Power level hardware-in-the-loop HIL test system and test device of execution motor controller

Abstract

The embodiment of the invention provides a power-level hardware-in-the-loop HIL test system and device for an execution motor controller, and the system and device achieve the working condition test of the execution motor controller through integrating an upper computer, a control module and an electronic load module. In the testing process, the upper computer sends a preset first testing working condition instruction to the motor controller to be tested, and the motor controller generates a voltage signal according to the first testing working condition instruction. The electronic load module collects the voltage signals, simulates corresponding motor current behaviors, and feeds back the simulated current signals to the control module. And the control module sends the operation parameters containing the analog current signals to the upper computer. And finally, the upper computer generates a power level HIL test result of the motor controller under a specific test working condition according to the operation parameters. The power-level hardware-in-loop HIL test system provided by the embodiment of the invention is adapted to power-level hardware-in-loop HIL tests of various execution motor controllers.

Description

Technical Field

[0001] The present application relates to the technical field of motor controllers, and in particular to a power-level hardware-in-the-loop (HIL) test system and a test device for executing a motor controller. Background Art

[0002] In the V-shaped development process, hardware-in-the-Loop simulation test (HIL) is a very important testing method. The HIL system uses a real-time processor to run a simulation model to simulate the operating state of the controlled object, connects to the motor controller through the I / O interface, and conducts comprehensive and systematic testing of the motor controller, reducing the number and time of actual vehicle road tests, verifying the software and hardware quality of the motor controller, and improving the performance and reliability of the vehicle. The motor controller HIL system is mainly divided into three categories: mechanical level HIL system, signal level HIL system, and power level HIL system.

[0003] In the power-level HIL system, the motor simulator is connected to the physical motor controller. Different load conditions of the motor simulator can test the performance of the motor controller under different working conditions.

[0004] Among them, the actuator motor drive system structure is widely used in wire control systems such as wire control steering and wire control braking. The actuator motor controller is the core component of the wire control system. In the early stage of project development, how to quickly verify and repeatedly test the control logic and functions of the actuator motor controller in the laboratory and test dangerous working conditions is of great significance to the rapid iterative optimization of the actuator motor controller.

[0005] However, in the related art, the power level HIL system for the motor controller cannot meet the testing requirements of some motor controllers. Therefore, there is an urgent need for a power level HIL system for the motor controller with higher scalability and comprehensive detection range. Summary of the invention

[0006] The purpose of the embodiments of the present application is to provide a power-level hardware-in-the-loop (HIL) test system and a test device for executing a motor controller, so as to achieve the technical effect of adapting to various power-level hardware-in-the-loop (HIL) tests for executing motor controllers.

[0007] A first aspect of an embodiment of the present application provides a power-level hardware-in-the-loop HIL test system for executing a motor controller, wherein the test system is connected to a motor controller to be tested, and the test system includes a host computer, a control module, and an electronic load module;

[0008] The host computer is used to send a first working condition test instruction to the motor controller to be tested according to a preset first test working condition;

[0009] The motor controller to be tested is used to generate a voltage signal according to the first working condition test instruction;

[0010] The electronic load module is used to simulate the motor current behavior according to the voltage signal collected from the motor controller to be tested, and send the generated simulated current signal to the control module;

[0011] The control module is used to generate operating parameters and send them to the host computer; the operating parameters include the analog current signal;

[0012] The host computer is further used to generate a power level HIL test result of the motor controller to be tested under the first test condition according to the operating parameters.

[0013] In the above implementation process, the power-level hardware-in-the-loop (HIL) test system of the motor controller implements the working condition test of the motor controller by integrating the host computer, the control module and the electronic load module. During the test, the host computer sends a preset first test condition instruction to the motor controller to be tested, and the motor controller generates a voltage signal accordingly. The electronic load module collects these voltage signals and simulates the corresponding motor current behavior, and feeds back the simulated current signal to the control module. The control module sends the operating parameters back to the host computer. Finally, the host computer generates the power-level HIL test results of the motor controller under specific test conditions based on the operating parameters.

[0014] Further, the motor controller to be tested includes a power board;

[0015] The motor controller to be tested is specifically used to control the power board to turn on the power switch to generate the voltage signal according to the first working condition test instruction.

[0016] In the above implementation process, precise control of the opening and closing of the power switch can ensure that the generated voltage signal highly meets the test requirements in terms of parameters such as amplitude and waveform, thereby improving the accuracy of the test.

