科学与技术

随着电动车的电池容量增加来提高续航里程，并要降低开车的里程焦虑，市场有更多安装直流快充充电桩的需求。随着安装地点不同，充电桩会有不同充电界面与功率范围的规划。现行的直流充电标准包括欧美的CCS或NACS、日本的CHAdeMO、中国的GB/T，除了充电*头外观有差异，采用的通讯协议也有所不同。内部组成包括AC-DC电源模块、充电控制器、通讯模块、人机接口、DC电表、断路器、漏电监控器、安全保护线路等。充电桩的妥善率也常被提出讨论，充电桩制造商要考虑在生产端提升产品质量，也要兼顾测试效率，就成为重要议题。

针(zhen)(zhen)对直流充电桩(zhuang)的自动测(ce)(ce)试(shi)系统(tong)(Automatic Test System, ATS)应用在产(chan)线EOL(End Of Line)测(ce)(ce)试(shi)，Chroma基于多年协(xie)助(zhu)产(chan)业(ye)界的经(jing)验(yan)，归纳出五大重(zhong)点针(zhen)(zhen)对生(sheng)产(chan)端会遇到的技术议题与解(jie)决建议。

01  充(chong)电介面(mian)与通讯协(xie)议(yi)标准

当充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)*插上(shang)电(dian)(dian)(dian)(dian)动(dong)车的(de)充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)座(zuo)之(zhi)后，双边的(de)接触侦测(ce)与通讯协议就(jiu)开始运(yun)作。当在(zai)充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)预备(bei)、开始和结(jie)束的(de)各状态(tai)中(zhong)，若充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)设备(bei)通讯控制器(SECC)和电(dian)(dian)(dian)(dian)动(dong)车通讯控制器(EVCC)交握有(you)任何异(yi)常(chang)(包含超时、资料(liao)格(ge)式辨识、异(yi)常(chang)处(chu)理、时序(xu)等)，充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)运(yun)行就(jiu)将会被迫中(zhong)断(duan)。所以(yi)自动(dong)化测(ce)试(shi)系统(tong)(ATS)必(bi)须具备(bei)模(mo)(mo)拟(ni)(ni)电(dian)(dian)(dian)(dian)动(dong)车通讯的(de)功(gong)能，甚至(zhi)可(ke)(ke)以(yi)故意设定(ding)异(yi)常(chang)动(dong)作，以(yi)验证充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)桩(zhuang)的(de)中(zhong)断(duan)保(bao)护功(gong)能。另外(wai)ATS还(hai)需模(mo)(mo)拟(ni)(ni)电(dian)(dian)(dian)(dian)动(dong)车的(de)充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)座(zuo)，规格(ge)必(bi)须能符合电(dian)(dian)(dian)(dian)气测(ce)试(shi)之(zhi)要(yao)求，且具备(bei)电(dian)(dian)(dian)(dian)子锁、温度监(jian)控、大功(gong)率断(duan)路器以(yi)及散(san)热功(gong)能，可(ke)(ke)确保(bao)测(ce)试(shi)过程的(de)安(an)全性(xing)。测(ce)试(shi)系统(tong)建议采(cai)用(yong)模(mo)(mo)组化且可(ke)(ke)更换的(de)EV模(mo)(mo)拟(ni)(ni)器与充(chong)(chong)(chong)(chong)(chong)电(dian)(dian)(dian)(dian)座(zuo)，可(ke)(ke)快速更换避免产(chan)线因(yin)异(yi)常(chang)问(wen)题造成长时间测(ce)试(shi)中(zhong)断(duan)。另外(wai)好处(chu)是可(ke)(ke)弹性(xing)调整测(ce)试(shi)不同标准的(de)产(chan)品，或未来需求而升级(ji)。

测试情境示意图

除(chu)此之外，建议EV模拟(ni)器搭配合适的(de)电(dian)池模拟(ni)器与(yu)测试软体，具有可载入充(chong)电(dian)功率曲线(如：图二)的(de)功能。可用来模拟(ni)实际(ji)对DC EVSE的(de)即时充(chong)电(dian)电(dian)流变(bian)化(hua)要(yao)求，以(yi)验证其响(xiang)应(ying)速(su)度与(yu)**度。

