Maintenance tips for intelligent functions of electric vehicle chargers

The maintenance of intelligent functions of electric vehicle chargers should be combined with their core functions and usage scenarios, focusing on four aspects: function verification, data monitoring, abnormal handling, and system updates. The following are specific tips:

First, verification of the intelligent charging function

Automatic recognition function test

Connect the charger with different types of batteries (such as lithium iron phosphate, ternary lithium) or capacity devices to verify whether it can automatically adjust the output current and voltage. For example, connect the 40kWh and 60kWh battery packs and check if the charging parameters are compatible.

Multimode switching test

Manually switch between fast charging, slow charging, scheduled charging and other modes, and observe the response speed and output stability of the charger. In fast charging mode, temperature changes need to be monitored to avoid overheating.

Second, real-time data monitoring and analysis

Charging status monitoring

Check the real-time voltage, current, battery level and charging time through the charger display screen or the APP. For instance, during fast charging, the current should be stabilized at the rated value (such as 32A), and the voltage fluctuation should not exceed ±5%.

Battery health assessment

Use the battery health diagnosis function of the charger to regularly check the battery's internal resistance and capacity attenuation rate. If the internal resistance increases by 20% or the capacity is lower than 80% of the nominal value, it is recommended to replace the battery.

Third, handling of abnormal protection mechanisms

Fault simulation test

Simulate scenarios such as overcharging, overcurrent, and short circuit to verify whether the protection mechanism is triggered. For example, artificially increase the output voltage to the overcharge threshold (such as 4.3V per cell), check whether the charger is powered off and give an alarm.

Troubleshooting Code:

Record the fault codes displayed by the charger (such as E01 indicating over-temperature), and locate the problem in combination with the manual. Common malfunctions include fan failure, sensor malfunction, etc. Components need to be replaced in a timely manner.

Fourth, system update and optimization

Firmware upgrade

Regularly update the charger firmware via the APP or USB interface to fix known vulnerabilities and enhance performance. For instance, after the upgrade, the charging efficiency is increased by 5%, or a new low-temperature charging protection function is added.

Communication protocol check:

Ensure that the charger communicates normally with the vehicle's BMS (Battery Management System) to avoid charging interruptions caused by protocol mismatch. Monitor the communication data using a CAN bus analyzer to confirm that there are no error frames.

Fifth, daily maintenance suggestions

Cleaning and heat dissipation

Clean the dust on the heat sink every month to ensure the fan operates normally. For liquid-cooled chargers, it is necessary to check the coolant level to prevent leakage.

Environmental adaptability

Avoid using the charger in an environment below -20℃ or above 50℃. Extreme temperatures will reduce charging efficiency and accelerate the aging of components.

Storage management

When not in use for a long time, store the charger in a dry environment and power it on once a month to maintain the activity of the components.