Pêşkêşkirina Testandina Şopîna Li Ber Bilindanên Bajarkeşanî yên Carên Elektrîkî

Wekarên amêrî ya ku di parzûna testkirina stantiyên şarj de were taybet kirin, ji bo dibeş û malpera xwe li ser yek dem: heke çi karên mafan a reng bikin, hewceya ji bar baxta bigihin. Bi serekeca pêşkêşkirina fikiran piştguhanyê, çarçoveya otomobîlên elektrîk (EV) da bermend e. Stantiyên şarj, bi nav "xwazgirdina" otomobîlên elektrîk, hesab dikin ku otomobîlên elektrîk bi rêjiyeyek bingeh û ewlehiyê bibexsin. Bêyî, malperamê li ser testkirina stantiyên şarj ye ku "destpêkirin" ne, ji bo êz diyariyek bingeh û ewlehî bibin. Ebe malpera wekî vê, hesab dikin ku destpêkirina herdewam û qadaqî bibe.

1. Tijîra Stantiyên Şarj Otomobîlên Elektrîk: Perguha Çarçoveya û Erhîya Testkirina

Çarçoveya endametî ya jihan ûst karkeriya berbend û resursên digirin mezin hatin. Resursên pir împortant yên wê, wêçe nîfityar, ji bo hemû çarçoveyan div û divan werin hildan, û darçan di tevahî de zêde din. Wêçe ke nîfityara petrol û dizel da, hewceya ji bo bar baxtan û nîfityaran zêde din. Ji derveka gavaresi û pêşketinê, otomobîlên nîfityar hatin ku bi rêjiyek dihetîn. Îma, otomobîlên hibrit û tu elektrîk, ji bo an jî nîfityar ne û nîfityar ne, hatin ku populer bikin, û çarçoveya cihedana şarj ûst "bermend e", bi teknolojî û cihedên naw werin.

Ji derveka testkirina, stantiyên şarj di navbera zimanên girîng de:

• Bi Girîngên Daxistin: Stantiyên şarj AC (di vir bikeşên on-board de veguhastin) û şargavan DC (bi serî şargav bike);

• Bi Rêza Qebûlkirina: Di ser zemin û di ser divar, bi serekeca şertên cîh;

• Bi Sernasî Pirantiyê: Divî û biryar, ku heseb dike ser qalib bikin û bêtir bike;

• Bi Daraja Serhatî: Klase 1 û Klase 2, ku heseb dike ser serhatîya qadegilkirina energy. Ev zimanên "baz" min dikin ku min parê li ser her testê bêtir bikim.

Stantiyên şarj AC wêne "navenda navend" ji bo danasîna girîng AC bi vir bikeşên on-board: stantiyên yek fasayî ji bo otomobîlan kêmkir û sedemî, di navbera 3-8 saet de şarj bide; stantiyên sê fasayî ji bo otobûsên mezopot û mezin, bi navbera 30 deqîqeyê 80% şarj bikin. Li ser salên testkirina, min girîda ku testkirina stantiyên şarj "herdu" bibe - parametrên wan, wêçe voltage, current, û feqr, bixwestina kontrol, data collection, û process bikin. Herî paş, ewlehiya stantiyên şarj "ser jîyan û mirina" ye; her çareseriya wî otomobîlê elektrîk bêtir bike.

Bêyî, rastên testkirina niha zorên hundur dikin. Metoda testkirina envîronmentî, ji bo bataryaya fîzik, nebêş bibe ku şartên real a şarj bikişînin, ku hundurek hata û efektivîyet zêde din. Vê me watekê testkirina li ser parzevan hewce dide ku bi R & D ya otomobîlên new energy ber bikerin, standarde testkirina bêtir bikin, ji bo bermendkirina çarçoveya.

