Pure electric bus electric appliance fault simulation test bench

Abstract

The invention relates to an electric appliance fault simulation test bench for a pure electric bus, and the test bench integrates all subsystems of the pure electric bus through a rack system. Comprising a test bed assembly, a power battery system, a high-voltage power supply system, a cockpit control system, a power driving system, a braking system, a steering system, a light signal system, an air conditioning system, a cooling system, a low-voltage power distribution system, a BMS battery management system, an OBD automobile fault diagnosis system, an LPDS fault injection module, a remote monitoring system and a whole automobile control system. All high and low voltage wire harnesses and communication wire harnesses are connected according to the use state of the whole vehicle, high voltage electricity is supplied to the rack system through external three-phase electricity transformation processing, 24V low voltage electricity is supplied through a storage battery, and the rack system completely simulates the low-speed state operation of the whole vehicle. According to the invention, rapid reproduction and solution simulation verification of various faults can be realized, dependence on manpower and material resources such as vehicles, sites and drivers is reduced, efficiency is improved, and cost is reduced.

Description

Technical Field

[0001] The present invention relates to an automobile fault simulation test bench, and in particular to a simulation test bench used for reproducing and simulating faults of pure electric buses caused by electrical component function and communication errors, omissions, etc., so as to guide vehicle repair and establish failure mode analysis. Background Art

[0002] At present, technical cases related to major vehicle manufacturers have been retrieved. The main ones with similar structures and principles include Case 1 "A vehicle electrical function test bench", patent number CN202220319401.3, and Case 2 "Automobile electrical simulation test bench", patent number CN104376773 A, etc.

[0003] Case One is a door test stand for a single functional module in the vehicle. The front and rear door wiring harnesses and front and rear door electrical components can simulate opening and closing. The purpose is to be compatible with all models of door module electrical function tests without being affected by the position and wiring harness direction, such as Figure 1 shown.

[0004] Case 2 is a test bench for the simulation of the electrical equipment of a passenger car, including a complete on-board electrical system such as the engine module, cabin module, instrument module, cockpit module and four-door module. However, only the circuit structure diagram and other bench ideas are shown, and the bench itself is not designed. Figure 2 shown.

[0005] The above patent solutions are all test benches for passenger car parts or vehicle electrical systems, which are quite different from pure electric buses in terms of structure, function, parts, etc. Moreover, the test benches cover fewer systems, and their integrity and functionality are relatively simple.

[0006] With the increasing electrification of pure electric buses, more and more parts have been electrified and CAN communication has been realized, and they support electronic control, which has caused the vehicles to show more functional failures related to the electrical system and communication error alarms during use. Some failures occur very rarely and are difficult to reproduce, and are subject to the limitations of vehicle, site, driver and other conditions. It not only consumes manpower and material resources to find and solve the problems through vehicle operation, but also prolongs the cycle of solving the problems.

[0007] Therefore, it is necessary to establish a pure electric bus high and low voltage electrical component fault simulation test bench, which is a complete test bench for all high and low voltage electrical components or systems designed for new energy pure electric buses. Through this test, the failure problems of various components of the whole vehicle can be quickly simulated and reproduced, providing a basis for rapid reproduction and troubleshooting for failure mode analysis in the design stage and after-sales maintenance. Summary of the invention

[0008] The present invention aims to provide a pure electric bus electrical fault simulation test bench, which can realize rapid reproduction of various faults and simulation verification of solutions, reduce dependence on human and material conditions such as vehicles, sites, drivers, etc., improve efficiency and reduce costs.

[0009] To achieve the above-mentioned purpose, the technical solution of the present invention is: a pure electric bus electrical fault simulation test bench, which integrates various subsystems of the pure electric bus through a test bench system, including a test bench assembly, a power battery system, a high-voltage power supply system, a cockpit control system, a power drive system, a braking system, a steering system, a lighting signal system, an air-conditioning system, a cooling system, a low-voltage power distribution system, a BMS battery management system, an OBD automobile fault diagnosis system, an LPDS fault injection module, a remote monitoring system, a vehicle control system, and a subsystem containing high- and low-voltage electrical devices, and connects all high- and low-voltage wiring harnesses and communication wiring harnesses according to the use status of the vehicle, and supplies high-voltage electricity to the test bench system through external three-phase power transformation, and supplies 24V low-voltage electricity through a battery, and the test bench system completely imitates the low-speed operation of the vehicle.