[0017] Furthermore, the host computer is further used to send the first operating condition test instruction to the control module;

[0018] The control module is further used to determine a simulated position signal according to the first operating condition test instruction;

[0019] The electronic load module is specifically used to send the collected voltage signal to the control module;

[0020] The control module is further used to determine a simulated current parameter according to the simulated position signal and the voltage signal, and send the simulated current parameter to the electronic load module;

[0021] The electronic load module is specifically used to simulate the motor current behavior according to the simulated current parameters.

[0022] In the above implementation process, the control module first determines the simulated position signal based on the working condition test instruction, and then determines the simulated current parameters according to the simulated position signal and the voltage signal and sends them to the electronic load module to simulate the motor current behavior, so as to improve the accuracy of the simulated current.

[0023] Further, the test system is connected to the first power module; the test system also includes a second power module, a third power module, and a fourth power module;

[0024] The first power module is used to transmit AC power to the second power module;

[0025] The second power module is used to transmit AC power to the third power module, the fourth power module, and the control module;

[0026] The third power supply module is used to rectify the AC power delivered by the second power supply module into DC power and then supply power to the electronic load module;

[0027] The fourth power supply module is used to rectify the alternating current delivered by the second power supply module into direct current and then supply power to the motor controller to be tested.

[0028] In the above implementation process, the test system has an external power supply power supply first power module, and internal second, third, and fourth power modules. These power modules constitute the power supply network of the system, wherein the first power module provides AC power to the second power module, and the second power module acts as a transfer station to further distribute the AC power to the third and fourth power modules and the control module. The third power module rectifies the AC power into DC power, which is used to power the electronic load module; and the fourth power module also rectifies the AC power into DC power, but is used to power the motor controller to be tested.

[0029] Further, the electronic load module includes a resistive-inductive load network for storing electrical energy;

[0030] The host computer is also used to send an electric energy recovery instruction to the motor controller to be tested;

[0031] The motor controller to be tested is further used to generate a recovery signal according to the electric energy recovery instruction;

[0032] The electronic load module is further used to recover the electric energy stored in the resistive-inductive load network to the second power module through the third power module according to the recovery signal collected from the motor controller to be tested.

[0033] In the above implementation process, through the power recovery function, the system can effectively recover and reuse the power stored in the resistive-inductive load network, thus avoiding the waste of this part of energy.

[0034] Further, the test system also includes a fault injection component;

[0035] The host computer is also used to send a fault test instruction to the fault injection component through the control module according to a preset fault condition;

[0036] The fault injection component is used to perform fault simulation on the motor controller to be tested under the fault condition according to the fault test instruction;

[0037] The motor controller to be tested is also used to perform fault diagnosis and send diagnostic information to the host computer;

[0038] The host computer is also used to generate a fault test report of the motor controller to be tested according to the diagnostic information.

[0039] In the above implementation process, a fault simulation test of the motor controller to be tested is implemented through the fault injection component to verify the fault diagnosis capability of the motor controller to be tested.

[0040] Further, the motor controller to be tested is a fully redundant motor controller; the electronic load module includes a first electronic load submodule and a second electronic load submodule;

[0041] The fully redundant motor controller is used to generate a first voltage signal and a second voltage signal according to the first working condition test instruction;

[0042] The first electronic load submodule is used to simulate the motor current behavior according to the first voltage signal collected from the fully redundant motor controller, and send the generated first simulated current signal to the control module;

[0043] The second electronic load submodule is used to simulate the motor current behavior according to the second voltage signal collected from the fully redundant motor controller, and send the generated second simulated current signal to the control module;

[0044] The control module is specifically used to generate a first operating parameter and a second operating parameter and send them to the host computer; the first operating parameter includes the first analog current signal; the second operating parameter includes the second analog current signal;

[0045] The host computer is further used to generate a power level HIL test result of the fully redundant motor controller under the first test condition according to the first operating parameter and the second operating parameter.

[0046] In the above implementation process, two independent electronic load submodules are used to simulate the current behavior of the fully redundant motor, which can more accurately simulate the current changes of the fully redundant motor in actual operation. This dual-channel simulation not only improves the accuracy of the test, but also increases the flexibility of the test, and the performance of each redundant channel can be tested separately.

