CN212083989U - Power assembly controller reliability test system for new energy automobile - Google Patents
Power assembly controller reliability test system for new energy automobile Download PDFInfo
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- CN212083989U CN212083989U CN202021050317.3U CN202021050317U CN212083989U CN 212083989 U CN212083989 U CN 212083989U CN 202021050317 U CN202021050317 U CN 202021050317U CN 212083989 U CN212083989 U CN 212083989U
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Abstract
The utility model discloses a power assembly controller reliability test system for a new energy automobile, which comprises a power assembly, an environment box unit and a vibration table unit; the environment box unit comprises an environment box and an external cooling water unit, and the environment box is used for simulating temperature and humidity changes of the tested object in an actual application environment; the vibration table unit is used for providing mechanical load for the tested object so as to simulate vibration in an actual application environment; the external cooling water unit is used for providing external cooling circulating water for the environment box and the vibration table unit, and the environment box is installed on the vibration table unit through a flexible connection structure. The utility model discloses a power assembly controller reliability test system for new energy automobile has advantages such as simple structure is compact, test function is abundant, fail safe nature height.
Description
Technical Field
The utility model mainly relates to a new energy automobile technical field refers in particular to a power assembly controller reliability test system for new energy automobile.
Background
The new energy automobile is generally accepted as being capable of reducing air pollution and relieving energy shortage, and the new energy automobile industry is bound to become a guide and target for the development of the future automobile industry on the premise of promoting global environmental protection at present. As is well known, the core components of a new energy electric vehicle are "three-electricity", namely, a motor, an electric control and a battery. The "three-power" reliability issue has been a focus of concern in the automotive industry. With the increasing development and popularization of new energy electric vehicles, reliability tests of whole new energy electric vehicles and parts are concerned more and more, and great manpower, material resources and financial resources are invested by various new energy vehicle enterprises and various large part suppliers to construct whole new energy electric vehicle and three-electricity reliability test systems, such as an electric dynamometer test bed, a battery pack energy density test system, a whole vehicle controller HILL test bench, a whole vehicle NVH and the like.
However, the above test platform has a single function, and cannot comprehensively simulate very complicated influence factors on the vehicle under actual running conditions. For example, the invention patent CN201610496090 and the utility model patent CN201620668355 disclose a new energy power assembly testing system respectively, but only include three systems of motor, battery and electric control and their corresponding control systems, and only can simulate the influence of the electrical load on the reliability of the power assembly, and do not consider the auxiliary source module and lack two influence factors of environment and machinery for comprehensive reliability evaluation.
SUMMERY OF THE UTILITY MODEL
The to-be-solved technical problem of the utility model lies in: to the technical problem that prior art exists, the utility model provides a power assembly controller reliability test system for new energy automobile that function is abundant.
In order to solve the technical problem, the utility model provides a technical scheme does:
a reliability test system for a power assembly controller for a new energy automobile comprises a power assembly, an environment box unit and a vibration table unit; the environment box unit comprises an environment box and an external cooling water unit, and the environment box is used for simulating temperature and humidity changes of the tested object in an actual application environment; the vibration table unit is used for providing mechanical load for the tested object so as to simulate vibration in an actual application environment; the external cooling water unit is used for providing external cooling circulating water for the environment box and the vibration table unit, and the environment box is installed on the vibration table unit through a flexible connection structure.
As a further improvement of the above technical solution:
the power assembly comprises a power supply unit and a load unit, wherein the load unit comprises a direct current load and an alternating current load; the power supply unit comprises a direct current power supply and is used for providing direct current input for the tested object and absorbing energy of the tested object under braking and power generation working conditions; the direct current load is connected with the output end of the tested product and used for absorbing the electric energy output by the tested product and feeding the electric energy back to the power grid; the alternating current load is connected with the output end of the tested product and used for simulating the oil pump and the air pump, absorbing the electric energy output by the tested product and feeding the electric energy back to the power grid.
The power assembly further comprises a water cooling system, wherein the water cooling system is used for providing cooling liquid with constant temperature, pressure and flow for the tested product so as to ensure the thermal stability of the tested product in operation under different working conditions.
The power assembly comprises a plurality of groups of counter-traction motors and is used for realizing power output and load when the vehicle actually runs.
The number of the counter-dragging motors is two, and the counter-dragging motors are arranged on the cast iron platform.
The power assembly further comprises a power analyzer for measuring input and output voltages and currents of the tested object.