[0010] Furthermore, the VCU fault injection module, BMS battery management system, and LPDS fault injection module in the vehicle control system are connected to the CAN communication fault simulation module for fault injection and analysis.

[0011] Furthermore, the VCU fault injection module in the vehicle control system is used to simulate the fault input of the vehicle control circuit; the ACU fault injection module is used to diagnose the fault of the ACU controller.

[0012] Furthermore, the power battery system uses power batteries to provide electrical energy for high-voltage electrical devices; the drive motor in the power drive system is provided with electrical energy by the MCU motor controller and controls the operation of the drive motor, and realizes real operation on the test bench by reducing power and speed; the drive motor simulates wheel rotation by driving the wheel assembly, thereby representing the vehicle's operating status.

[0013] Furthermore, the brake pedal in the braking system is used to simulate the braking effect during driving; the hand brake switch is used to manually control the parking brake; the steering oil pump module in the steering system is used to simulate the operation of the steering oil pump; the air compressor module is used to simulate the working condition of the air compressor of the braking system.

[0014] Furthermore, the air conditioning / defroster motor module in the air conditioning system is used to simulate the failure of the air conditioning and defrosting systems; the air conditioning / defrosting control switch is used to control the operation of the air conditioning and defrosting systems; the expansion water tank in the cooling system is used to provide the cooling system with a coolant storage function;

[0015] Furthermore, the ACU high-voltage auxiliary controller in the high-voltage power supply system is used to receive electrical energy from the power battery and provide electrical energy for the steering oil pump and air compressor electrical equipment; the low-voltage battery in the low-voltage power distribution system is used to provide electrical energy for the low-voltage equipment of the entire vehicle and store electrical energy; the low-voltage distribution board is used for low-voltage power distribution and insurance; the low-voltage front module is used to supply low-voltage electricity to various devices at the front of the vehicle.

[0016] Furthermore, the front left and right combination lights in the lighting signal system are used to simulate and demonstrate the front lighting control of the entire vehicle; the light / door control combination switch is used to control the opening of the door and the lights; the light adjustment switch is used to turn on the lights and change the high beam and low beam.

[0017] Furthermore, the vehicle diagnostic instrument in the OBD automobile fault diagnosis system is used for vehicle fault diagnosis and display; the BMS simulation node in the BMS battery management system is used for battery management system fault simulation.

[0018] Furthermore, the low-voltage control panel in the vehicle control system is used to control the low-voltage components of the test bench; the computer host is used to display the test bench operation content and operation guidance demonstration; the gear control switch is used to simulate the function of changing gears during driving; the multi-function steering wheel buttons are used to simulate the functions of the buttons on the steering wheel; the accelerator pedal is used to simulate the acceleration action during driving; the handbrake switch is used to manually control the parking brake; the start key is used to lock the workbench and start the workbench; the remote monitoring module in the remote monitoring system is used to remotely collect vehicle operation data.

[0019] The beneficial effects of the present invention are:

[0020] The invention provides a pure electric bus electrical fault simulation test bench, which can integrate the electrical system of the whole bus on a test bench for display according to the layout characteristics of the electrical components of the whole bus, so that the fault and detection of the electrical components are more convenient and intuitive, and the work efficiency is improved.

[0021] The present invention can detect the function of electrical components before they are installed on a vehicle, avoiding the inconvenience of testing after the components are assembled on the vehicle, affecting production efficiency, delaying production progress, and increasing the workload of workers. This reduces the production cost of the vehicle, reduces the workload of workers, and better controls product quality.

[0022] The present invention can be applied to the quality and function detection of incoming parts, so as to prevent unqualified parts and faulty parts from entering the factory, and to prevent faulty parts from entering the production workshop, thereby affecting the loading progress and causing interference to production.

[0023] The present invention can be used for training new employees, so that new employees can quickly master the electrical principle of the whole vehicle and avoid the problem that the actual vehicle training is not intuitive and difficult to understand. The test bench is easy to move, transfer and transport.

[0024] The present invention can also be used for after-sales vehicle problem troubleshooting and fault simulation reproduction, so as to quickly troubleshoot and deal with market problems, reduce actual vehicle troubleshooting, affect customer vehicle use, and reduce customer complaints.