[0047] Further, the motor controller to be tested includes an external power board;

[0048] The control module is communicatively connected with the power board;

[0049] The host computer is further used to send a second working condition test instruction to the control module according to a preset second test working condition;

[0050] The control module is further configured to send a modulation signal to the power board according to the second operating condition test instruction;

[0051] The power board is used to generate a third voltage signal according to the modulation signal;

[0052] The electronic load module is further used to simulate the motor current behavior according to the third voltage signal collected from the power board, and send the third voltage signal and the modulated current signal generated by simulating the motor current behavior to the host computer through the control module;

[0053] The host computer is further used to generate a test result of the power board under the second test condition according to the third voltage signal and the modulated current signal.

[0054] In the above implementation process, a separate test of the power board is achieved.

[0055] Furthermore, the host computer is equipped with an automated testing platform and engineering software;

[0056] The automated testing platform is used to obtain test data input by the user;

[0057] The engineering software is used to generate test instructions based on the test data.

[0058] In the above implementation process, the host computer equipped with an automated testing platform and engineering software can significantly improve test efficiency, reduce test costs, improve test accuracy, and facilitate test management and maintenance.

[0059] A second aspect of an embodiment of the present application provides a testing device, which includes a testing system as described in any one of the first aspects. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments of the present application will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0061] Figure 1 A schematic diagram of a power-level hardware-in-the-loop (HIL) test system for executing a motor controller provided in an embodiment of the present application;

[0062] Figure 2 A schematic diagram of a power supply structure of a test system provided in an embodiment of the present application;

[0063] Figure 3 A schematic diagram of electric energy recovery provided in an embodiment of the present application;

[0064] Figure 4 A schematic diagram of the structure of a test system for a fully redundant motor controller provided in an embodiment of the present application;

[0065] Figure 5 A schematic diagram of the structure of a separate test control board provided in an embodiment of the present application. DETAILED DESCRIPTION

[0066] The technical solutions in the embodiments of the present application will be described below in conjunction with the drawings in the embodiments of the present application.

[0067] It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. At the same time, in the description of this application, the terms "first", "second", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0068] At present, most of the HIL systems for motor controller power level are used for single three-phase motor controllers, and few can directly recover energy from motor simulators. For single three-phase motor controller power level HIL systems, it is generally composed of AC / DC module, DC / DC module, motor simulator, motor controller under test and host computer. After the AC power is connected to the system, it is rectified by the AC / DC module and converted into a stable primary DC power supply to power the DC / DC module and motor simulator. The secondary DC power supply converted by the DC / DC module powers the motor controller under test. The host computer gives torque instructions to the motor controller under test according to the working conditions. The motor controller under test drives the motor simulator. The motor simulator simulates the stator current when the motor is working like the physical motor, and simulates the rotary transformer and temperature signals, which are fed back to the host computer. The host computer calculates the motor load at the next moment. This system cannot be used for fully redundant motor controllers, cannot realize the recovery of virtual motor power loss, and can only simulate rotary transformer position signals. It is not suitable for other types of execution motor controllers with position signal interfaces. It can only test the entire controller, and lacks the test process of controller disassembly.

[0069] In response to any of the above-mentioned problems, the present application provides a power level hardware-in-the-loop HIL test system for executing a motor controller, referring to Figure 1 , Figure 1 A schematic diagram of a power-level hardware-in-the-loop (HIL) test system for executing a motor controller provided in an embodiment of the present application.

[0070] In this embodiment, the test system 10 is connected to the motor controller 20 to be tested, and the test system 10 includes a host computer 30, a control module 40, and an electronic load module 50;

[0071] The host computer 30 is used to send a first working condition test instruction to the motor controller 20 to be tested according to a preset first test working condition;

[0072] The motor controller 20 to be tested is used to generate a voltage signal according to the first working condition test instruction;

[0073] The electronic load module 50 is used to simulate the motor current behavior according to the voltage signal collected from the motor controller 20 to be tested, and send the generated simulated current signal to the control module 40;

[0074] The control module 40 is used to generate operating parameters and send them to the host computer 30; the operating parameters include the analog current signal;

[0075] The host computer 30 is further used to generate a power level HIL test result of the motor controller 20 to be tested under the first test condition according to the operating parameters.

[0076] It should be understood that power-level hardware-in-the-loop (HIL) testing is a type of testing technology that is mainly used to fully verify the performance of complex devices such as motor controllers under high-power conditions. Specifically, power-level HIL testing involves connecting a real controller to a simulated controlled object (in this embodiment, mainly an electronic load module, which is used to simulate the current and other behaviors of a real motor) to simulate the operating environment of the system, thereby achieving in-depth testing of the controller.

