Mfano wa Utaratibu wa Ujaribisho wa Viwanda vya Kuchambua Magari ya Umeme

Kama mteja anayefanya kazi ya kutathmini vifaa vya kupunguza chenchi na uchafuzi wa magari, kazi yangu kila siku inaonyesha kitu moja tu: mara kwa mara watu wanapata maisha bora, mapenzi ya magari yanapanda. Pamoja na ubunifu wa ufikiri wa hifadhi ulimwengu, sekta ya magari ya umeme (EV) inaendelea kujitumaini. Vifaa vya kupunguza chenchi, kama "mzunguko wa umma" wa magari ya umeme, huamua kwa urahisi ikiwa magari ya umeme zinaweza kukabiliana na kufanya kazi vizuri. Kwa maneno mengine, kazi yetu katika utathmini ni "kudhibiti" vifaa vya kupunguza chenchi, kuaminika kwamba ufanyiko wao unaweza kusaidia. Hii inahitaji uwepo na ukweli.

1. Mazingira ya Vifaa vya Kupunguza Chenchi ya Magari ya Umeme: Maendeleo ya Sekta na Ufano wa Utathmini

Sekta ya kimataifa ya ujenzi inaendelea kwa nguvu, kuchukua rasilimali kwa haraka kamili. Rasilimali muhimu kama mafuta yanaingizwa kwa haraka kwenye sekta mbalimbali, na radhifo zinapungua kwa haraka. Kama asilimia ya mafuta, mapenzi ya mafuta na mafuta ya diesel yamepanda pamoja na idadi ya magari. Kutoka kwa mtazamo wa mazingira na maendeleo yenye uzima, magari vinavyotumia mafuta yanaenda kushindwa. Sasa, magari vilivyovunja na magari visivyo vya mafuta yanapanda kwa sababu ya upatikanaji mdogo au usio wa mafuta, na sekta ya vifaa vya kupunguza chenchi inaanza kujitumaini, na teknolojia mpya na vifaa vya kipekee vinafanyika mara kwa mara.

Kutoka kwa mtazamo wa utathmini, kuna majengo muhimu kadhaa kwa vifaa vya kupunguza chenchi:

• Kulingana na Ingizo la Umeme: Vifaa vya kupunguza chenchi AC (kutumia on-board charger kwa ajili ya kubadilisha nguvu) na vifaa vya kupunguza chenchi DC (kutoa nguvu moja kwa moja kwenye batilinya);

• Kulingana na Njia ya Kuweka: Kilichowekeleka na kilichowekeleka kwenye ukuta, kuchaguliwa kulingana na mahali;

• Kulingana na Muundo wa Vifaa: Aina ya kugawanya na imara, kuhusu ukosefu na ugumu wa kurejesha;

• Kulingana na Daraja la Ukweli: Kisasa cha Kiwango 1 na Kiwango 2, kuchaguliwa kulingana na ukweli wa kutosha wa kutosha. Majengo haya yanajenga "msingi wa maarifa" ambayo nikitumaini kwanza kabla ya kila utathmini.

Vifaa vya kupunguza chenchi AC huwa kama "wakati wa kati" kutoa nguvu AC kwenye mfumo wa kupunguza chenchi: vifaa vya kupunguza chenchi single-phase yanafaa kwa magari madogo, mara kwa mara inachukua masaa 3-8 kwa kupunguza chenchi kwa kamilifu; vifaa vya kupunguza chenchi three-phase yanaweza kupunguza chenchi kwa busi za kati hadi kubwa, kufikia 80% ya chenchi ndani ya dakika 30. Kwa miaka mingi ya kutathmini, nimekuelewa kuwa utathmini wa vifaa vya kupunguza chenchi lazima kuwa "tofauti" - viwango kama tovuti, mzunguko, na muda huonyesha uwezo wa vifaa vya kupunguza chenchi kwa kawaida, kutoa data, na kusimamia. Pia, salama ya vifaa vya kupunguza chenchi ni "sauti ya kiholela"; chochote kinachofanya kosa kunaweza kuwa matumizi ya EV.

Hata hivyo, njia za utathmini za sasa zina changamoto. Njia ya utathmini wa mazingira, ambayo hutumia mabatilini halisi, haiwezi kufanikiwa kwa kutosha kutathmini mazingira halisi, kuleta makosa makubwa na ukosefu wa ustawi. Hii inasimama na sisi wale wanaohitimu kwa ujumla kutathmini, kuboresha viwango vya utathmini ili kusaidia sekta kwa kutosha.