[0025] The test bench is preset with "fault setting" and "fault simulation" devices, which have high voltage, low voltage and communication interfaces respectively, to realize the working status of each module of the whole vehicle and the collection and analysis of each signal pin, to realize the analysis of the working status and fault status of each signal, to accurately and truly understand the working parameters of the module and the current phenomenon, so as to complete the analysis of occasional faults that occur during driving and the compilation of new energy maintenance manuals, and form a maintenance manual to provide a platform for the advancement of new energy maintenance technology. Through the diagnostic tooling (BOB short circuiter) on the test bench, all controllers on the whole vehicle as well as high and low voltage modules and line faults can be set. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of an existing vehicle electrical function test bench case 1;

[0027] Figure 2 This is a schematic diagram of the existing vehicle electrical simulation test bench case 2;

[0028] Figure 3 The invention discloses a general schematic diagram of a pure electric bus electrical fault simulation test bench. DETAILED DESCRIPTION

[0029] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0030] The present invention provides a pure electric bus electrical fault simulation test bench, which integrates various subsystems of the pure electric bus in a bench manner, including a test bench assembly, a power battery system, a high-voltage power supply system, a cockpit control system, a power drive system, a braking system, a steering system, a lighting signal system, an air conditioning system, a cooling system, a low-voltage power distribution system, a BMS battery management system, an OBD vehicle fault diagnosis system, an LPDS fault injection module, a remote monitoring system, a vehicle control system, and all subsystems containing high- and low-voltage electrical devices. All high- and low-voltage wiring harnesses and communication wiring harnesses are connected according to the use status of the whole vehicle, and the high-voltage electricity of the bench system is supplied through an external three-phase power transformation process, and 24V low-voltage electricity is supplied through a battery. The bench can completely imitate the low-speed operation of the whole vehicle. In addition, a special module for CAN communication fault simulation is added to the VCU fault injection module, the BMS battery management system, and the LPDS fault injection module, so that fault injection and analysis can be performed.

[0031] The layout and component composition of the test bench in the embodiment of the present invention are as follows: Figure 3As shown, it includes: a bench assembly 1, which is used to provide a fixed installation platform for the vehicle electrical components; a VCU fault injection module 2, which is used to simulate the fault input of the vehicle control circuit; a power battery 3, which is used to provide power for high-voltage electrical components; an air-conditioning / defroster motor module 4, which is used to simulate the fault of the air-conditioning and defrosting system; an ACU high-voltage auxiliary controller 5, which is used to receive power from the power battery and provide power for electrical equipment such as a steering oil pump and an air compressor; a high-voltage wiring harness assembly 6, which is used to provide circuit connection for each high-voltage electrical component; an MCU motor controller 7, which is used to provide power for the drive power and control the operation of the motor; a steering oil pump module 8, which is used to simulate the operation of the steering oil pump; a low The low-voltage DC distribution box 9 is used to provide electric energy for low-voltage electrical components; the wheel assembly 10 driven by the motor is used to simulate the rotation of the wheel and represent the running state of the vehicle; the left and right combined taillights 11, 12 are used to simulate the rear light control of the whole vehicle; the drive motor 13 realizes the real operation on the test bench by reducing the power and speed; the expansion water tank 14 is used to store coolant for the cooling system; the universal wheel 15 is used to facilitate the movement of the test bench; the low-voltage battery 16 is used to provide electric energy for the low-voltage equipment of the whole vehicle and store electric energy; the mechanical power switch 17 is used to manually cut off the low-voltage power supply; the air compressor module 18 is used to simulate the working condition of the air compressor of the brake system; The process monitoring module 19 is used to remotely collect vehicle operation data; the radiator module 20 is used to provide water cooling for the motor, motor controller, ACU, etc.; the low-voltage rear module 21 is used to supply low-voltage electricity to various components at the rear of the vehicle; the water pump 22 is used to provide power for the circulation of the coolant; the water pipe assembly 23 is used to provide a circulation channel for the coolant; the low-voltage distribution board 24 is used for low-voltage power distribution and insurance; the low-voltage front module 25 is used to supply low-voltage electricity to various components at the front of the vehicle; the low-voltage wiring harness assembly 26 is used to connect various low-voltage electrical components, and the low-voltage control board 27 is used to control various low-voltage components of the test bench; the BMS simulation node 28 is used for battery management system fault simulation; Instrument display 29, used to display vehicle speed, drive motor speed, lights and other information; LPDS fault injection module 30, used to input the fault mode of the low-voltage control board; front left and right combination lights 31, 32, used to simulate and display the front light control of the whole vehicle; emergency stop switch 33, used to stop the test bench in an emergency; OBD interface 34, used as the external interface of the vehicle CAN communication network; hand brake switch 35, used to manually control the parking brake; light / door control combination switch 36, used to control the door opening and control the lights; brake pedal 37, used to simulate the braking effect during driving; computer host 38, used to display the test bench operation content and operation guidance demonstration, etc.The accelerator pedal 39 is used to simulate the acceleration action during driving. The air conditioning / defrosting control switch 40 is used to control the working of the air conditioning and defrosting systems. The light adjustment switch 41 is used to turn on the lights, change the high beam and low beam, etc. The gear control switch 42 is used to simulate the function of changing the gear during driving. The multi-function steering wheel button 43 is used to simulate the function of the buttons on the steering wheel. The low-voltage power switch 44 is used to control the low-voltage power supply. The start key 45 is used to lock the workbench and start the workbench. The ACU fault injection 46 is used to diagnose the fault of the ACU controller. The vehicle diagnostic instrument 47 is used to diagnose and display the faults of the vehicle.