[0077] In view of the high voltage and high current characteristics of the motor controller, HIL testing can simulate the current and position behavior of the motor under different working conditions, thereby verifying the control algorithm and performance of the controller.

[0078] It should be noted that the power-level hardware-in-the-loop (HIL) test system includes hardware equipment and software modules, and the test system is used to evaluate the performance of the motor controller under test. Specifically, the test system tests the response and control capabilities of the motor controller under test by simulating a real or preset motor working environment.

[0079] The motor controller 20 to be tested may be an executive motor controller, which is dedicated to controlling and driving the operation of the motor. This embodiment is described by taking the motor controller 20 to be tested as an executive motor controller.

[0080] The motor controller 20 to be tested is the object to be tested, which is a hardware device and generally includes a motor control algorithm and necessary hardware interfaces for receiving test instructions and generating corresponding motor control signals.

[0081] The host computer 30 is a hardware device on which a program or software for testing is running. The host computer 30 is mainly used to manage and control the test process. Specifically, the host computer 30 is used to send a first working condition test instruction to the motor controller to be tested according to a preset first test working condition, receive operating parameters from the control module, and generate a power level HIL test result of the motor controller to be tested under the first test working condition according to the received operating parameters.

[0082] The control module 40 is a software module used to generate operating parameters and send them to the host computer. The control module 40 is mainly responsible for processing signals and generating necessary control signals or data.

[0083] The electronic load module 50 is a hardware device that tests the performance of the motor controller by simulating the current behavior of an actual motor.

[0084] It is understandable that the first test condition:

[0085] Definition: A preset set of specific conditions or parameters used to simulate a working scenario that a motor controller may encounter in actual applications. These conditions may include the motor's speed range, load size, temperature conditions, etc. Exemplarily, a test condition table is pre-stored in the host computer, which contains multiple sets of specific conditions, covering all working scenarios that the motor controller may encounter in actual applications, and tests are performed in sequence based on the conditions included in the table. Specifically, after completing a set of condition tests, the host computer gives the motor torque command for the next moment according to the test condition table, and completes all condition tests in sequence.

[0086] Function: The purpose of the first test condition is to evaluate the performance, stability and reliability of the motor controller under specific working conditions. By simulating these conditions, it is possible to verify whether the controller can meet the design requirements and find possible problems or defects.

[0087] First condition test instruction:

[0088] Definition: Used to specify the specific working condition of the test. The contents of the first working condition test instruction may include but are not limited to: Target speed: specifies the target speed that the motor should reach; Load simulation: indicates how to simulate the motor load, which may be through external load equipment or software simulation; Duration: specifies the duration of the test condition.

[0089] The first operating condition test command may be a torque command.

[0090] Function 1: Instruct the motor controller under test on how to operate during the test process.

[0091] Voltage signal:

[0092] Definition: An electrical signal generated by the motor controller under test to control the operation of the motor (or electronic load module in the HIL environment).

[0093] Function: Drive the electronic load module to simulate the current behavior of the motor.

[0094] Analog current signal:

[0095] Definition: The signal generated by the electronic load module after simulating the current response of the motor under different working conditions.

[0096] Function: Serves as the basis for the control module to generate operating parameters.

[0097] Run parameters:

[0098] Definition: Data generated by the control module and sent to the host computer during the test, including analog current signals. Of course, the operating parameters can be set according to the test requirements. For example, in addition to the analog current signal, the operating parameters can also include the voltage signal generated by the motor controller under test.

[0099] Function: As the basis for generating power level HIL test results of the motor controller under specific test conditions.

[0100] Test results:

[0101] Definition: The conclusion drawn by the host computer based on the received operating parameters is used to evaluate the performance of the motor controller under test.

[0102] Function: Provide important reference for the design, optimization and verification of motor controllers.

[0103] In this embodiment, on the one hand, the host computer can send instructions to the motor controller to be tested according to the preset first test condition. These conditions can be flexibly configured according to the characteristics of different execution controllers, and the system can simulate the motor operation behavior under various conditions, including normal conditions and extreme conditions, to comprehensively evaluate the performance of the execution motor controller. On the other hand, by adjusting the simulation-related parameters, the system can simulate different types of motors (such as permanent magnet synchronous motors, AC asynchronous motors, etc.), so as to adapt to the test requirements of different execution motor controllers.