The vibration table unit includes a vibration table.
The environment box unit further comprises a portal frame and a track, the environment box is mounted on the portal frame, and the portal frame is slidably mounted on the track.
The flexible connection structure comprises a flexible layer located between the environment box and the vibration table unit, and a heating resistance wire is arranged inside the flexible layer.
The vehicle-mounted terminal is connected with the power assembly, the environment box unit and the vibrating table unit through the measurement and control unit.
Compared with the prior art, the utility model has the advantages of:
the utility model changes the original single independent load application into the integration of three loads of environment, electricity and machinery into a test system, and covers the loads of an oil pump, an air pump and a DC/DC module of a power assembly controller; the overall structure is compact and reasonable, safety and high efficiency are realized, the complex external factors borne by the vehicle in the actual running process are restored to the greatest extent, and the reliability test of the controller is greatly optimized; the environment and the mechanical load are skillfully applied at the same time through the flexible connection structure, and the stability and the accuracy of the test system are not influenced; the other three loads can be loaded independently, and can be combined randomly or loaded simultaneously; the whole set of test system carries the vehicle-mounted terminal, has the cloud processing function, can remotely monitor the test system and send instructions, and realizes the unattended function. Meanwhile, the reliability test period is considered, the bus working condition and the function of feeding back the load equipment to the power grid are simulated in a mode of dragging two motors, and the energy consumption of the test system is effectively reduced.
Drawings
Fig. 1 is a block diagram of an embodiment of the present invention.
Fig. 2 is a pipeline connection diagram of the controller according to the present invention.
Fig. 3 is a front view structural diagram of the environment box unit and the vibration table unit according to the embodiment of the present invention.
Fig. 4 is a side view structural diagram of the environment box unit and the vibration table unit according to the embodiment of the present invention.
Fig. 5 is a block structure diagram of the measurement and control unit of the present invention in the embodiment.
The reference numbers in the figures denote: 1. a power assembly; 101. a power supply unit; 102. a direct current load; 103. an alternating current load; 104. a water cooling system; 105. a pair-dragging motor; 106. a cast iron platform; 107. a test article; 108. a power analyzer; 2. an environmental chamber unit; 201. an environmental chamber; 202. a gantry; 203. a track; 204. an external cooling water unit; 3. a vibration table unit; 301. a vibration table; 4. a measurement and control unit; 5. a vehicle-mounted terminal; 6. a flexible connection structure.
Detailed Description
The invention is further described with reference to the drawings and the specific embodiments.
As shown in fig. 1, the system for testing reliability of the powertrain controller for the new energy automobile in the embodiment includes a powertrain 1, an environmental box unit 2, a vibration table unit 3, and a measurement and control unit 4; the environment box unit 2 comprises an environment box 201 and an external cooling water unit 204, wherein the environment box 201 is used for simulating temperature and humidity changes of the tested object 107 under the actual application environment; the vibration table unit 3 is used for providing mechanical load for the tested object 107 so as to simulate a vibration road spectrum under an actual application environment; the external cooling water unit 204 is used for providing external cooling circulating water for the environment box 201 and the vibration table unit 3, and the environment box 201 is installed on the vibration table unit 3 through the flexible connecting structure 6.
As shown in fig. 1, in the present embodiment, the power assembly 1 unit includes a power supply unit 101, two dc loads 102, four ac loads 103, a water cooling system 104, two sets of counter-traction motors 105, a cast iron platform 106, a power analyzer 108, and a control power supply. The power supply unit 101 is also called a direct current power supply, the output voltage is DC 200-800V, the function is to provide direct current input for the tested object 107 (power assembly controller), the function of energy feedback to the power grid is provided, and the energy of the tested object 107 under the braking and power generation working conditions can be absorbed. The direct current load 102 is connected with the output end of the power assembly controller, and the input voltage is 0-60 VDC; the function of the system is to absorb the electric energy output by a DC/DC module of a power assembly controller and feed the electric energy back to a power grid. The alternating current load 103 is connected with the output end of the power assembly controller, the input voltage is 0-380 VAC, the function of the alternating current load simulates an oil pump and an air pump, and the alternating current load absorbs electric energy output by the DC/AC module of the power assembly controller and feeds the electric energy back to a power grid. The water cooling system 104 mainly functions to provide a cooling liquid with constant temperature, pressure and flow for the power assembly controller so as to ensure the thermal stability of the power assembly controller in operation under different working conditions, and the main parameters are as follows: flow regulating range: 0-50L/min, continuously adjustable; temperature control range: -40-85 ℃ (constant temperature adjustable), temperature control precision: 1 ℃ C. The two sets of counter-traction motors 105 mainly function to realize the driving and loading of the system and simulate the power output and load of the vehicle in actual running. The counter-dragging motor 105 is arranged on a cast iron platform 106, the cast iron platform 106 fixes the counter-dragging motor 105, bears the dead weight of the motor and transmits the dynamic load of the counter-dragging motor 105 to the ground during operation; the reliability test period is considered to be long, the bus working condition and the function of feeding back the load equipment to the power grid are simulated in a mode of dragging two motors, and the energy consumption of the test system is effectively reduced.
