CN110596590B - Reliability test method of range extender system - Google Patents
Reliability test method of range extender system Download PDFInfo
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- CN110596590B CN110596590B CN201911011138.0A CN201911011138A CN110596590B CN 110596590 B CN110596590 B CN 110596590B CN 201911011138 A CN201911011138 A CN 201911011138A CN 110596590 B CN110596590 B CN 110596590B
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- 239000004606 Fillers/Extenders Substances 0.000 title claims abstract description 215
- 238000010998 test method Methods 0.000 title abstract description 12
- 238000012360 testing method Methods 0.000 claims abstract description 114
- 239000000446 fuel Substances 0.000 claims abstract description 112
- 238000010248 power generation Methods 0.000 claims abstract description 81
- 239000011159 matrix material Substances 0.000 claims abstract description 42
- 238000000034 method Methods 0.000 claims abstract description 15
- 238000004891 communication Methods 0.000 claims description 5
- 125000004122 cyclic group Chemical group 0.000 claims description 3
- 238000006243 chemical reaction Methods 0.000 claims description 2
- 239000003921 oil Substances 0.000 description 14
- 238000005299 abrasion Methods 0.000 description 4
- 239000003638 chemical reducing agent Substances 0.000 description 3
- 230000008878 coupling Effects 0.000 description 3
- 238000010168 coupling process Methods 0.000 description 3
- 238000005859 coupling reaction Methods 0.000 description 3
- 230000003044 adaptive effect Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000295 fuel oil Substances 0.000 description 2
- 238000013486 operation strategy Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000011217 control strategy Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000004071 soot Substances 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M15/00—Testing of engines
- G01M15/02—Details or accessories of testing apparatus
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M15/00—Testing of engines
- G01M15/04—Testing internal-combustion engines
- G01M15/05—Testing internal-combustion engines by combined monitoring of two or more different engine parameters
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M17/00—Testing of vehicles
- G01M17/007—Wheeled or endless-tracked vehicles
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/005—Testing of electric installations on transport means
- G01R31/006—Testing of electric installations on transport means on road vehicles, e.g. automobiles or trucks
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/34—Testing dynamo-electric machines
- G01R31/343—Testing dynamo-electric machines in operation
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Abstract
The invention provides a reliability test method of a range extender system, and relates to the technical field of range extender test. The reliability test method of the range extender system comprises the following steps: the method comprises the steps of obtaining universal characteristic data of the fuel engine and efficiency data of the generator, and obtaining a matrix array of the range extender system according to the universal characteristic data of the fuel engine and the efficiency data of the generator. And acquiring a curve of the lowest fuel consumption rate of power generation of the range extender system according to the matrix array of the range extender system. And determining the rotating speed and the generated power of a plurality of operating points on the lowest fuel consumption curve of the power generation. The reliability of the range extender system is tested based on the rotating speed and the generating power corresponding to the multiple working condition points, so that the reliability test result of the range extender system is more accurate, and the reliability of the range extender under the actual operation working condition can be ensured.
Description
Technical Field
The invention relates to the technical field of range extender testing, in particular to a reliability testing method of a range extender system.
Background
The range extender is a necessary device in the range-extending electric automobile, and can convert kinetic energy generated by fuel oil consumed by a fuel oil engine into electric energy through the generator to be output to the battery for storage so as to improve the endurance mileage of the electric automobile. The reliability of the range extender system is directly related to the reliability of the whole vehicle, and the reliability test of the range extender system is particularly important.
In the prior art, a fuel engine operates between the lowest power generation rotating speed and the highest power generation rotating speed in a circulating and alternating mode, and then the reliability of a range extender system is tested.
However, in actual operation of the range extender system, different generated powers correspond to different generated rotational speeds. The existing reliability test method cannot comprehensively and truly simulate the actual operation condition, so that the result of the reliability test is inaccurate.
Disclosure of Invention
The invention aims to provide a reliability test method of a range extender system aiming at the defects in the prior art, so as to solve the problem that the existing reliability test method cannot simulate the actual operation condition, so that the result of the reliability test is inaccurate.
In order to achieve the above purpose, the embodiment of the present invention adopts the following technical solutions:
the embodiment of the invention provides a reliability test method of a range extender system, wherein the range extender system comprises the following steps: the fuel engine is in power connection with the generator, the fuel engine is connected with the fuel engine controller, the generator is electrically connected with the generator controller, the generator controller is electrically connected with the battery, and the fuel engine controller and the generator controller are also in communication connection with a control center respectively, wherein the method comprises the following steps:
acquiring universal characteristic data of a fuel engine and efficiency data of a generator; wherein, the universal characteristic data of the fuel engine comprises: torque, speed and fuel consumption, the efficiency data of the generator includes: torque, speed, and motor efficiency. Acquiring a matrix array of a range extender system according to the universal characteristic data of the fuel engine and the efficiency data of the generator; wherein, the matrix array of range extender system includes: power, rotational speed, and generated power specific fuel consumption. And acquiring a power generation minimum fuel consumption rate curve of the range extender system according to the matrix array of the range extender system, wherein the power generation minimum fuel consumption rate curve is used for indicating the minimum fuel consumption rate corresponding to the power generation power. And determining the rotating speed and the generated power of a plurality of operating points on the lowest fuel consumption curve of the power generation. And carrying out reliability test according to the rotating speed and the generating power corresponding to the plurality of working condition points to obtain a reliability test result of the range extender system.