充电功率曲线示意图

02 提升对多*充电桩的(de)快速(su)检测(ce)能力

为适应不(bu)(bu)同(tong)(tong)(tong)电(dian)(dian)动车(che)采(cai)用的(de)直流充(chong)电(dian)(dian)标(biao)准(zhun)不(bu)(bu)同(tong)(tong)(tong)，目(mu)前充(chong)电(dian)(dian)桩(zhuang)(zhuang)厂(chang)商纷纷推出(chu)(chu)具有多(duo)个不(bu)(bu)同(tong)(tong)(tong)介面(mian)的(de)直流充(chong)电(dian)(dian)*的(de)产品(pin)，例(li)如(ru)适用CCS与CHAdeMO标(biao)准(zhun)，甚(shen)至包括交流充(chong)电(dian)(dian)*。这(zhei)样(yang)的(de)充(chong)电(dian)(dian)桩(zhuang)(zhuang)产品(pin)在(zai)(zai)测(ce)(ce)(ce)试(shi)系统(tong)的(de)配(pei)置上，就需多(duo)个不(bu)(bu)同(tong)(tong)(tong)标(biao)准(zhun)的(de)充(chong)电(dian)(dian)模拟(ni)器，使测(ce)(ce)(ce)试(shi)流程更加复杂。且(qie)若多(duo)*产品(pin)采(cai)用轮流测(ce)(ce)(ce)试(shi)的(de)方式，所需时间(jian)便会(hui)被拉长，也(ye)与实际同(tong)(tong)(tong)时多(duo)*使用的(de)情况(kuang)不(bu)(bu)同(tong)(tong)(tong)。因(yin)此产线(xian)的(de)自(zi)测(ce)(ce)(ce)试(shi)系统(tong)(ATS)需能(neng)(neng)多(duo)工模拟(ni)不(bu)(bu)同(tong)(tong)(tong)介面(mian)，并(bing)模拟(ni)多(duo)台电(dian)(dian)动车(che)在(zai)(zai)同(tong)(tong)(tong)时间(jian)充(chong)电(dian)(dian)之情境(jing)。如(ru)此，可(ke)测(ce)(ce)(ce)试(shi)充(chong)电(dian)(dian)桩(zhuang)(zhuang)于不(bu)(bu)同(tong)(tong)(tong)协议(yi)之电(dian)(dian)动车(che)同(tong)(tong)(tong)步(bu)进(jin)行(xing)通(tong)讯交握，并(bing)检测(ce)(ce)(ce)其输出(chu)(chu)状态。尤(you)其可(ke)验(yan)证(zheng)验(yan)证(zheng)充(chong)电(dian)(dian)桩(zhuang)(zhuang)在(zai)(zai)多(duo)台电(dian)(dian)动车(che)同(tong)(tong)(tong)时发出(chu)(chu)充(chong)电(dian)(dian)电(dian)(dian)流需求下，内(nei)部(bu)的(de)智能(neng)(neng)输出(chu)(chu)功(gong)率分(fen)配(pei)功(gong)能(neng)(neng)，不(bu)(bu)致发生误动作或保护。各(ge)*的(de)输出(chu)(chu)也(ye)能(neng)(neng)同(tong)(tong)(tong)步(bu)检测(ce)(ce)(ce)输出(chu)(chu)电(dian)(dian)压/电(dian)(dian)流/Wh的(de)**度规(gui)格，如(ru)此可(ke)缩短(duan)产线(xian)测(ce)(ce)(ce)试(shi)时间(jian)。

03  验证安规(gui)标准与保护机(ji)制(zhi)

