The device is used in conjunction with a operable mainstream pure electric car BYD Qin EV (the ex-factory date of the vehicle is June 2020 or later). On the basis of not damaging any wiring harnesses of the original car, the whole vehicle is transformed into a teaching aid vehicle for online detection of faults. It can realize modular real-time detection and diagnosis of the original vehicle controller’s dynamic and static signal parameters of the VCU control unit, power battery management system BMS control unit, drive system three-in-one motor controller control unit, high-voltage three-in-one charging and distribution assembly control unit, air conditioning control unit, gear control unit, combination instrument control unit, gateway control unit, smart key control unit, AC charging port control unit, etc. The trainees can set the main lines of the main control unit for faults such as open circuit, virtual connection and short circuit, and the fault setting method is reliable.The equipment is managed by a movable placement cabinet spliced with aluminum alloy frame, which integrates the function of Internet of things to uniformly manage the use of the equipment and allocate the use authority. The product applies to the teaching needs of the theory of pure electric vehicle and maintenance training of secondary and senior vocational schools, ordinary education and training institutions.
II. Features
1. The product is connected to the whole vehicle through specific wiring harness. After disconnecting the specific wiring harness, the function of vehicle is complete, and all the functions of the original vehicle and the integrity of the wiring harness will be maintained.
2. The structure of the whole vehicle is complete, and the control systems, sensors and actuators are complete and can operate normally without damaging any wire harness of the original vehicle.
3. The module evaluation box adopts: light and portable all-aluminum frame structure, hidden sliding fault setting mechanism, military-grade aviation connector, stainless steel three-gear double shift switch, and the durability of the equipment is ensured.
4. The multifunctional placement management cabinet can store the module assessment box and harness, and four 3-inch wear-resistant nylon casters with 2 self-locking device are installed to make it stable and movable.
5. Through the special integrated modular detection and fault setting box, it is connected in series with the original vehicle wiring harness, and the control signal is led out to the modular detection and fault setting box for detection and fault setting. The lead-out interfaces are the main control parts of the original vehicle, including vehicle controller VCU control unit, power battery management system BMS control unit, drive system three-in-one motor controller control unit, high-voltage three-in-one charging and distribution assembly control unit, air conditioning control unit, gear control unit, combination instrument control unit, gateway control unit, smart key control unit, AC charging port control unit, etc. After detecting the fault, the control signal shall be connected back to the original vehicle control unit, and the plug is the same as the original vehicle harness. The connecting wire adopts the national standard Teflon automobile special wire, with a withstand voltage of 600V to ensure the normal circuit signal of the whole vehicle. And the pin of the original vehicle control unit is drawn on the upper part of the measurement box. A 2mm gold-plated terminal is installed on the small panel to measure the real-time signal of the module system directly on the terminal and master the variation law of parameters of different control units. The measuring box adopts the design of hidden sliding fault setting mechanism, which can set faults through mechanical switches and short-circuit connecting wires. It can carry out open circuit, virtual connection, short circuit and other faults on the main lines of the control unit. There are 180 fault points in the whole vehicle.
6. Vehicle controller VCU control unit teaching and training system, which can detect signals including brake switch signal, vacuum pump relay 1 control signal, vacuum pump relay 2 control signal, vacuum pump relay detection signal, power network CAN-H, power network CAN- L, accelerator pedal sensor signal, vacuum pressure sensor signal, low-speed fan control signal, high-speed fan control signal, airbag collision signal, mode switch signal, etc.. It can set and diagnose open circuit, virtual connection, short circuit and other faults on the main lines of the VCU control unit of the whole vehicle controller.
7. BMS control unit teaching and training system can detect signals, including dual-circuit IG3 signal, power network CAN-H, power network CAN-L, charging instrument indicator light signal, DC charging negative contactor control signal, DC charging positive contactor control signal, DC charging contactor sintering detection signal, charging connection signal, charging interlock output signal, charging interlock input signal, airbag collision signal, etc.. And it can set and diagnose open circuit, virtual connection, short circuit and other faults on the main lines of BMS control unit of power battery management system.
8. The three-in-one motor controller control unit teaching and training system of the drive system can detect signals, including IG3 working power supply and ground wire, airbag collision signal, power network CAN-H, power network CAN-L, etc.. And it can set and diagnose the faults such as open circuit, virtual connection and short circuit of the main circuit of the motor controller control unit.
9. High-voltage three-in-one charging and distribution assembly control unit teaching and training system can detect signals, including AC charging port charging connection confirmation CC, AC charging port charging control and guide CP, AC charging port temperature detection, power network CAN-H, Power network CAN-L, high voltage interlock output, high voltage interlock input, DC charging positive contactor control signal, DC charging negative control signal, DC charging contactor sintering detection signal, etc.. And it can set and diagnose the open circuit, virtual connection, short circuit and other faults of the main lines of the control unit of the high-voltage three in one charging and distribution assembly.
10. The air conditioning control unit teaching and training system can detect signals, including blower feedback signal, blower speed regulation signal, electronic expansion valve (evaporator) control signal, electronic expansion valve (battery thermal management) control signal, pressure switch medium pressure signal, Pressure switch high-voltage signal, Comfort 2CAN-H, Comfort 2CAN-L, four-way water valve control signal, mode cycle motor control signal, cooling and heating cycle motor control signal, internal and external circulation motor control signal, etc.. And it can set and diagnose the faults such as open circuit, virtual connection and short circuit of the main lines of the air conditioning control unit.