Optionally, obtaining a matrix array of the range extender system according to the universal characteristic data of the fuel engine and the efficiency data of the generator, including: dividing the engine fuel consumption rate with the same torque and the same rotating speed in the universal characteristic data of the fuel engine and the efficiency data of the generator by the efficiency of the motor to obtain an initial matrix array of the range extender system; the initial matrix array of the range extender system comprises: torque, rotational speed, generated power, fuel consumption rate. And calculating and acquiring the output electric power, the rotating speed and the generating power fuel consumption rate of the range extender system according to the torque and the rotating speed in the initial matrix array of the range extender system and the conversion efficiency of the generator system to obtain the matrix array of the range extender system.
Optionally, on determining a relation curve between the generated power and the fuel consumption, determining the rotating speed and the generated power corresponding to the multiple operating points, including: and determining a plurality of working condition points from the lowest fuel consumption curve of power generation according to preset control factors, wherein the preset control factors comprise at least one of oil consumption, noise, vibration, Noise Vibration and Harshness (NVH) level and power demand. And determining the rotating speed and the power generation power corresponding to each working condition point according to the coordinate value corresponding to each working condition point on the lowest fuel consumption rate curve of power generation.
Optionally, the reliability test is performed according to the rotating speed and the generated power corresponding to the multiple working point, and the reliability test result of the range extender system is obtained, including: and sequentially controlling the range extender system to operate for a preset time at the rotating speed and the generated power corresponding to the plurality of working condition points. And circularly operating for N times to obtain the test result of the cyclic alternation durability of the range extender system, wherein N is an integer greater than 1.
Optionally, the reliability test is performed according to the rotating speed and the generated power corresponding to the multiple working point, and the reliability test result of the range extender system is obtained, including: and determining the operating point with the lowest generating power in the plurality of operating points. And sequentially controlling the range extender system to start, generate power and close according to the rotating speed corresponding to the working condition point with the lowest generating power. And circularly operating for K times to obtain the start-stop endurance test result of the range extender system, wherein K is an integer greater than 1.
Optionally, the reliability test is performed according to the rotating speed and the generated power corresponding to the multiple working point, and the reliability test result of the range extender system is obtained, including: and determining a working condition point of rated power generation power and a working condition point of maximum power generation power in the plurality of working condition points. And controlling the range extender system to start according to the rotating speed corresponding to the working condition point of the rated power generation power, operating at the rotating speed corresponding to the working condition point of the rated power generation power for a second preset time after operating at an idle speed for the first preset time, operating at the rotating speed corresponding to the working condition point of the maximum power generation power for a third preset time, and then controlling the range extender system to stop. And (4) circularly operating for i times to obtain a test result of the rated power durability of the range extender system, wherein i is an integer greater than 1.
Optionally, the reliability test is performed according to the rotating speed and the generated power corresponding to the multiple working point, and the reliability test result of the range extender system is obtained, including: and determining the operating point with the maximum generating power in the plurality of operating points. And controlling the range extender system to start according to the rotating speed corresponding to the working condition point of the maximum generating power, and operating at the idle speed for a fourth preset time. And controlling the range extender system to operate at a rotating speed corresponding to the working condition point of the maximum generating power for a fifth preset time. And controlling a generator in the range extender system to disconnect the load, and after the fuel engine automatically adjusts the rotating speed, controlling the range extender system to continuously operate for a sixth preset time length under the preset multiple of the rotating speed corresponding to the working point of the maximum generating power. And controlling the rotating speed of the fuel engine to be reduced to an idle speed. And (5) circularly operating j times to obtain the overspeed endurance test result of the range extender system, wherein j is an integer greater than 1.
The invention has the beneficial effects that: the method comprises the steps of obtaining a matrix array of a range extender system to obtain a power generation minimum fuel consumption rate curve through universal characteristic data of a fuel engine and efficiency data of a generator, determining rotating speeds and power generation power of a plurality of working condition points on the power generation minimum fuel consumption rate curve, and carrying out reliability test according to the rotating speeds and the power generation power corresponding to the working condition points, so that a reliability test result of the range extender system is obtained. According to the method, the rotating speed and the generating power corresponding to the working condition points for reliability testing are obtained according to a curve of lowest fuel consumption rate of power generation, the relation curve is obtained according to a matrix array in the range extender system obtained by a matrix array of a fuel engine and a matrix array of a generator, the rotating speed, the oil consumption, the generating power and the like of a vehicle in actual operation are actually simulated by the relation curve, reliability testing is carried out on the reliability of the range extender system based on the rotating speed and the generating power corresponding to the working condition points, the reliability testing result of the range extender system can be more accurate, and the reliability of the range extender under the actual operation working condition can be ensured.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
Fig. 1 is a schematic structural diagram of a range extender system in a reliability testing method of the range extender system provided in the present application;
fig. 2 is a schematic flowchart of a reliability testing method for a range extender system according to an embodiment of the present disclosure;
fig. 3 is a schematic flowchart of a reliability testing method for a range extender system according to another embodiment of the present disclosure;
fig. 4 is a schematic flowchart of a reliability testing method for a range extender system according to another embodiment of the present disclosure;
fig. 5 is a schematic flowchart of a reliability testing method for a range extender system according to another embodiment of the present disclosure;
fig. 6 is a test result of cycle alternation endurance of the range extender system in the reliability test method of the range extender system according to an embodiment of the present application;
fig. 7 is a schematic flowchart of a reliability testing method for a range extender system according to another embodiment of the present application;
fig. 8 is a test result of endurance of the start-stop of the range extender system in the reliability test method of the range extender system according to an embodiment of the present disclosure;
fig. 9 is a schematic flowchart of a reliability testing method for a range extender system according to another embodiment of the present application;
fig. 10 is a test result of the endurance of the rated power of the range extender system in the reliability test method of the range extender system according to an embodiment of the present application;
fig. 11 is a schematic flowchart of a reliability testing method for a range extender system according to another embodiment of the present application;
fig. 12 is a test result of the overspeed endurance of the range extender system in the reliability test method of the range extender system according to an embodiment of the present application.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention.