[0032] The positional relationship of each component in the test bench is as close to the actual installation as possible, and the electrical components and wiring harness assemblies used are consistent with those used on the actual bus, achieving the effect of simulating the actual state of the actual vehicle.

Claims

1. A pure electric bus electrical fault simulation test bench, characterized by: The test bench system is used to integrate various subsystems of the pure electric bus, including the test bench assembly, power battery system, high-voltage power supply system, cockpit control system, power drive system, braking system, steering system, lighting signal system, air-conditioning system, cooling system, low-voltage power distribution system, BMS battery management system, OBD vehicle fault diagnosis system, LPDS fault injection module, remote monitoring system, vehicle control system and subsystems containing high and low voltage electrical devices. All high and low voltage wiring harnesses and communication wiring harnesses are connected according to the usage status of the vehicle, and high voltage electricity is supplied to the test bench system through external three-phase power transformation, and 24V low voltage electricity is supplied through the battery. The test bench system completely imitates the low-speed operation of the vehicle.

2. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The VCU fault injection module, BMS battery management system, and LPDS fault injection module in the vehicle control system are connected to the CAN communication fault simulation module for fault injection and analysis.

3. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The VCU fault injection module in the vehicle control system is used to simulate the fault input of the vehicle control circuit; the ACU fault injection module is used to diagnose the fault of the ACU controller.

4. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The power battery system uses power batteries to provide power for high-voltage electrical devices. The drive motor in the power drive system is powered by the MCU motor controller and controls the operation of the drive motor. The real operation on the test bench is achieved by reducing the power and speed. The drive motor simulates wheel rotation by driving the wheel assembly to represent the vehicle's operating status.

5. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The brake pedal in the braking system is used to simulate the braking effect during driving; the handbrake switch is used to manually control the parking brake; the steering oil pump module in the steering system is used to simulate the operation of the steering oil pump; the air compressor module is used to simulate the working condition of the air compressor of the braking system.

6. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The air conditioning / defrost motor module in the air conditioning system is used to simulate the failure of the air conditioning and defrost systems; the air conditioning / defrost control switch is used to control the operation of the air conditioning and defrost systems; the expansion water tank in the cooling system is used to provide the cooling system with the function of storing coolant.

7. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The ACU high-voltage auxiliary controller in the high-voltage power supply system is used to receive power from the power battery and provide power to the steering oil pump and air compressor electrical equipment; the low-voltage battery in the low-voltage power distribution system is used to provide power to the low-voltage equipment of the vehicle and store power; Low voltage switchboard, used for low voltage power distribution and insurance; The low-voltage front module is used to supply low-voltage electricity to various devices at the front of the vehicle.

8. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The front left and right combination lights in the light signal system are used to simulate and demonstrate the front light control of the entire vehicle; the light / door control combination switch is used to control the door opening and the lights; the light adjustment switch is used to turn on the lights and change the high beam and low beam.

9. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The vehicle diagnostic instrument in the OBD automobile fault diagnosis system is used for vehicle fault diagnosis and display; the BMS simulation node in the BMS battery management system is used for battery management system fault simulation.

10. The pure electric bus electrical fault simulation test bench according to claim 1 is characterized by: The low-voltage control panel in the vehicle control system is used to control the low-voltage components of the test bench; the computer host is used to display the test bench operation content and operation guidance demonstration, etc.; the gear control switch is used to simulate the function of changing gears during driving; The multi-function steering wheel buttons are used to simulate the functions of the buttons on the steering wheel; the accelerator pedal is used to simulate the acceleration action during driving; the handbrake switch is used to manually control the parking brake; the start key is used to lock and start the workbench; the remote monitoring module in the remote monitoring system is used to remotely collect vehicle operation data.

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