11. The gear control unit teaching and training system can detect signals, including backlight +, backlight -, power supply IG1, power network CANH, power network CANL, etc.. And it can set and diagnose the faults such as open circuit, virtual connection and short circuit of the main circuit of the gear control unit.
12. The combination instrument control unit teaching and training system can detect signals, including steering signal input, power network CANH, power network CANL, power battery charging connection signal, engine simulator control signal, brake fluid switch signal, etc.. And it can set and diagnose the faults such as open circuit, virtual connection and short circuit of the main circuit of the combination instrument control unit.
13. Gateway control unit teaching and training system can detect signals, including constant power, IG1 power, power network CANH, power network CANL, ESC network CANH, ESC network CANL, comfortable 1CAN-H, comfortable 1CAN-L, comfortable 2CAN-H , Comfort 2CAN-L, etc.. And it can set and diagnose the faults such as open circuit, virtual connection and short circuit of the main lines of the gateway control unit.
14. The intelligent key control unit teaching and training system can detect signals, including start-up sub-network CANH, start-up sub-network CANL, rear door switch signal, rear trunk external magnetic card detection antenna signal, front magnetic card detection antenna assembly signal, The central magnetic card detects the antenna assembly signal, the rear magnetic card detects the antenna assembly signal, and the left front door detects the antenna signal outside the vehicle, etc.. And it can set and diagnose the open circuit, virtual connection, short circuit and other faults of the main circuits of the smart key control unit.
15. The AC charging port unit teaching and training system can detect signals, including unlocking power supply, locking power supply, high temperature sensor, low temperature sensor, CC signal, CP signal, etc.. And it can set and diagnose the open circuit, virtual connection, short circuit and other faults of the main lines of the AC charging port unit.
16. The device is also equipped with a teaching board for vehicle control schematic diagram. Teaching board drawing, which includes vehicle controller, accelerator pedal sensor, vacuum pressure sensor, air conditioning controller, compressor, PTC, warm air pump, warm air pump relay, electronic expansion valve (evaporation tank), electronic expansion valve (battery thermal management), pressure switch, AC Blower, blower commissioning module, gear sensor, gateway, diagnostic port, combination instrument, engine simulator, instrument panel distribution box, smart key controller, Pin definitions of drive motor controller, three in one charging and distribution assembly, battery management controller, AC charging port, DC charging port, power battery pack, etc., can guide students for circuit analysis, vehicle fault diagnosis and troubleshooting.
17. It is equipped with a special AC charging connection device for the national standard new energy electric vehicle. The input power is 220VAC-50/60HZ-8A, the input end is connected to a 16A three-hole socket, and the cable specification is 3*1.5+1*0.75. The output end is connected with the vehicle, which is a 7-core slow charging gun head with CC and CP detection power.
18. Equipped with the teaching resource package software V1.0 of the new energy vehicle drive system. The structural composition and control principle of the charging and distribution assembly of mainstream new energy vehicles are explained by three-dimensional animation.
III.Basic Configuration:
Mainstream pure electric car
1. Power battery: original mainstream pure electric car nickel-cobalt lithium manganate ternary power battery.
The total capacity of the power battery pack is 408.8V 130AH (53.1 kWh), and a total of 112 single cells are connected in series.
The distributed battery management system is adopted, which consists of a battery management controller (BMC), multiple battery information collectors (BIC) and a set of power battery sampling lines. And the power battery adopts battery liquid cooling and PTC heating system to adjust the temperature.
2. High-voltage three-in-one charging and distribution assembly (including DC/DC converter, on-board charger OBC and high-voltage distribution box PDU)
Cooling method: water cooling
Control module: IGBT
Maximum output capacity: 180KW
Maximum output current: 270A
Protection class: IP67
OBC charging power: 6.6KW
OBC type: one-way, isolation
DC rated output voltage: 13.8V, DC rated output current: 145A
3. Three-in-one drive system (including drive motor, motor controller, reducer)
Motor Type: Permanent Magnet Synchronous Drive Motor
Continuous power: 35KW
Peak power: 100KW
Continuous torque: 70N.m
Peak torque: 180N.m
Maximum speed: 12100rpm
Cooling method: water cooling
Gearbox Ratio: 10.7
4. Air conditioning and heating system:
Electric air conditioner, working voltage 408.8V, electric PTC heating water circulation
5. Other parameters are as follows:
Body: Length: 4678mm. Width: 1770mm. Height: 1500mm
Wheelbase: 2670mm
Front track: 1525mm
Rear track: 1520mm
Maximum speed: 130Km/h
Constant speed pure electric driving range: 505Km
Fast charge: DC 1.5h
Slow charge: 220V/7KW AC slow charge. more than 8h
Number of doors: 4
Number of seats: 5
Body structure: Sedan
Steering assist: Electric assist
Front brake type: Ventilated Disc
Rear brake type: Disc
Handbrake type: Electronic Parking Brake
Drive mode: front wheel drive
Front suspension type: Independent Suspension
Rear suspension type: torsion beam semi-independent suspension
IV. Technical Parameter:
1. 1 online testing teaching car
2. 1 set of dedicated wiring harness (10 pieces, each wiring harness length is 2.5 meters)
3. 1 set of modular detection and fault setting box (10 pieces)
4. 1 multi-functional and high-strength placement management cabinet (8 layers, double doors, with smart password lock)
5. 3 detection and diagnosis trolleys (2 floors)
6. 1 vehicle control schematic diagram teaching board