Fig. 1 is a schematic structural diagram of a range extender system in the reliability testing method of the range extender system provided by the present application.
As shown in fig. 1, the range extender system 100 includes: the system comprises a fuel engine 101, a generator 102, a generator controller 103, an engine controller 104 and a control center 108, and also comprises a battery 105, a battery management system 106 and a power supply control cabinet 107, wherein the durability test bench of the range extender is formed for reliability test. The generator controller 103 can be installed on the generator 102, the engine controller 104 is used for controlling the fuel engine 101, the battery management system 106 is used for managing the battery 105, the fuel engine 101 is connected with the generator 102 through a mechanical shaft, and the fuel engine 101 can drive the generator 102 to operate when rotating.
The generator 102 is electrically connected to a power source control cabinet 107 through a generator controller 103, the power source control cabinet 107 includes a plurality of switches therein, and the generator controller 103 is connected to the battery 105 through the plurality of switches in the power source control cabinet.
The generator controller 103, the engine controller 104, and the battery management system 106 are respectively in communication connection with a control center 108, and the control center 108 may be a terminal device with computing capability, such as a notebook computer, a desktop computer, and a tablet computer, which is not limited herein.
In some embodiments, the generator 102 is operated to convert kinetic energy into electrical energy, and the electrical energy is transmitted to the battery 105 through the power control cabinet 107 by the generator controller 103, and the battery 105 stores the electrical energy. The control center 108 may control the operation of the fuel engine 101 through the engine controller 104, and obtain the operating parameters of the fuel engine 101 and the generator 102, such as the torque, the speed, and the oil consumption of the fuel engine, the torque, the speed, and the motor efficiency of the generator, which is not limited herein.
It should be noted that the range extender system simulates the structure and the operation mode of the range extender on the range extender car, so that the reliability test result obtained by the test of the range extender system can represent the reliability in practical application.
Fig. 2 is a schematic flow chart of a reliability testing method of a range extender system according to an embodiment of the present application. The execution main body of the reliability testing method of the range extender system can be the control center, and the form of the control center can be a desktop computer, a notebook computer, a tablet computer, a customized terminal, a cloud server, a smart phone and the like, but not limited thereto.
As shown in fig. 2, the method includes:
and S210, acquiring universal characteristic data of the fuel engine and power generation efficiency data of the generator.
Wherein, the universal characteristic data of the fuel engine comprises: torque, speed and fuel consumption, the efficiency data of the generator includes: torque, rotational speed, and power generation efficiency.
It should be noted that the corresponding relations between the rotating speed, the torque and the oil consumption of different models of fuel engines are different, and in practical application, the corresponding relation between the rotating speed, the torque and the oil consumption is obtained from the real bench test data of the same model of engine, so as to ensure the accuracy of the reliability test.
In some embodiments, the rotor of the generator is coupled or otherwise dynamically coupled to the crankshaft of the fuel engine. Therefore, the rotational speed and the input torque of the generator are the same as the output rotational speed and the torque of the fuel engine. Alternatively, if a speed reducer is provided between the engine and the generator, the rotation speed and torque of the generator may be determined based on the reduction ratio of the speed reducer and the rotation speed of the fuel engine. Therefore, the engine is connected with the generator through the speed reducer, the rotating speed of the engine is reduced, but the torque is increased, namely the input torque of the generator is correspondingly increased.
S220, acquiring a matrix array of the range extender system according to the universal characteristic data of the fuel engine and the efficiency data of the generator.
Wherein, the matrix array of range extender system includes: power, rotational speed, and generated power specific fuel consumption.
In some embodiments, the matrix array of the range extender system can be calculated and obtained through a preset formula according to parameters in the universal characteristic data of the fuel engine and the efficiency data of the generator.
And S230, acquiring a power generation minimum fuel consumption rate curve of the range extender system according to the matrix array of the range extender system.
In some embodiments, a power generation minimum fuel consumption rate curve can be drawn by taking the rotation speed and the generated power as coordinate axes, and the curve can be used for representing the minimum fuel consumption required by the expected generated power at different rotation speeds, namely the relation between the fuel consumption and the generated power in an ideal state, and the target generated power, the rotation speed and the like of the range extender for power following control when the vehicle runs are simulated.
And S240, determining the rotating speed and the generated power of a plurality of working condition points on the lowest fuel consumption rate curve of the power generation.