各(ge)种(zhong)(zhong)保护机制是(shi)直流充电桩(zhuang)的(de)(de)重要(yao)功(gong)能，包含(han)：输出(chu)过(guo)电压(ya)/过(guo)电流、接(jie)地(di)与(yu)(yu)绝(jue)缘(yuan)(yuan)(yuan)异常、紧急停止、过(guo)温度以及入电异常等。测(ce)试系(xi)统需要(yao)具(ju)备各(ge)种(zhong)(zhong)情境模(mo)(mo)拟，确实测(ce)试每一(yi)台(tai)充电桩(zhuang)的(de)(de)保护机制能正常动作。例如当进行充电桩(zhuang)绝(jue)缘(yuan)(yuan)(yuan)监控测(ce)试时(shi)，可透过(guo)测(ce)试系(xi)统设定绝(jue)缘(yuan)(yuan)(yuan)电阻(zu)箱，来模(mo)(mo)拟电池(chi)与(yu)(yu)车体(ti)间的(de)(de)阻(zu)抗变化(hua)。甚至(zhi)于不同的(de)(de)通讯交握(wo)阶段，将其搭接(jie)在输出(chu)DC+或(huo)DC-到(dao)接(jie)地(di)端回路上，检测(ce)充电桩(zhuang)绝(jue)缘(yuan)(yuan)(yuan)侦测(ce)功(gong)能是(shi)否正常。系(xi)统集成时(shi)必需选用(yong)合适的(de)(de)继(ji)电器及电阻(zu)的(de)(de)耐(nai)电压(ya)及耐(nai)电流规格，才不会(hui)(hui)容(rong)易(yi)损坏。另(ling)外若电池(chi)模(mo)(mo)拟器的(de)(de)内(nei)部(bu)Y电容(rong)过(guo)大，可能会(hui)(hui)影(ying)响到(dao)绝(jue)缘(yuan)(yuan)(yuan)监测(ce)的(de)(de)功(gong)能测(ce)试，甚至(zhi)误报(bao)导致测(ce)试中(zhong)断，必须特别留意。

绝缘阻抗测试示意图

04  验证电源模(mo)组

充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)桩(zhuang)接受电(dian)(dian)(dian)(dian)动车(che)的(de)电(dian)(dian)(dian)(dian)流及电(dian)(dian)(dian)(dian)压(ya)(ya)命令，由内部电(dian)(dian)(dian)(dian)源(yuan)模组将电(dian)(dian)(dian)(dian)网(wang)(wang)的(de)交流电(dian)(dian)(dian)(dian)做转(zhuan)换来(lai)(lai)对电(dian)(dian)(dian)(dian)池(chi)充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)。测(ce)试系统需(xu)整合电(dian)(dian)(dian)(dian)池(chi)模拟(ni)器(qi)，可(ke)设定在定电(dian)(dian)(dian)(dian)压(ya)(ya)或定电(dian)(dian)(dian)(dian)流模式，来(lai)(lai)验证充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)桩(zhuang)的(de)充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)输出参数的(de)规格**度(du)。因为其(qi)输出功率范围从20kW到(dao)400kW，会建议(yi)(yi)使用具有(you)能(neng)源(yuan)回收(shou)功能(neng)的(de)设备。将充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)能(neng)量回馈到(dao)电(dian)(dian)(dian)(dian)网(wang)(wang)循环使用，这(zhei)样可(ke)以节省充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)测(ce)试时(shi)的(de)电(dian)(dian)(dian)(dian)能(neng)消(xiao)耗(hao)，同(tong)时(shi)有(you)利于控(kong)制工厂环境(jing)温度(du)。另外(wai)，建议(yi)(yi)选择双向(xiang)的(de)电(dian)(dian)(dian)(dian)池(chi)模拟(ni)器(qi)，可(ke)以被充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)及放电(dian)(dian)(dian)(dian)，以因应未来(lai)(lai)充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)桩(zhuang)必(bi)须(xu)具备V-to-G的(de)功能(neng)。充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)桩(zhuang)输入(ru)由电(dian)(dian)(dian)(dian)网(wang)(wang)模拟(ni)电(dian)(dian)(dian)(dian)源(yuan)来(lai)(lai)供电(dian)(dian)(dian)(dian)，需(xu)验证在电(dian)(dian)(dian)(dian)压(ya)(ya)及频率的(de)规格范围内，仍能(neng)正(zheng)常(chang)运作。更重要的(de)是(shi)模拟(ni)电(dian)(dian)(dian)(dian)网(wang)(wang)的(de)异(yi)常(chang)变(bian)动，举(ju)例SAE-J1772和UL2231-2要求，建议(yi)(yi)进行电(dian)(dian)(dian)(dian)压(ya)(ya)骤(zhou)降(Voltage Dip)、电(dian)(dian)(dian)(dian)压(ya)(ya)中断(Voltage Interruption)、变(bian)动测(ce)试(Voltage Variation Test)与谐波(bo)失真(zhen)波(bo)形***测(ce)试(Harmonic Distortion Immunity Test)，来(lai)(lai)测(ce)试充(chong)(chong)(chong)电(dian)(dian)(dian)(dian)桩(zhuang)不会损坏，或能(neng)顺利进入(ru)保(bao)护模式。