2. Njia za Utathmini ya Vifaa vya Kupunguza Chenchi ya Magari ya Umeme: Maarifa ya Kijiji kutoka kwa Kijiji
2.1 Usimamizi wa Platform ya Utathmini ya Kijiji
2.1.1 Platform ya Hardware

Platform ya utathmini automatiki tunayotumia lazima iwe na uhakika na kutoa AC pile testing na kusaidia interoperability. Kwa mfano, wakati kutathmini three-phase 63A pile, AC power supply imezalishwa kwa 60kVA, kutoa 0VAC-300VAC kusisitisha harmonic current na kutokana na grid interference. Single-phase independent loading, kila phase inafanya kazi kwa kifupi, inaonyesha mikono ya charging modules na chargers, kutengeneza nguvu mara mbili ya rated current. Viwango vya setting haya ni "battle-tested" maarifa yanayopatikana kutokana na majaribio mengi.

Vifaa vya kupunguza chenchi vyanatumia AC power supplies na yanapaswa kufanikiwa "disruptions" kama harmonics na voltage sags katika mains supply, kuaminika kuwa data ya pile inafanana na viwango vya kimataifa chini ya mazingira extreme. Pure resistive loads zimeprogrammeka kwa ajili ya single-phase control, kufanana na maagizo ya testing kwa both single-phase na three-phase piles.

Kutumia interface ya AC charging test kutofautiana na ground faults na switch logic, pamoja na power supplies na loads, tunaweza kuelewa compatibility kati ya pile na EV, kutathmini effectiveness ya protective actions. High-precision power meters zinakusanya data ya voltage na current; digital multimeter ya 6.5-digit imezalishwa kwenye data acquisition card na channels 20 za simultaneous measurement. Signal gating devices zinajitayarisha na oscilloscopes kutengeneza switching signals, na serial servers zinajihusisha na industrial computers kwa real-time data exchange na reporting. Setup hii ya hardware ni "backbone" ya accuracy ya testing.

2.1.2 Testing Software

Software lazima iwe open, kusambaza data ya testing mbalimbali ili kusimamia devices, programs, na reports central while ensuring data security. Software ninayotumia kwa karibu ina secondary programming interface, kusaidia testers wa kijiji kubadilisha programs na kuprocess data.

Human-machine interface (HMI) ni na uwezo mkubwa: parameter detection, dynamic display, operation control, na report generation, online customization ya interface effects. Client module inahusisha data interfaces na control commands; control command module inapokea, inajaribu, na inaverify commands, unifiedly managing device interfaces. Ikiwa hardware inabadilika, configurations zinabadilishwa kusaidia upgrades. Data module inahusika kwa data collection, storage, na processing, separating parameter na result verification, na defining hardware configurations.

Ninajua mchakato wa software operation mzuri: login, select test items, adjust program commands in real-time, na send instructions to the control cabinet. Baada ya kutekeleza project, view edit commands kulia na variables/reports kulia. Online monitoring ina allow adjustment of oscilloscopes na power analyzers; start testing, collect data, na save kwenye folder. Mchakato huu wa kutosha unaboresha efficiency ya testing sana.

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

Katika kila test, hatua yangu ya kwanza ni kuchukua tasnia na nameplate ya charging pile. Nameplate lazima iwe clear na kamili, na safety protections sahihi, na isiyokuwa na rust au dust. "Hidden aspects" kama power supply, operating environment, electric shock protection, na electrical clearance lazima ziwe na standards. Pile body lazima iwe clean, free of cracks na burrs, na wiring arranged neatly. Emergency stop button ni must, allowing for immediate power cutoff in case of faults. Pile body lazima iwe durable, resistant to corrosion na high temperatures, na components zake za ndani zinaweza kuprotekta dhidi ya maji na rust. Kuvunjika kwa chochote kati ya details hizi inaweza kuwa na hatari.

2.2.2 Inspection of Indicators and Displays

Hata ingawa ni ndogo, indicators na displays ni muhimu! Verify their status during charging, faults, na operation: indicators yanapaswa kuwa na light au flash during operation, remain steadily lit during normal power-on, stay lit (operation indicator) with the charging indicator turning off during charging, na show a steady operation indicator with a flashing fault indicator during overvoltage/overcurrent. Wanapaswa pia kuonyesha battery info ya real-time, charging duration, voltage, na current, na fault warnings na 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.