The system comprises a relation curve, a plurality of working condition points, a range extender system, a plurality of working condition points and a plurality of working condition points, wherein the plurality of working condition points can be determined according to test requirements, each working condition point represents the running state of the range extender system, and the lowest fuel consumption rate curve of power generation takes the rotating speed and the power generation power as coordinate axes, so that after the working condition points are determined, the rotating speed and the power generation power of the working condition points can be determined according to the coordinate values corresponding to the working condition points on the relation curve.
And S250, performing reliability test according to the rotating speed and the generating power corresponding to the plurality of working condition points to obtain a reliability test result of the range extender system.
In some embodiments, a plurality of different test strategies may be set, each test strategy includes at least one operating point when the range extender system operates and an operating duration corresponding to the at least one operating point, and the reliability test of the range extender system is performed according to each test strategy, that is, a plurality of reliability test results about the range extender system can be obtained.
In this embodiment, a minimum fuel consumption rate curve for power generation is obtained according to the matrix array of the range extender system through the matrix array of the fuel engine and the matrix array of the generator, the rotating speeds and the power generation powers of a plurality of operating points are determined on the minimum fuel consumption rate curve for power generation, and reliability tests are performed according to the rotating speeds and the power generation powers corresponding to the operating points, so that a reliability test result of the range extender system is obtained. According to the method, the rotating speed and the generating power corresponding to the working condition points for reliability testing are obtained according to a curve of lowest fuel consumption rate of power generation, the relation curve is obtained according to a matrix array in the range extender system obtained by a matrix array of a fuel engine and a matrix array of a generator, the relation curve actually simulates ideal rotating speed, oil consumption, generating power and the like when a vehicle actually runs, reliability testing is conducted on the reliability of the range extender system based on the rotating speed and the generating power corresponding to the working condition points, the reliability testing result of the range extender system can be more accurate, and the reliability of the range extender under the actual running working condition can be guaranteed.
Fig. 3 is a schematic flow chart of a reliability testing method of a range extender system according to another embodiment of the present application.
Alternatively, as shown in fig. 3, the obtaining a matrix array of the range extender system according to the data of the universal characteristic of the fuel engine and the data of the power generation efficiency of the generator may include:
s221, in the universal characteristic data of the fuel engine and the efficiency data of the generator, the oil consumption of the engine with the same torque and the same rotating speed is divided by the efficiency of the motor, and an initial matrix array of the range extender system is obtained.
Wherein, the initial matrix array of the range extender system comprises: torque, rotational speed, generated power, fuel consumption rate.
It should be noted that the oil consumption of the engine with the same torque and the same rotating speed is divided by the efficiency of the motor, so that the parameters of the fuel engine and the generator are coupled to obtain the parameters in the initial matrix array of the range extender system, and the initial matrix array of the range extender system is obtained.
S222, calculating and obtaining the power, the rotating speed and the fuel consumption rate of the generating power of the range extender system according to the torque and the rotating speed in the initial matrix array of the range extender system and the generating efficiency to obtain the matrix array of the range extender system.
In some embodiments, the power of the fuel engine in the range extender system can be calculated by the following equation (1):
power (kW) ═ torque (Nm) × rotational speed (rpm)/9549 (equation 1)
Likewise, the generated power of the generator in the range extender system can be calculated by the following formula (2):
generated power (kWe) ═ torque (Nm) × rotational speed (rpm)/9549 × motor efficiency (formula 2)
In the embodiment, the oil consumption rate matrix data of the range extender is obtained by dividing the oil consumption of the engine with the same torque and the same rotating speed by the efficiency of the motor, the lowest oil consumption rate matrix data of power generation is calculated according to the matrix, and a plurality of most representative working condition points are selected as the test working conditions according to the real control strategy of the range extender. When the reliability test is carried out according to the method, the obtained result is more accurate.
Fig. 4 is a flowchart illustrating a reliability testing method for a range extender system according to another embodiment of the present application.
Alternatively, as shown in fig. 4, determining the rotation speed and the generated power corresponding to a plurality of operating points on the lowest fuel consumption curve of power generation includes:
and S241, determining a plurality of working condition points from the lowest fuel consumption curve of power generation according to preset control factors.
The preset control factors comprise at least one of oil consumption, NVH performance and power demand.
In some embodiments, when the vehicle equipped with the range extender system runs, the operation strategy of the range extender system is a strategy based on multiple control factors to improve the driving experience of the vehicle, and therefore, when the operating point is determined, the operating point can be determined according to at least one control factor such as oil consumption, NVH performance and power demand. The weights for different control factors may be different in different scenarios. For example, in a congested scenario, where the vehicle is traveling at a low speed, the weight of fuel consumption is greatest; in a driving scene of an expressway, a vehicle stably drives at a high speed, and the weight of NVH performance is the largest; in a heavy driving scenario, the vehicle is speeding up and the power demand is weighted the most, but not limited to this.
And S242, determining the rotating speed and the power generation power corresponding to each operating point according to the coordinate value corresponding to each operating point on the lowest fuel consumption rate curve of power generation.
In some embodiments, two coordinate axes of a planar coordinate system may respectively represent the rotation speed and the generated power, and a generated minimum fuel consumption curve is plotted on the planar coordinate system, so that the rotation speed and the generated power corresponding to each operating point on the relationship curve may be determined according to the coordinates corresponding to each operating point on the relationship curve, for example, the rotation speed may be represented by a horizontal axis, the generated power may be represented by a vertical axis, and the horizontal axis coordinate of each operating point on the relationship curve is the rotation speed of the generator and the vertical axis coordinate is the generated power.