[0104] Based on any of the above embodiments, the motor controller to be tested includes a power board;

[0105] The motor controller to be tested is specifically used to control the power board to turn on the power switch to generate the voltage signal according to the first working condition test instruction.

[0106] It should be noted that the positional relationship between the power board and the motor controller may vary according to different motor control system designs and application requirements. Their positional relationship may be that the power board is directly integrated into the controller, or that the power board is external to the motor controller, and the power board is connected to the controller body as an independent module. In this embodiment, the power board is integrated into the controller.

[0107] The power board is an important component of the motor controller. It usually contains multiple power switches (such as IGBT, MOSFET, etc.) to control the size and direction of the motor drive current. The high-frequency switching action of these power switches can achieve efficient control of the motor. During the motor control process, the power board adjusts the current flowing to the motor by turning on or off the power switch according to the control signal sent by the controller, thereby controlling the speed and torque of the motor.

[0108] In the specific implementation, when the motor controller to be tested receives the first working condition test instruction, it will first parse the various parameters in these instructions, such as target speed, load simulation, duration, transition conditions, and parameters that need to be monitored. Then, based on these parameters, the controller will calculate the corresponding control strategy and generate a control signal to send to the power board. After receiving the control signal, the power board will turn on or off the corresponding power switch according to the instruction of the signal. The switching state of these power switches determines the current path in the motor drive circuit, thereby generating the required voltage signal. These voltage signals are then applied to the simulated motor to drive the simulated motor to operate according to the predetermined working conditions.

[0109] In this embodiment, by precisely controlling the power switch of the power board, the motor controller to be tested can generate a voltage signal that meets the requirements of the test working condition.

[0110] On the basis of any of the above embodiments, the host computer is further used to send the first working condition test instruction to the control module;

[0111] The control module is further used to determine a simulated position signal according to the first operating condition test instruction;

[0112] The electronic load module is specifically used to send the collected voltage signal to the control module;

[0113] The control module is further used to determine a simulated current parameter according to the simulated position signal and the voltage signal, and send the simulated current parameter to the electronic load module;

[0114] The electronic load module is specifically used to simulate the motor current behavior according to the simulated current parameters.

[0115] It should be noted that the control module includes a motor model algorithm and a position signal simulation interface. Exemplarily, the motor model algorithm may be a three-phase motor model algorithm. When the motor controller to be tested is a fully redundant motor controller, the motor model algorithm may be a dual three-phase motor model algorithm. The position signal simulation interface may include an incremental encoder (ABZ) type / PWM type / Hall switch type / sine-cosine type / resolver type position signal simulation interface. Select the corresponding position signal simulation interface according to the type of the motor controller to be tested.

[0116] Among them, the motor model algorithm is used to simulate the dynamic behavior of the motor and calculate the motor parameters under various working conditions. This algorithm is based on the physical characteristics and electrical parameters of the motor, and simulates the actual operation of the motor through mathematical formulas and numerical methods. The position signal simulation interface can be an independent hardware device, such as a position signal generator; it can also be part of a software module, which generates and outputs signals through programming. Specifically, the position signal simulation interface is a hardware or software interface for generating and outputting simulated position signals. This interface generates the corresponding type of position signal based on the calculation results of the motor model algorithm or external input to simulate the actual position of the motor.

[0117] Specifically, after receiving the first working condition test instruction, the control module uses the position signal simulation interface to determine the simulated position signal, and calculates the simulated current parameters corresponding to the voltage signal and the simulated position signal through the motor model algorithm. The simulated current parameters include the amplitude, phase, waveform, etc. of the current, which are used to guide the electronic load module to simulate the current behavior of the motor under specific working conditions.

[0118] In this embodiment, the operating parameters may also include a simulated position signal calculated by the control module, and the control module sends the operating parameters including the simulated position signal and the simulated current signal to the host computer. The position signal and the current signal represent different aspects of the motor system, respectively. By comprehensively analyzing the position signal and the current signal, the host computer can more accurately evaluate the performance and stability of the motor controller, thereby generating more accurate power level HIL test results.

[0119] It should be understood that, based on the received simulated current parameters, the electronic load module simulates the current behavior of the motor, which is usually achieved by adjusting the circuit or software algorithm inside the electronic load module so that the electronic load module can output a current value that matches the simulated current parameters.