2. Rastên Testkirina Stantiyên Şarj Otomobîlên Elektrîk: Hesabdarên Praktîkî yên Parzevan
2.1 Cihedana Platformê ya Testkirina Li Ser Parzevan
2.1.1 Platformê Hardware

Platformê automatîkê ya ku min bikar in, ya ku bi testkirina stantiyên AC kompatîbl e û interoperability support bide. Mînak, ji bo testkirina stantiyên sê fasayî 63A, girîng AC set bikin 60kVA, 0VAC-300VAC dideger bikin, ku harmonic current zêde bikin û interference grid bine. Loading yekfasayî independent, har fasayek bi navbera xwendin, şartên loading a module û şargavan non-linear bikişînin, impact force twice the rated current bide. Ev parametrên set bikin "battle-tested" hesabdarên ku ji her testê hilîn.

Stantiyên şarj bi girîngên AC dîtin û disruptions like harmonics û voltage sags di mains supply de simule bikin, ku data stantiyên şarj standardên nasional under extreme conditions bide. Loads resistive pure bi control yekfasayî program bikin, ji bo testkirina stantiyên yekfasayî û sê fasayî.

Bi interface testkirina şarj AC ground fault û switch logic simule bikin, bi power supplies û loads, compatibility between stantiyên şarj û EV bide, verifying effectiveness of protective actions. High-precision power meters collect voltage û current data; digital multimeter 6.5-digit installed in data acquisition card with 20 channels for simultaneous measurement. Signal gating devices work with oscilloscopes to capture switching signals, and serial servers connect to industrial computers for real-time data exchange and reporting. This hardware setup is the "backbone" of testing accuracy.

2.1.2 Testing Software

Software must be open, integrating various test data to centrally manage devices, programs, and reports while ensuring data security. The software I commonly use features a secondary programming interface, facilitating frontline testers to adjust programs and process data.

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

I'm well-versed in the software operation process: log in, select test items, adjust program commands in real-time, and send instructions to the control cabinet. After executing a project, view edit commands on the left and variables/reports on the right. Online monitoring allows adjustment of oscilloscopes and power analyzers; start testing, collect data, and 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 and Structure

During each test, my first step is to check the charging pile's casing and nameplate. The nameplate must be clear and complete, with proper safety protections in place, and free from rust or dust. "Hidden aspects" like the power supply, operating environment, electric shock protection, and electrical clearance must strictly comply with standards. The pile body must be clean, free of cracks and burrs, and have neatly arranged wiring. An emergency stop button is mandatory, allowing for immediate power cutoff in case of faults. The pile body must be durable, resistant to corrosion and high temperatures, and its internal components must be protected against water and rust. Overlooking any of these details could pose potential hazards.

2.2.2 Inspection of Indicators and Displays

Though small, indicators and displays are crucial! Verify their status during charging, faults, and 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, and show a steady operation indicator with a flashing fault indicator during overvoltage/overcurrent. They must also display real-time battery info, charging duration, voltage, and current, with fault warnings and 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, and 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, and clock error. When the load current is between maximum and minimum, Class 1 piles must have an error ≤±1%, Class 2 ≤±2%; payment amounts must align with unit price and 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 and charging experience.

3. Application Examples of On-site Testing for Electric Vehicle Charging Piles: Frontline Battle Records
3.1 Actual Pile and 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 and DC side measurements, enabling the charger to operate under load, maintaining constant voltage stability. With an input voltage of 500V, load current was optimized, and power was measured in real-time — this comprehensive approach thoroughly assessed the pile's performance.

3.2 Testing Issues and Improvements: Frontline Challenges and 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 and portability, with bulky resistive loads.

Solution: My team and I added protocol consistency reporting to devices, introduced constant voltage/current modes, and 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 and 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 and fault self-recovery — frontline issues must be exposed and 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 and durable, efficient supervision and inspection systems are essential. As frontline testers, we work closely with piles daily, hoping to identify performance and safety issues through real-time testing and implement practical solutions, ensuring the new energy vehicle industry thrives. Industry progress hinges on solid work, and we testers must "hold the line" in this critical link.