It should be noted that the rotation speed of each operating point may be a target rotation speed of the range extender system during power generation, and the rotation speed may fluctuate within a certain range because the rotation speed during actual operation cannot be accurate to the target rotation speed. In this regard, in the present application, the generated power corresponding to the target rotation speed is the average generated power of the range extender system operating at the target rotation speed.
In this embodiment, the operating point may be determined according to a control factor of at least one of the oil consumption, the NVH performance, and the power demand, that is, the demand of the vehicle in actual operation is considered when determining the operating point, so that the determined operating point is closer to the actual condition, and the result obtained by performing the reliability test at the operating point is more accurate.
In the following, the reliability test of the range extender system performed under different operation strategies is described, and the rotation speed mentioned below is the rotation speed of the generator if not otherwise stated.
Fig. 5 is a flowchart illustrating a reliability testing method of a range extender system according to another embodiment of the present application, and fig. 6 is a testing result of cycle alternation endurance of the range extender system in the reliability testing method of the range extender system according to the embodiment of the present application.
Optionally, as shown in fig. 5, performing a reliability test according to the rotation speed and the generated power corresponding to the multiple operating point, and obtaining a reliability test result of the range extender system, includes:
and S251, sequentially controlling the range extender system to operate for a preset time at the rotating speed and the generated power corresponding to the multiple working condition points.
In some embodiments, the range extender system may be controlled to operate according to the rotation speed which rises and falls alternately and the rotation speed and the generated power which correspond to the multiple operating points in sequence, so as to test the cycle alternation durability of the range extender system, for example, as shown in fig. 6 and table 1, the range extender system may be operated for a certain period of time at each operating point numbered from 1 to 18, and different operating points may correspond to different operating periods of time, for example, the range extender system may be operated for 180 seconds at the operating point No. 3 (rotation speed 1000rpm, generated power 5kWe), then the rotation speed is increased to 2500rpm within 2 seconds, and the range extender system may be operated for 180 seconds at the operating point No. 5 (rotation speed 2500rpm, generated power 20kWe), and the rotation speed, generated power and the operation time of the operating points are not limited, and the actual requirements in application are met.
And S252, circularly running for N times to obtain a test result of the cyclic alternation durability of the range extender system, wherein N is an integer greater than 1.
In some embodiments, the step in S251 needs to be cycled for multiple times to obtain sufficiently accurate results, for example, as shown in fig. 6 and table 1, the step in S251 needs 1350 seconds for one execution, and N may be 1600, i.e., the cycle is 1600 times.
TABLE 1
After the circulation is finished, disassembling the range extender assembly, measuring whether the abrasion degree of each kinematic pair part is within an allowable range, checking whether each part has cracks and the like which possibly cause failure phenomena, and accordingly judging the cycle alternation endurance test result of the range extender system.
In the embodiment, the range extender system is operated at different rotating speeds and is continued for a certain time, so that the operation condition of cycle alternation can be simulated to the maximum extent, and the obtained durable test result of cycle alternation of the range extender system is more accurate.
Fig. 7 is a flowchart illustrating a reliability testing method of a range extender system according to another embodiment of the present application, and fig. 8 is a testing result of start-stop endurance of the range extender system in the reliability testing method of the range extender system according to the embodiment of the present application.
Optionally, as shown in fig. 7, performing a reliability test according to the rotation speed and the generated power corresponding to the multiple operating point, and obtaining a reliability test result of the range extender system, includes:
and S253, determining the working condition point with the lowest generating power in the plurality of working condition points.
In some embodiments, the operating point with the lowest generated power in the curve of the lowest fuel consumption rate for power generation of the range extender system can be determined as the operating point with the lowest generated power.
And S254, sequentially controlling the range extender to start, generate power and close according to the rotating speed corresponding to the working condition point with the lowest generating power.
According to the method, the fuel engine in the range extender system is controlled to start firstly, the generator in the range extender system is controlled to generate power secondly, and the fuel engine in the range extender system is controlled to close finally according to the rotating speed corresponding to the working condition point with the lowest generating power. The control time periods corresponding to the starting of the fuel engine, the power generation of the generator and the closing of the fuel engine can be different time periods respectively.
In some embodiments, as shown in fig. 8 and table 2, if the rotation speed corresponding to the operating point with the lowest power generation power is 1500rpm, the range extender system may be operated under the operating conditions numbered 1 to 5, that is, the rotation speed is increased to 1500rpm within 3 seconds after the start, the rotation speed continues to 10 seconds after the rotation speed is increased to 1500rpm, the power generation power of 10kWe is reached, and then the rotation speed is decreased from 1500rpm to 0rpm within 3 seconds, and the next cycle is started after two seconds.
The rotating speed, the generating power and the running time of the working condition point are not limited, and the actual requirements in application are taken as the standard.
And S255, circularly operating for K times to obtain the starting and stopping endurance test result of the range extender system, wherein K is an integer larger than 1.
In some embodiments, the step in S254 needs to be cycled for many times to obtain sufficiently accurate results, for example, as shown in fig. 8 and table 2, the step in S254 needs 18 seconds to be performed once, and K may be 100000, i.e., 10 ten thousand cycles.
