CN114942141A - Range extender rack joint debugging test method for controlling operation of range extender based on INCA - Google Patents
Range extender rack joint debugging test method for controlling operation of range extender based on INCA Download PDFInfo
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- CN114942141A CN114942141A CN202210658370.9A CN202210658370A CN114942141A CN 114942141 A CN114942141 A CN 114942141A CN 202210658370 A CN202210658370 A CN 202210658370A CN 114942141 A CN114942141 A CN 114942141A
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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
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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
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/16—Information or communication technologies improving the operation of electric vehicles
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Abstract
A range extender rack joint debugging test method based on INCA control of the operation of a range extender belongs to the technical field of engine tests. The method comprises the following steps: s1, performing a monomer performance test on an engine and a motor system; s2, building a range extender rack, and setting rack parameters according to test requirements so as to meet test boundary conditions; s3, basic debugging; s4, performance test; s5, reliability test; s6, carrying out a durability test; s7, re-testing the performance and evaluating the test result; s8, re-testing the single bodies of the engine and the motor system, and evaluating the final test result; and S9, ending. The bench test of the range extender can be carried out to obtain the specific oil consumption data of the range extender under the full operating condition of the range extender, so that a system MAP is drawn, and the optimal fuel oil operating condition point is conveniently selected in the system MAP; meanwhile, the endurance test of the range extender can be carried out based on the INCA control, and the reliability of the endurance test can be verified; in the process, the INCA software can control the range extender to automatically and continuously run each working condition in the endurance cycle working condition, so that the operation amount of personnel is reduced.
Description
Technical Field
The invention belongs to the technical field of engine tests, and particularly relates to a range extender rack joint debugging test method.
Background
The output characteristic of the range extender is a key item in the design stage, and the specific oil consumption and the maximum power which can be output of the range extender under various working conditions directly influence the power generation efficiency, the economy and the dynamic property of the range extender. Therefore, it is important to examine the output characteristics of the test bench and verify whether the design requirements are met through the measured data.
Therefore, it is an urgent technical problem to be solved by those skilled in the art to provide a method for performing a bench joint debugging test by controlling the operation of a range extender through INCA.
Disclosure of Invention
The invention provides a test method for controlling the operation of a range extender based on INCA software so as to carry out joint debugging test to obtain the output characteristic of the range extender and verify the reliability of the range extender.
The technical scheme adopted by the invention is as follows: a range extender rack joint debugging test method based on INCA control range extender operation comprises the following steps:
s1, performing a monomer performance test on an engine and a motor system;
s2, building a rack, and setting rack parameters to meet test boundary conditions according to test requirements;
s3, basic debugging;
s4, performance test;
s5, reliability test;
s6, carrying out a durability test;
s7, re-testing the performance and evaluating the test result;
s8, re-testing the single bodies of the engine and the motor system, and evaluating the final test result;
and S9, ending.
Compared with the prior art, the invention has the following beneficial effects:
by the method, the bench test of the range extender can be carried out to obtain the specific oil consumption data of the range extender under the full operating condition of the range extender, so that a system MAP is drawn, and the optimal fuel oil operating condition point is conveniently selected from the system MAP; meanwhile, the endurance test of the range extender can be carried out based on the INCA control, and the reliability of the endurance test can be verified; in addition, in the process, an operator does not need to change the cycle working condition directly and manually, and the INCA software can control the range extender to automatically and continuously run each working condition in the durable cycle working condition, so that the operation amount of the operator is reduced, and the advantages of simplicity, convenience, accuracy and the like are realized.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a schematic diagram of the connection of the range extender stand of the present invention;
FIG. 3 shows endurance cycle conditions selected by the endurance test of the present invention.
Detailed Description
For a better understanding of the objects, structure and function of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings.
Referring to fig. 1, a range extender rack joint debugging test method for controlling the operation of a range extender based on INCA includes the following steps:
s1, performing a monomer performance test on an engine and a motor system;
s2, building a rack, and setting rack parameters to meet test boundary conditions according to test requirements;
s3, basic debugging;
s31, debugging INCA to realize successful communication between the INCA and a domain controller and between the INCA and an ECU (electronic control unit) and between the domain controller and the ECU and between the INCA and a GCU;
s32, the range extender can be started successfully, can run well and generate electricity normally;
s4, performance test;
s41, determining the range of the sweep point working condition of the range extender and the interval of each working condition according to the test requirement by the INCA operation and the combination of the universal data of an engine and a motor system;
s42, adjusting the operation condition of the range extender through INCA operation, acquiring data of output power and fuel consumption of the range extender under each condition through a power analyzer and a rack fuel consumption monitoring device, and calculating specific fuel consumption data under the condition point through a formula (1);
specific oil consumption (g/kWh) 1000 kg/h/power (kW) and (1)
S5, reliability test;
s51, before the endurance test is started, performing a performance test on the range extender to obtain a system MAP of the range extender;
s52, determining an endurance cycle working condition of the endurance test of the range extender according to the endurance test assessment requirement;
s6, carrying out a durability test; the endurance cycle working condition can be directly led in by controlling the operation of the range extender INCA to carry out the 600h endurance test of the range extender, and the range extender can operate the endurance cycle working condition by controlling the INCA after the heat engine is finished.
