DC charging pile testing solution

I. Industry Background

The development of electric vehicles is an inevitable path for China to transform from a major automotive country to a powerful one, 

and it is an important direction of the national new energy strategy. The industrial system of electric vehicles is becoming increasingly 

complete, with growing competitiveness and significantly improved technological levels. This has promoted the development of the

electric vehicle charging market and the construction of basic charging facilities such as charging piles. However, there are currently 

few charging piles in total, and their distribution is uneven, with an imbalance in development between cities and rural areas. 

Manufacturers have inconsistent standards, and the compatibility of charging interfaces is poor. The construction of private charging 

piles faces significant obstacles. Industry management lags behind, resulting in low safety and utilization rates of charging piles,

as well as low service capabilities. The profit model is relatively single.

The working principle of electric vehicle charging piles can be divided into two types. 

High-power electric vehicle chargers input AC power through a three-phase grid, which is converted into DC power through 

a three-phase bridge uncontrolled rectifier circuit. After filtering, it is provided to a high-frequency DCD converter. 

The converter changes the power and outputs DC power to charge the electric vehicle battery. AC charging piles use LED 

color touch screens, and charging can be selected in full charge stop, timing, fixed electricity, and fixed quota modes. 

The AC working voltage is 220V, and the output power is 3.5kw and 7kw. 

II. Industry Pain Points

With the rapid development of new energy vehicles, more and more families are choosing new energy vehicles, and the proportion of

new energy vehicles in social vehicle usage is increasing. This has led to a growing demand for DC charging piles in society. 

At the same time, the testing process for DC charging piles is complex, with numerous testing items and complicated operation steps. 

It requires a large number of expensive testing devices and poses higher requirements for operators.

The testing of DC charging piles needs to meet the following standards:

■ GB/T 20234.3-2015: Connectors for Conductive Charging of Electric Vehicles - Part 3: DC Charging Interface

■ GB/T 18487.1-2015: Conductive Charging System for Electric Vehicles - Part 1: General Requirements

■ GB/T 27930-2015: Communication Protocol between Off-board Conductive Charging Equipment and Battery

Management System for Electric Vehicles

■ GB/T 34657-2017: Test Specifications for Interoperability of Conductive Charging of Electric Vehicles

■ GB/T 34658-2017: Communication between Off-board Conductive Charging Equipment and Battery

Management System for Electric Vehicles

Therefore, there is an urgent need for a product that can standardize and simplify the testing process of DC charging piles, 

and meet comprehensive functional and performance testing requirements. 

III. Solution

The Ruijie Smart independently developed DC charging pile interoperability tester is a dedicated testing device capable of rapidly 

detecting various performance parameters of DC charging piles. It adopts a standard 5U modular design and integrates vehicle 

interface circuit simulation module, CAN message acquisition module, battery voltage simulation module, charging pile metering 

verification module, BMS simulation module, and embedded controller and other functional modules. 

The device features:

■ Equipped with a standard national standard DC charging gun socket, meeting the requirements stipulated in GB/T 20234.3-2015.

■ Designed with vehicle charging interface circuit fault simulation, capable of simulating faults in DC+, DC-, PE, S+, S-, CC1, CC2, A+, A- circuits.

■ Equipped with a standard parameter acquisition interface, enabling external acquisition of various signals.

■ Equipped with a CAN communication simulation module, capable of simulating vehicle BMS and editing various vehicle operating conditions 

to test various corresponding states of the charging pile.

■ Built-in temperature measurement chip, with environmental temperature measurement function.

■ Equipped with a CAN communication message acquisition module, capable of synchronously collecting CAN bus messages and voltage, 

current and other data parameters.

■ The DC charging pile interoperability tester, in conjunction with dedicated upper computer software, can simulate the communication 

between the vehicle and the charging pile in real time, achieving the interaction of message information in four stages: low-voltage 

auxiliary power-on and charging handshake stage, parameter configuration stage, charging stage, and charging end stage during vehicle charging.