The powertrain controller, which is usually used as the tested object 107 of the test system, is the core of the coordinated control of the entire powertrain 1, and is the main location for power distribution and regulation, and the corresponding pipeline connection mode is shown in fig. 2. The power analyzer 108 is used for measuring input/output voltage, current, torque and rotating speed of the power generation and driving motor of the control assembly. The control power supply is a 0-40V programmable power supply, and can simulate the low-voltage electrical environment of the actual application environment of the whole vehicle.
In this embodiment, the temperature and humidity parameters of the environmental chamber 201 may be either single constant, such as constant temperature and constant humidity, or continuously changing in a temperature and humidity manner, such as alternating damp heat and humidity, temperature and humidity combined cycle, and the temperature range is as follows: -50 ℃ to +130 ℃, humidity range: 10% -98% RH, temperature rise and fall rate: 10 ℃/min. As shown in fig. 3 and 4, specifically, the environment box 201 is mounted on the gantry 202, the gantry 202 is slidably mounted on the rail 203, the environment box can move up and down and left and right through the gantry 202, and is flexibly connected with the vibration table unit 3 through the flexible connecting structure 6, so as to ensure the temperature/humidity control precision in the environment box 201, wherein the flexible connecting structure 6 is a rubber layer with heating resistance wires.
In this embodiment, the vibration table unit 3 is a vertical electric vibration table 301 with a thrust of 10T, and provides a mechanical load for the tested object 107, so as to simulate a vibration road spectrum in an actual application environment and check the vibration resistance of the controller. The measurement and control unit 4 comprises an upper computer and a PXI system, has fault protection and diagnosis functions, can perform interlock protection with the tested object 107, each device is in real-time communication with the measurement and control unit 4, meanwhile, the system is additionally provided with a limit switch, a camera, a smoke sensor and an automatic fire extinguisher, can automatically adopt a proper mode to protect the safety of personnel, the device and the tested control assembly when the device fails, and can automatically record, diagnose and position fault data, as shown in figure 5.
In this embodiment, the vehicle-mounted terminal 5 adopts a 4g communication mode to realize real-time communication and data acquisition between the cloud platform and the measurement and control unit 4, the acquisition cycle is 100ms, the acquired real-time data is stored in the internal storage medium, the medium capacity meets certain real-time data storage, when the internal storage medium is full of storage, the stored data before the automatic cycle coverage is realized, and the functions of self-checking, remote query, remote parameter setting (parameters such as voltage, current and water temperature) and the like are realized.
The utility model changes the original single independent load application into the integration of three loads of environment, electricity and machinery into a test system, and covers the loads of an oil pump, an air pump and a DC/DC module of a power assembly controller; the overall structure is compact and reasonable, safety and high efficiency are realized, the complex external factors borne by the vehicle in the actual operation process are reduced to the greatest extent, and the reliability test of the controller is greatly optimized. Wherein environment and mechanical load realize two kinds of loads simultaneously through flexible connection structure 6 ingeniously and exert, and do not influence test system's stability and accuracy nature, and the whole set of test system carries on vehicle terminal 5, has cloud processing function, can long-rangely monitor and instruction send test system, realizes unmanned on duty's function.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention. The technical solution of the present invention can be used by anyone skilled in the art to make many possible variations and modifications, or to modify equivalent embodiments, without departing from the scope of the technical solution of the present invention, using the technical content disclosed above. Therefore, any simple modification, equivalent change and modification made to the above embodiments by the technical entity of the present invention should fall within the protection scope of the technical solution of the present invention.