S7, re-testing the performance and evaluating the test result; and after the endurance test is finished, performing performance retest again (performing the performance test of the range extender assembly again), acquiring performance data of the range extender after endurance, comparing the system MAP obtained by the performance test before and after endurance, and verifying the reliability of the range extender.
S8, re-testing the single bodies of the engine and the motor system, and evaluating the final test result;
s81, carrying out retesting on the single bodies of the engine and the motor system, and comparing test results before and after endurance, wherein performance attenuation is within +/-3%, and determining that the performance of the single bodies of the engine and the motor is not problematic;
and S82, evaluating the reliability of the range extender by combining test data.
And S9, ending.
Taking a project range extender bench joint debugging test as an example, the specific implementation method comprises the following steps:
the method comprises the following steps:
s1, performing a monomer performance test on an engine and a motor system;
performing initial performance test on the engine and the range-extended motor until the performance is qualified; the performance initial test of the engine is executed according to an automobile engine reliability test method GB/T19055 and 2003, and the performance initial test of the range-extended motor is executed according to an electric automobile motor and a controller thereof GB/T18488.2-2006;
s2, building a rack according to the bench connection principle diagram of the range extender, and setting rack parameters to meet test boundary conditions according to test requirements;
all parts in the figure 2 are connected according to requirements, one INCA, 582.1 and an engine ECU are sequentially connected, the other INCA, 582.1 and a domain controller are sequentially connected, the engine ECU and a generator GCU are connected, a simulation battery cabinet and the generator GCU are connected through a line, a current sensor is connected on the line, a power analyzer is connected on the line and the current sensor, the power analyzer is connected with a rack computer, the engine ECU, the generator GCU and the domain controller are all connected with a low-voltage communication wire harness, and the low-voltage communication wire harness is connected with a low-voltage storage battery.
Installing the range extender on a test bench; the connection state of the rack is checked according to test requirements, and the phenomena of water leakage, electric leakage and oil leakage are avoided in the operation process of the range extender;
setting each limiting parameter of the rack according to the test requirement, which specifically comprises: the temperature of cooling water of an engine, the flow rate and the temperature of cooling water of a generator and a GCU (general gasoline unit), the pressure of fuel oil, the temperature of the fuel oil, the rated voltage of a motor and the like; at least the following important parameters, including the temperature of inlet and outlet water of an engine, the temperature of fuel oil, the pressure of the fuel oil, the power generation power of a range extender, the voltage and the current of a direct current bus read from a power analyzer, the specific oil consumption of the range extender and the like, can be monitored in a computer of the rack;
s3, basic debugging;
s31, debugging INCA to realize successful communication between the INCA and a domain controller and between the INCA and an ECU (electronic control unit) and between the domain controller and the ECU and between the INCA and a GCU; the successful communication mark is that the INCA calibration interface for controlling the operation of the range extender has no fault prompt, the direct current bus voltage value fed back by the GCU, the motor temperature, the IGBT temperature in the GCU and the parameter value read by the sensor actually installed in the rack, the calibration quantity in the INCA can be successfully input, and the INCA interface for monitoring ECU data can read each monitored quantity parameter value of the engine; after the communication operation is finished, setting the speed change slope of the range extender to 290rpm/s and the torque change slope to 30N.m/s respectively at the INCA, and ensuring that the range extender switches the working condition at a stable speed to avoid the damage of an engine;
s32, the range extender can be started successfully, can run well and generate electricity normally; controlling the range extender to start, and if the range extender can normally generate power after starting, controlling the range extender to operate 1400rpm/5kW to heat the engine until the water temperature of the engine reaches 88 +/-5 ℃ and the temperature of engine oil reaches over 80 ℃; if the power cannot be normally generated after the power is started, the fault elimination of the range extender assembly, the INCA software and the program is required;
s4. Performance test
S41, determining the range of the sweep point working condition of the range extender and the interval of each working condition according to the test requirement by INCA operation in combination with universal data of an engine and a motor system; the performance test has the following selected working condition ranges: the rotating speed is 0-6000rpm, one point per 400rpm, the torque is 30-140N.m, and one point per 10 N.m;
s42, adjusting the operation condition of the range extender by the INCA operation, controlling the range extender to operate at a first operating point of 1000rpm/30N.m, continuously operating until the specific oil consumption value of the operating point is stabilized within 3% of a certain numerical value, confirming that the oil consumption of the range extender is stable, acquiring the output power and the fuel consumption data of the range extender under each operating condition by a power analyzer and a rack oil consumption monitoring device, and calculating the specific oil consumption data under the operating point by a formula (1); repeating the above operation to complete the test of the full working condition; the test data are sorted and a system MAP is drawn;
specific oil consumption (g/kWh) 1000 kg/h/power (kW) and (1)
S5, reliability test
S51, before the endurance test is started, performing a range extender performance test to obtain a system MAP of the range extender;
s52, determining the endurance cycle working conditions (the writing rotating speed and the torque listed later) of the endurance test of the range extender according to the endurance test assessment requirements;
s6, carrying out a durability test; controlling the range extender through the INCA to perform a 600h endurance test of the range extender according to a cycle working condition table; in the endurance test process, an operator only needs to monitor the state of the rack to ensure that no problem exists in the operation process of the range extender;
s7, re-testing the performance and evaluating the test result; and after the endurance test is finished, performing performance retest again (performing performance test on the range extender assembly again), acquiring performance data of the range extender after endurance, comparing system MAP (MAP data) obtained by the performance test before and after endurance, and verifying the reliability of the range extender when the performance change range of the test data obtained before and after endurance is within 3%.