Alternatively, the range extender may be ramped up to 4000rpm for a 30 minute period of power generation at 40kWe every 50 hours to remove accumulated soot from the fuel engine during low speed operation.
TABLE 2
After the circulation is completed, the range extender system is disassembled, whether the abrasion degree of each kinematic pair part is within an allowable range or not is measured, whether each part has cracks or the like which possibly causes failure is checked, and accordingly, the start-stop durability test result of the range extender system is judged.
In this embodiment, by starting the range extender system, after the rotating speed of the lowest power generation power is reached, the range extender system is closed for a certain time, so that the start-stop running condition of the range extender system can be simulated to the greatest extent, and the obtained durable start-stop test result of the range extender system is more accurate.
Fig. 9 is a flowchart illustrating a reliability testing method of a range extender system according to another embodiment of the present application, and fig. 10 is a testing result of power rating endurance of the range extender system in the reliability testing method of the range extender system according to the embodiment of the present application.
Optionally, as shown in fig. 9, performing a reliability test according to the rotation speed and the generated power corresponding to the multiple operating point, and obtaining a reliability test result of the range extender system, includes:
and S256, determining a working condition point of rated power generation and a working condition point of maximum power generation in the plurality of working condition points.
In some embodiments, the rated power generation power of the range extender system is known, and in the curve of the lowest fuel consumption rate of power generation, the operating point where the power generation power value is equal to the rated power generation power can be determined as the operating point of the rated power generation power; the operating point with the highest power generation power in the curve of the lowest fuel consumption rate of power generation of the range extender system can be determined as the operating point with the maximum power generation power.
S257, controlling the range extender system to start according to the rotating speed corresponding to the working condition point of the rated power generation power, operating at the rotating speed corresponding to the working condition point of the rated power generation power for a second preset time after operating at an idle speed for the first preset time, operating at the rotating speed corresponding to the working condition point of the maximum power generation power for a third preset time, and then controlling the range extender system to stop.
In some embodiments, as shown in fig. 10 and table 3, if the rated power of the range extender system is 40kWe, the rotation speed at the rated power is 4000rpm, the first preset time period is 60 seconds, the second preset time period is 3464 seconds, and the third preset time period is 60 seconds, the range extender system may be operated under the conditions numbered 1 to 8, that is, after being turned on for 3 seconds, the rotation speed is increased to an idle speed, that is, 1000rpm, and then the rotation speed is operated for 60 seconds at 1000 rpm.
Thereafter, the rotation speed was increased to 4000rpm in 5 seconds, the generated power reached 40kWe for 3464 seconds, then increased from 4000rpm to 4500rpm in 1s, the generated power reached 60kWe, and run at 4500rpm for 60s, and finally decreased to 1000rpm in 7 seconds, ready for the start of the next cycle.
The rotating speed, the generating power and the running time of the working condition point are not limited, and actual parameters in application are taken as the standard.
And S258, circularly operating for i times to obtain a test result of the durability of the rated power of the range extender system, wherein i is an integer larger than 1.
In some embodiments, the step in S257 needs to be cycled many times to obtain sufficiently accurate results, for example, as shown in fig. 10 and table 3, the step in S257 needs 3600 seconds to be performed once, and i may be 600, that is, 600 cycles are performed.
TABLE 3
After the circulation is completed, the range extender system is disassembled, whether the abrasion degree of each kinematic pair part is within an allowable range or not is measured, whether each part has cracks or the like which possibly causes failure phenomena is checked, and accordingly, the test result of the durability of the rated power of the range extender system is judged.
In this embodiment, the range extender system is started, continues for a certain time after the rotating speed of the rated power generation is reached, and then is closed, so that the running condition of the range extender system under the rated power can be simulated to the maximum extent, and the obtained durable test result of the rated power of the range extender system is more accurate.
Fig. 11 is a flowchart illustrating a reliability testing method of a range extender system according to another embodiment of the present application, and fig. 12 is a testing result of overspeed endurance of the range extender system in the reliability testing method of the range extender system according to the embodiment of the present application.
Optionally, as shown in fig. 11, performing a reliability test according to the rotation speed and the generated power corresponding to the multiple operating point, and obtaining a reliability test result of the range extender system, includes:
and S259, determining the operating point with the maximum generating power in the plurality of operating points.
In some embodiments, the operating point at which the power generation power is highest in the lowest fuel consumption curve of the range extender system may be determined as the operating point at which the power generation power is maximum.
And S2510, controlling the range extender system to start according to the rotating speed corresponding to the working condition point of the maximum generating power, and operating at an idle speed for a fourth preset time.
In some embodiments, the speed is raised to idle, i.e. 1000rpm, within 3 seconds after the fuel engine is started. As shown in fig. 12, the fourth preset time period may be 60 s.
And S2511, controlling the range extender system to operate at a rotating speed corresponding to the working condition point of the maximum generating power for a fifth preset time.
In some embodiments, as shown in fig. 12 and table 4, where the maximum generated power is 60kWe, and the generated power corresponds to 4500rpm, the speed of the range extender system may be controlled to increase from idle to 4500rpm within 3 seconds and operate at 4500rpm for 60 seconds, i.e., the fifth predetermined period may be 60 seconds.