[0120] In this embodiment, based on the simulated position signal and the voltage signal, the control module can calculate the simulated current parameters and send these parameters to the electronic load module. The electronic load module simulates the current behavior of the motor under different working conditions according to these parameters. This method can accurately simulate the current characteristics of the motor in actual operation and provide reliable data support for the performance evaluation of the motor controller to be tested.

[0121] On the basis of any of the above embodiments, the test system is connected to the first power module; the test system further includes a second power module, a third power module, and a fourth power module;

[0122] The first power module is used to transmit AC power to the second power module;

[0123] The second power module is used to transmit AC power to the third power module, the fourth power module, and the control module;

[0124] The third power supply module is used to rectify the AC power delivered by the second power supply module into DC power and then supply power to the electronic load module;

[0125] The fourth power supply module is used to rectify the alternating current delivered by the second power supply module into direct current and then supply power to the motor controller to be tested.

[0126] It should be noted that this embodiment is described by taking the first power module as a three-phase power supply, the second power module as an uninterruptible power supply, the third power module as a bidirectional DC power supply, and the fourth power module as a programmable DC power supply module as an example.

[0127] Converting three-phase AC power to DC power is a common requirement in power systems and various electronic devices because:

[0128] Improve efficiency and stability: During the transmission and distribution process of direct current (DC), since there is no phase and frequency change of alternating current (AC), it can reduce energy loss caused by factors such as resistance and inductance, thereby improving the efficiency of power transmission. In addition, the voltage and current waveforms of direct current are stable, which is conducive to the stable operation and precise control of electronic equipment.

[0129] Adapting to specific equipment needs: Many electronic devices, especially modern electronic devices such as computers, communication equipment, motor controllers, etc., require DC as a working power source. The circuits and components inside these devices are often designed for DC, so converting AC to DC is a necessary step to meet the working needs of these devices.

[0130] Simplify circuit design: In some cases, using DC can simplify circuit design. For example, in motor control systems, using DC motors can eliminate the complex commutation devices and control systems required for AC motors. In addition, DC also facilitates precise regulation of voltage and current to meet the needs of different working conditions.

[0131] Reduce electromagnetic interference: AC will generate electromagnetic fields during transmission, which may cause electromagnetic interference (EMI), affecting the normal operation of surrounding electronic equipment. DC will not generate such electromagnetic fields, so it can reduce the problem of electromagnetic interference.

[0132] Easy to store and distribute energy: DC power is easy to connect to and charge energy storage devices because the energy storage device itself is a DC power source.

[0133] It is understandable that the three-phase power supply (first power module) serves as the main power supply of the entire test system and provides three-phase AC power. The three-phase power supply transmits AC power to the uninterruptible power supply (second power module) as the power source for subsequent power modules. The three-phase power supply usually has high power and stability and is suitable as the main power supply for large test systems.

[0134] The uninterruptible power supply (UPS) receives three-phase AC power from the three-phase power supply (first power module) and provides stable AC output. As an intermediate link, the UPS not only provides AC power to the bidirectional DC power supply (third power module) and the programmable DC power supply module (fourth power module), but also supplies power to the control module. The main function of the UPS is to ensure that the HIL system can continue to be powered when the external power supply of the cabinet is interrupted or fluctuates, so as to provide power guarantee for the test system to continue to operate stably.

[0135] The bidirectional DC power supply rectifies the AC power provided by the uninterruptible power supply into DC power. The bidirectional DC power supply is used to supply power to the electronic load module. The electronic load module is used to simulate the motor load under actual working conditions to test the performance of the motor controller. The bidirectional DC power supply also has the ability to invert DC power back to AC power. The bidirectional DC power supply can be a power supply device that includes hardware components such as rectifiers and filters.

[0136] The programmable DC power module also rectifies the AC power provided by the uninterruptible power supply (second power module) into DC power. The programmable DC power module provides two KL15 interfaces and KL30 interfaces to power the motor controller under test. The programmable DC power module has higher flexibility and accuracy, and can control the output voltage and current through programming to meet the needs of different test scenarios. This is crucial for accurately testing the performance of the motor controller. The programmable DC power module usually contains high-precision power management circuits and communication interfaces, and its programmable function is realized through a built-in microprocessor or controller and corresponding hardware circuits.

[0137] like Figure 2 As shown, Figure 2 A schematic diagram of a power supply structure of a test system provided in an embodiment of the present application. The figure shows that when a three-phase power supply is connected to the test system, the uninterruptible power supply is first powered, and the uninterruptible power supply powers the bidirectional DC power supply, the programmable DC power supply module and the control module. The bidirectional DC power supply powers the electronic load module after AC / DC rectification, and the programmable power supply module powers the motor controller to be tested through the DC power line after AC / DC rectification. Multiple power supply modules work together to power the entire test system.