可(ke)程控电网模拟器产生的各(ge)式波形示(shi)意(yi)图

充电桩还需测试待机耗电、功率因素以及充电效率的规格，测试系统(ATS)的功率表要符合高量测精度(<0.2%)外，甚至mW等级的功率解析度。同时建议要具备不同的量测模式(功率积分模式-Power Integration)与智慧档位(Smart Range)功能，才能更弹性的应用。随着充电桩功率有增大的趋势，测试系统建议需具备功率设备的可扩充性。并也需考量到未来通讯协议的升级需求，便可降低后续产线测试系统扩增的建置成本。

DC充电椿测试系(xi)统可扩充性示意(yi)图(tu)

05  跨领域的整合工(gong)作(zuo)

充电(dian)桩产(chan)线EOL测(ce)试(shi)站也需要(yao)与自动(dong)线的(de)(de)PLC(Programmable Logic Controller)交握, 以确定(ding)待(dai)测(ce)物是否已到站定(ding)位，并能透过(guo)PLC交握确认工(gong)厂运(yun)作(zuo)安全状况与消防等级。并需与MES(Manufacturing Execution System)确认前一站的(de)(de)测(ce)试(shi)状况与结果，来决定(ding)是否开始(shi)进(jin)行测(ce)试(shi)。为(wei)了提升生产(chan)效率与测(ce)试(shi)报告汇整，透过(guo)产(chan)品序号上传MES做(zuo)控管，产(chan)生生产(chan)履历所需要(yao)的(de)(de)测(ce)试(shi)结果与数据做(zuo)分析。甚至能自动(dong)下载(zai)对应(ying)的(de)(de)测(ce)项程序(TP)，做(zuo)产(chan)线弹性生产(chan)不同型号的(de)(de)测(ce)试(shi)控管，避免可能的(de)(de)人(ren)为(wei)错误。**须(xu)注意PLC、MES和(he)ATS之间的(de)(de)程序交握，并清楚定(ding)义分责表(biao)，明确不同单位的(de)(de)责任归属。

在产(chan)线(xian)(xian)EOL的测(ce)试(shi)系统需(xu)要整合各(ge)领域不(bu)同的技(ji)(ji)术，还要累积相关经验才能顺利(li)开发出来。希(xi)望此篇文章中提到(dao)5点技(ji)(ji)术议题及(ji)(ji)建议，可提供充(chong)电(dian)(dian)桩业者在产(chan)线(xian)(xian)测(ce)试(shi)规(gui)画时参考。能有助提高测(ce)试(shi)覆盖率，确(que)保产(chan)品的安全与(yu)品质(zhi)，也(ye)提升使用者满意(yi)度。并能运用多(duo)工的技(ji)(ji)术加(jia)速(su)自动测(ce)试(shi)流(liu)程，提高工厂(chang)的产(chan)出。Chroma已(yi)提供电(dian)(dian)动车(che)充(chong)电(dian)(dian)桩、车(che)载充(chong)电(dian)(dian)器(qi)、驱动器(qi)及(ji)(ji)电(dian)(dian)池(chi)包的测(ce)试(shi)方案(an)。