And S2512, controlling a generator in the range extender system to disconnect load, and continuously operating the range extender system for a sixth preset time after the rotation speed of the fuel engine is automatically adjusted or under the preset multiple of the rotation speed corresponding to the working point of the maximum power generation power.
In some embodiments, the load of the generator is disconnected, that is, the battery charging circuit is disconnected, so that the fuel engine runs with the generator in an idle state, and the fuel engine adaptively adjusts the rotation speed, and correspondingly, the rotation speed of the generator also changes synchronously, for example, as shown in fig. 12 and table 4, the change condition of the adaptive rotation speed can be represented by the operating points numbered 6-7. The preset multiple of the operating point corresponding to the maximum generated power to the rotating speed may be 1.2 times, for example, the maximum generated power to the rotating speed is 1.2 times of 4500rpm, that is, the rotating speed in the operating point 6 is 5400 rpm. The sixth preset time period may be 120s, and the operation may be performed at a rotation speed of 5400rpm for 120 s.
And S2513, controlling the rotation speed of the fuel engine to be reduced to an idle speed.
In some embodiments, as shown in fig. 12 and table 4, the fuel engine may be brought down to idle within 5 seconds in preparation for the next cycle to begin.
The rotation speed, the generated power and the running time of the working point in S2510, S2511, S2512 and S2513 are not limited, and the actual requirement in application is taken as the standard.
It should be noted that the fourth preset time period, the fifth preset time period and the sixth preset time period may be different preset time periods, and the specific time period may also be other values, and the above time periods are only some possible examples, and the application is not limited thereto.
And S2514, circularly running for j times to obtain the overspeed endurance test result of the range extender system, wherein j is an integer larger than 1.
In some embodiments, the steps in S2510 to S2513 need to be cycled for multiple times to obtain sufficiently accurate results, for example, as shown in fig. 12 and table 4, the step in S257 needs 252 seconds to be performed once, and j may be 2500, i.e., the cycle is 2500 times.
TABLE 4
After the circulation is completed, the range extender system is disassembled, whether the abrasion degree of each kinematic pair part is within an allowable range or not is measured, whether each part has cracks or the like which possibly cause failure is checked, and the overspeed and durability test result of the range extender system is judged according to the results.
In this embodiment, the range extender system is started, the power generation load is removed after the rotating speed of the maximum power generation power is reached, the rotating speed is adaptive, then the range extender system is operated for a period of time under the preset multiple of the rotating speed corresponding to the working point of the maximum power generation power, and then the range extender system is reduced to the idle speed, so that the condition that the range extender system operates under the overspeed can be simulated to the maximum extent, and the obtained overspeed endurance test result of the range extender system is more accurate.
In the embodiments provided in the present invention, it should be understood that the disclosed apparatus and method may be implemented in other ways. For example, the above-described apparatus embodiments are merely illustrative, and for example, the division of the units is only one logical division, and other divisions may be realized in practice, for example, a plurality of units or components may be combined or integrated into another system, or some features may be omitted, or not executed. In addition, the shown or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, devices or units, and may be in an electrical, mechanical or other form.
The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.
In addition, functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may exist alone physically, or two or more units are integrated into one unit. The integrated unit can be realized in a form of hardware, or in a form of hardware plus a software functional unit.
The integrated unit implemented in the form of a software functional unit may be stored in a computer readable storage medium. The software functional unit is stored in a storage medium and includes several instructions to enable a computer device (which may be a personal computer, a server, or a network device) or a processor (processor) to execute some steps of the methods according to the embodiments of the present invention. And the aforementioned storage medium includes: a U disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and other various media capable of storing program codes.
Claims (6)
1. A reliability testing method of a range extender system, the range extender system comprising: the system comprises a fuel engine, a generator controller, a fuel engine controller and a battery, wherein the fuel engine is in power connection with the generator, the fuel engine is connected with the fuel engine controller, the generator is electrically connected with the generator controller, the generator controller is electrically connected with the battery, the fuel engine controller and the generator controller are also in communication connection with a control center respectively, and the system is characterized by comprising:
acquiring all-characteristic data of the fuel engine and efficiency data of the generator; wherein the universal characteristic data of the fuel engine comprises: torque, speed and fuel consumption, the efficiency data of the generator includes: torque, rotational speed, and motor efficiency;
acquiring a matrix array of the range extender system according to the universal characteristic data of the fuel engine and the efficiency data of the generator; wherein the matrix array of the range extender system comprises: power, rotational speed, and generated power fuel consumption rate;
acquiring a power generation minimum fuel consumption rate curve of the range extender system according to the matrix array of the range extender system, wherein the power generation minimum fuel consumption rate curve is used for indicating the minimum fuel consumption rate corresponding to the power generation power;
determining the rotating speeds and the generating power of a plurality of working condition points on the curve of the lowest fuel consumption rate of power generation;
performing reliability test according to the rotating speed and the generating power corresponding to the plurality of working condition points to obtain a reliability test result of the range extender system;
the acquiring the matrix array of the range extender system according to the universal characteristic data of the fuel engine and the efficiency data of the generator comprises the following steps:
dividing the engine fuel consumption rate with the same torque and the same rotating speed in the universal characteristic data of the fuel engine and the efficiency data of the generator by the efficiency of the motor to obtain an initial matrix array of the range extender system; the initial matrix array of the range extender system comprises: torque, rotation speed, generated power and fuel consumption rate;
and calculating and acquiring the output electric power, the rotating speed and the generating power fuel consumption rate of the range extender system according to the torque and the rotating speed in the initial matrix array of the range extender system and the conversion efficiency of the generator system to obtain the matrix array of the range extender system.