Claims (10)
1. A reliability test system for a power assembly controller for a new energy automobile is characterized by comprising a power assembly (1), an environment box unit (2) and a vibration table unit (3); the environment box unit (2) comprises an environment box (201) and an external cooling water unit (204), wherein the environment box (201) is used for simulating temperature and humidity changes of a tested article (107) in an actual application environment; the vibration table unit (3) is used for providing mechanical load for the tested object (107) so as to simulate vibration in an actual application environment; the external cooling water unit (204) is used for providing external cooling circulating water for the environment box (201) and the vibration table unit (3), and the environment box (201) is installed on the vibration table unit (3) through a flexible connection structure (6).
2. The powertrain controller reliability test system for the new energy automobile according to claim 1, characterized in that the powertrain (1) includes a power supply unit (101) and a load unit, the load unit including a direct current load (102) and an alternating current load (103); the power supply unit (101) comprises a direct current power supply and is used for providing direct current input for the tested object (107) and absorbing energy of the tested object (107) under braking and power generation working conditions; the direct current load (102) is connected with the output end of the tested article (107) and is used for absorbing the electric energy output by the tested article (107) and feeding the electric energy back to the power grid; the alternating current load (103) is connected with the output end of the tested article (107) and is used for simulating an oil pump and an air pump, absorbing electric energy output by the tested article (107) and feeding back the electric energy to a power grid.
3. The reliability testing system for the powertrain controller for the new energy automobile is characterized in that the powertrain (1) further comprises a water cooling system (104) which is used for providing a cooling liquid with constant temperature, pressure and flow for the tested object (107) so as to ensure the thermal stability of the tested object (107) in operation under different working conditions.
4. The reliability test system for the powertrain controller for the new energy automobile is characterized in that the powertrain (1) comprises a plurality of groups of counter-traction motors (105) for simulating the power output and load of the vehicle in actual operation.
5. The reliability test system for the powertrain controller for the new energy automobile is characterized in that the number of the pair of traction motors (105) is two, and the two groups of traction motors are mounted on a cast iron platform (106).
6. The reliability testing system of the powertrain controller for the new energy automobile according to any one of claims 1 to 5, characterized in that the powertrain (1) further comprises a power analyzer (108) for measuring input and output voltages and currents of a tested object (107).
7. The reliability testing system for the powertrain controller for the new energy automobile according to any one of claims 1 to 5, characterized in that the vibration table unit (3) includes a vibration table (301).
8. The reliability testing system for the powertrain controller for the new energy automobile is characterized in that the environmental box unit (2) further comprises a portal frame (202) and a rail (203), wherein the environmental box (201) is mounted on the portal frame (202), and the portal frame (202) is slidably mounted on the rail (203).
9. The reliability testing system for the powertrain controller for the new energy automobile is characterized in that the flexible connecting structure (6) comprises a flexible layer located between the environment box (201) and the vibration table unit (3), and a heating resistance wire is arranged inside the flexible layer.
10. The reliability testing system of the powertrain controller for the new energy automobile is characterized by further comprising a vehicle-mounted terminal (5), wherein the vehicle-mounted terminal (5) is connected with the powertrain (1), the environmental box unit (2) and the vibrating table unit (3) through a measurement and control unit (4).
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| CN202021050317.3U CN212083989U (en) | 2020-06-09 | 2020-06-09 | Power assembly controller reliability test system for new energy automobile |
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| CN202021050317.3U CN212083989U (en) | 2020-06-09 | 2020-06-09 | Power assembly controller reliability test system for new energy automobile |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113970916A (en) * | 2021-09-30 | 2022-01-25 | 武汉小安科技有限公司 | Test platform for electrified simulated motion environment of central control box |
| CN114323683A (en) * | 2021-12-16 | 2022-04-12 | 苏州长菱测试技术有限公司 | Fatigue endurance test system and test method |
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2020
- 2020-06-09 CN CN202021050317.3U patent/CN212083989U/en active Active
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113970916A (en) * | 2021-09-30 | 2022-01-25 | 武汉小安科技有限公司 | Test platform for electrified simulated motion environment of central control box |
| CN113970916B (en) * | 2021-09-30 | 2024-05-31 | 武汉小安科技有限公司 | Center-control cassette tape electric simulation motion environment test platform |
| CN114323683A (en) * | 2021-12-16 | 2022-04-12 | 苏州长菱测试技术有限公司 | Fatigue endurance test system and test method |
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