S8, carrying out retesting on the engine and motor system monomers, and evaluating the final test result;
s81, carrying out retesting on the single bodies of the engine and the motor system, and comparing test results before and after endurance, wherein performance attenuation is within +/-3%, and determining that the performance of the single bodies of the engine and the motor is not problematic;
s82, combining the test data to obtain the range extender with good reliability.
And S9, ending.
It is to be understood that the present invention has been described with reference to certain embodiments and that various changes in form and details may be made therein by those skilled in the art without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (7)
1. A range extender rack joint debugging test method based on INCA control range extender operation is characterized in that: the method comprises the following steps:
s1, performing a monomer performance test on an engine and a motor system;
s2, building a rack, and setting rack parameters to meet test boundary conditions according to test requirements;
s3, basic debugging;
s4, performance test;
s5, reliability test;
s6, carrying out a durability test;
s7, re-testing the performance and evaluating the test result;
s8, re-testing the single bodies of the engine and the motor system, and evaluating the final test result;
and S9, ending.
2. The range extender rack joint debugging test method based on INCA control range extender operation of claim 1, characterized in that: the S3 includes the steps of:
s31, debugging INCA to realize successful communication between the INCA and a domain controller and between the INCA and an ECU (electronic control unit) and between the domain controller and the ECU and between the INCA and a GCU;
s32, the range extender can be started successfully, can run well and generate power normally.
3. The range extender rack joint debugging test method based on INCA control range extender operation of claim 1, characterized in that: the S4 includes the steps of:
s41, determining the range of the sweep point working condition of the range extender and the interval of each working condition according to the test requirement by the INCA operation and the combination of the universal data of an engine and a motor system;
s42, adjusting the operation condition of the range extender through INCA operation, acquiring data of output power and fuel consumption of the range extender under each condition through a power analyzer and a rack fuel consumption monitoring device, and calculating specific fuel consumption data under the condition point through a formula (1);
the specific oil consumption (g/kWh) of the range extender is 1000 per power generation (kW) (1).
4. The range extender rack joint debugging test method based on INCA control range extender operation of claim 1, characterized in that: the S5 includes the steps of:
s51, before the endurance test is started, performing a range extender performance test to obtain a system MAP of the range extender;
s52, determining the endurance cycle working condition of the endurance test of the range extender according to the endurance test assessment requirement.
5. The range extender rack joint debugging test method based on INCA control range extender operation according to claim 1, characterized in that: in the step S6, the endurance cycle working condition can be directly led in by controlling the range extender to operate, the 600h endurance test of the range extender is carried out, and the range extender can operate the endurance cycle working condition by controlling the INCA after the heat engine is finished.
6. The range extender rack joint debugging test method based on INCA control range extender operation of claim 1, characterized in that: in S7, after the endurance test is completed, the performance retest is performed again, and the system MAPs obtained in the performance tests before and after endurance are compared to verify the reliability of the range extender.
7. The range extender rack joint debugging test method based on INCA control range extender operation of claim 1, characterized in that: the S8 includes the steps of:
s81, carrying out retesting on the single bodies of the engine and the motor system, and comparing test results before and after endurance, wherein performance attenuation is within +/-3%, and determining that the performance of the single bodies of the engine and the motor is not problematic;
and S82, evaluating the reliability of the range extender by combining test data.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116027699A (en) * | 2022-10-26 | 2023-04-28 | 浙江和夏科技股份有限公司 | Automatic calibration optimization method for electric drive MCU (micro control Unit) based on iTest software platform |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116027699A (en) * | 2022-10-26 | 2023-04-28 | 浙江和夏科技股份有限公司 | Automatic calibration optimization method for electric drive MCU (micro control Unit) based on iTest software platform |
| CN116027699B (en) * | 2022-10-26 | 2023-09-29 | 浙江和夏科技股份有限公司 | Automatic calibration optimization method for electric drive MCU (micro control Unit) based on iTest software platform |
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