2. The method of claim 1, wherein determining the rotational speed and the generated power corresponding to a plurality of operating point locations on the power generation minimum specific fuel consumption curve comprises:
determining a plurality of working condition points from the curve of the lowest fuel consumption rate of power generation according to preset control factors, wherein the preset control factors comprise at least one of oil consumption, noise, vibration, Noise Vibration and Harshness (NVH) level and power demand;
and determining the rotating speed and the power generation power corresponding to each working condition point according to the coordinate value corresponding to each working condition point on the power generation minimum fuel consumption rate curve.
3. The method according to any one of claims 1-2, wherein the performing a reliability test according to the rotational speed and the generated power corresponding to the plurality of operating point to obtain a reliability test result of the range extender system comprises:
sequentially controlling the range extender system to operate for a preset time at the rotating speed and the generated power corresponding to the plurality of working condition points;
and circularly operating for N times to obtain a test result of the cyclic alternation durability of the range extender system, wherein N is an integer greater than 1.
4. The method according to any one of claims 1-2, wherein the performing a reliability test according to the rotational speed and the generated power corresponding to the plurality of operating point to obtain a reliability test result of the range extender system comprises:
determining a working condition point with the lowest generating power in a plurality of working condition points;
according to the rotating speed corresponding to the working condition point with the lowest generating power, the range extender system is sequentially controlled to be started, generated and closed;
and circularly operating for K times to obtain the start-stop endurance test result of the range extender system, wherein K is an integer greater than 1.
5. The method according to any one of claims 1-2, wherein the performing a reliability test according to the rotational speed and the generated power corresponding to the plurality of operating point to obtain a reliability test result of the range extender system comprises:
determining a working condition point of rated power generation power and a working condition point of maximum power generation power in the plurality of working condition points;
controlling the range extender system to start according to the rotating speed corresponding to the working condition point of the rated power generation power, after the range extender system runs for a first preset time at an idle speed, running for a second preset time at the rotating speed of the working condition point of the rated power generation power, then running for a third preset time at the rotating speed corresponding to the working condition point of the maximum power generation power, and then controlling the range extender system to stop;
and circularly operating for i times to obtain a test result of the rated power durability of the range extender system, wherein i is an integer greater than 1.
6. The method according to any one of claims 1-2, wherein the performing a reliability test according to the rotational speed and the generated power corresponding to the plurality of operating point to obtain a reliability test result of the range extender system comprises:
determining a working condition point with the maximum power generation power in the plurality of working condition points;
controlling the range extender system to start according to the rotating speed corresponding to the working condition point of the maximum generating power, and operating at an idle speed for a fourth preset time;
controlling the range extender system to operate at a rotating speed corresponding to the working condition point of the maximum generating power for a fifth preset time;
controlling a generator in the range extender system to cut off load, and after the fuel engine automatically adjusts the rotating speed, controlling the range extender system to continuously operate for a sixth preset time under the preset multiple of the rotating speed corresponding to the working condition point of the maximum generating power;
controlling the rotating speed of the fuel engine to be reduced to an idle speed;
and circularly operating j times to obtain the overspeed endurance test result of the range extender system, wherein j is an integer greater than 1.
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| CN111856272A (en) * | 2020-06-15 | 2020-10-30 | 杭州赫日新能源科技有限公司 | Endurance test system and method for range extender |
| CN111896264B (en) * | 2020-07-28 | 2023-02-24 | 上海元城汽车技术有限公司 | Method and device for generating test working condition of range extender engine and electronic equipment |
| CN111976711A (en) * | 2020-09-01 | 2020-11-24 | 宁波洁程汽车科技有限公司 | Matching method for range extender efficient area |
| CN112238911A (en) * | 2020-09-10 | 2021-01-19 | 宝能(广州)汽车研究院有限公司 | Type selection method of range extender |
| CN112855363B (en) * | 2021-01-19 | 2023-01-17 | 浙江吉利控股集团有限公司 | Range extender, control method and vehicle |
| CN112985831B (en) * | 2021-02-06 | 2023-08-15 | 哈尔滨东安汽车发动机制造有限公司 | Range extender assembly reliability test method for range-extending electric automobile |
| CN113375948A (en) * | 2021-06-24 | 2021-09-10 | 哈尔滨东安汽车动力股份有限公司 | Range extender rack joint debugging test method |
| CN113834651A (en) * | 2021-09-22 | 2021-12-24 | 哈尔滨东安汽车发动机制造有限公司 | Method for carrying out durability test of rated power of range-extending transmission on rack |
| CN113916524B (en) * | 2021-10-12 | 2023-06-02 | 江西昌河汽车有限责任公司 | Range extender assembly critical rotation speed endurance test method for range extender electric automobile |
| CN113925563A (en) * | 2021-10-13 | 2022-01-14 | 杭州柳叶刀机器人有限公司 | Polishing power adjusting method and device, electronic equipment and storage medium |
| CN114942141A (en) * | 2022-06-10 | 2022-08-26 | 哈尔滨东安汽车动力股份有限公司 | Range extender rack joint debugging test method for controlling operation of range extender based on INCA |
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