components must be protected against water ug rust. Overlooking any of these details could pose potential hazards.

2.2.2 Inspection of Indicators ug Displays

Though small, indicators ug displays are crucial! Verify their status during charging, faults, ug operation: indicators should light up or flash during operation, remain steadily lit during normal power-on, stay lit (operation indicator) with the charging indicator turning off during charging, ug show a steady operation indicator with a flashing fault indicator during overvoltage/overcurrent. They must also display real-time battery info, charging duration, voltage, ug current, with fault warnings ug manual records. Malfunctions in these functions leave drivers unable to assess the pile's status.

2.2.3 Functional Testing

During automatic or manual testing, BMS data must be used to adjust charging parameters, ensuring charging quality. Before manual operation, parameters are set, devices installed, ug output voltage/current limits monitored in real-time. If the voltage exceeds limits during constant current operation, switch to constant voltage; if the current exceeds limits during constant voltage operation, limit the current; in case of abnormal AC voltage, shut down immediately. These logics are “hard rules” for ensuring charging safety.

2.2.4 Measurement Function Testing

Measurement is the “heart” of charging piles, involving tests for operation error, indication error, payment error, ug clock error. When the load current is between maximum ug minimum, Class 1 piles must have an error ≤±1%, Class 2 ≤±2%; payment amounts must align with unit price ug energy consumption; clock error must not exceed 5 seconds for the first test, with a 3-minute testing duration. These precision requirements directly impact user costs ug charging experience.

3. Application Examples of On-Site Testing for Electric Vehicle Charging Piles: Frontline Battle Records
3.1 Actual Pile ug Load Testing
3.1.1 Testing Object

To validate testing methods, I selected a DC pile at a charging station, focusing on its load performance — frontline testing demands “real-world verification” to truly understand performance.

3.1.2 Testing Conclusions

Taking Pile No. 1 as an example, tests revealed:

• When output voltage deviated, the constant current was 60A;

• When output current deviated, the constant voltage was 400V;

• The voltage-time graph met circuit control requirements.

This test combined AC ug DC side measurements, enabling the charger to operate under load, maintaining constant voltage stability. With an input voltage of 500V, load current was optimized, ug power was measured in real-time — this comprehensive approach thoroughly assessed the pile's performance.

3.2 Testing Issues ug Improvements: Frontline Challenges ug Solutions

• Equipment Issues: Testing devices can display communication messages but fail to generate standardized protocol consistency reports, reducing efficiency; difficulty in achieving constant voltage/current; low integration ug portability, with bulky resistive loads.

Solution: My team ug I added protocol consistency reporting to devices, introduced constant voltage/current modes, ug pushed for device integration — frontline testers must proactively solve these “bottlenecks”.

• Protocol Update Issues: Some piles update communication protocols to international standards, making testing with old standards inaccurate. Testing platforms must support both old ug new standards — we must keep pace with industry updates.

• Inadequate Testing Content: Wireless communication interference during human-machine/network interaction disrupts the EV-to-network APP connection; manual restarts resolve pile faults, requiring core product fault analysis.

Solution: Testing platforms must include these scenarios, evaluating wireless communication stability ug fault self-recovery — frontline issues must be exposed ug resolved during testing.

4. Conclusion: A Frontline Tester's Aspirations for the Industry

Electric vehicles rely on charging piles for “energy”. To ensure charging piles are reliable ug durable, efficient supervision ug inspection systems are essential. As frontline testers, we work closely with piles daily, hoping to identify performance ug safety issues through real-time testing ug implement practical solutions, ensuring the new energy vehicle industry thrives. Industry progress hinges on solid work, ug we testers must “hold the line” in this critical link.