Research on Board‑level Hierarchical Fault Detection and Standardized Component Maintenance Technology for Vehicle‑mounted On‑Board Charger

Abstract

Aiming at the industry pain points of lack of standardized processes for on‑board charger (OBC) fault maintenance and high maintenance costs caused by excessive assembly‑level replacement, this paper proposes a five‑level board‑level hierarchical maintenance process system: non‑destructive disassembly, visual preliminary diagnosis, precise instrument‑aided detection, component‑level repair, and pre‑assembly static re‑inspection. This paper systematically elaborates on anti‑static tooling configuration, board‑level functional partitioning and hierarchical fault‑location methods, and analyzes high‑frequency error‑prone risks in maintenance and corresponding avoidance countermeasures. Verified by complete maintenance cases of typical faulty samples, the proposed maintenance process can realize accurate repair of faulty components such as power devices and electrolytic capacitors, effectively eliminate the risk of component burnout caused by secondary power‑on, and significantly improve the reliability and cost‑effectiveness of OBC board‑level maintenance. The proposed process has direct application value for on‑board power supply maintenance practice and new‑energy‑vehicle maintenance teaching and training.