[0138] In this embodiment, the entire test system realizes the conversion and distribution from three-phase AC to DC through the coordinated work of multiple power modules, providing stable and reliable power support for the HIL test of the motor controller.

[0139] Based on any of the above embodiments, the electronic load module includes a resistive-inductive load network for storing electrical energy;

[0140] The host computer is also used to send an electric energy recovery instruction to the motor controller to be tested;

[0141] The motor controller to be tested is further used to generate a recovery signal according to the electric energy recovery instruction;

[0142] The electronic load module is further used to recover the electric energy stored in the resistive-inductive load network to the second power module through the third power module according to the recovery signal collected from the motor controller to be tested.

[0143] It should be noted that in addition to the resistance-inductance load network, the electronic load module can also include components such as current tracking and three-phase inverter bridge. Among them, current tracking is a core function in the electronic load module, which means that the electronic load can accurately control its input or output current to track (i.e. match) the set reference current value or the dynamically changing current signal. This function enables the electronic load to simulate the current characteristics of the real load, including steady-state and dynamic change processes. The three-phase inverter bridge is a key component in the electronic load module for converting direct current (DC) to alternating current (AC). It is usually composed of six power devices (such as MOSFET or IGBT), which are connected together in a specific way to form three bridge arms. By controlling the switching state of these power devices, DC can be inverted into three-phase AC, thereby simulating the working conditions of the three-phase load. The resistance-inductance load network is a load circuit composed of resistors and inductors, which is used to simulate the resistive and inductive characteristics in the real load. In the electronic load module, the resistance-inductance load network is usually used to absorb and consume energy to simulate the power consumption under different load conditions.

[0144] The recovery signal may be a voltage signal.

[0145] It should be understood that the triggering of the energy recovery instruction can be based on a variety of conditions, such as the motor is in a braking state, the grid load is low, the energy storage device needs to be charged, etc. The energy recovery instruction can be transmitted to the motor controller through a digital communication interface (such as CAN bus, Ethernet, serial port, etc.). The instruction content may include parameters such as the voltage range of the recovered energy, current limit, recovery mode (such as fast charging, constant current charging, etc.) and recovery time. After receiving the energy recovery instruction, the motor controller controls the power board to generate a corresponding voltage signal so that the electronic load module adjusts its working state after collecting the voltage signal and starts to recover the electric energy stored in the resistive-inductive load network. The termination of the energy recovery instruction may be based on a variety of conditions, such as the energy storage device is full, the grid load suddenly increases, the motor needs to be restarted, etc.

[0146] like Figure 3 As shown, Figure 3 A schematic diagram of energy recovery provided for an embodiment of the present application. It is known that in the driving mode, the power module supplies electric energy to the motor controller, and the motor controller converts the electric energy into current and voltage signals and outputs them to the motor (equivalent to the electronic load module in this embodiment), so that the motor generates torque to drive the vehicle; while in the energy recovery mode, such as when the vehicle decelerates or goes downhill, the motor (equivalent to the electronic load module in this embodiment) works as an engine, converts mechanical energy into electric energy and recovers the electric energy to the power module through the motor controller.

[0147] In this embodiment, a power recovery mechanism in a motor controller hardware-in-the-loop (HIL) test system is provided. In this mechanism, various components work together to achieve effective recovery and reuse of lost power, greatly reducing energy waste.

[0148] Based on any of the above embodiments, the test system further includes a fault injection component;

[0149] The host computer is also used to send a fault test instruction to the fault injection component through the control module according to a preset fault condition;

[0150] The fault injection component is used to perform fault simulation on the motor controller to be tested under the fault condition according to the fault test instruction;

[0151] The motor controller to be tested is also used to perform fault diagnosis and send diagnostic information to the host computer;

[0152] The host computer is also used to generate a fault test report of the motor controller to be tested according to the diagnostic information.

[0153] It should be noted that the fault injection component may include a signal conditioning module and a fault injection module. Specifically, when a fault is injected into the motor controller to be tested, a low current fault injection and a high current fault injection can be performed through the host computer, the control module, the signal conditioning module and the fault injection module to achieve a short circuit fault to ground, a short circuit fault to power, an open circuit fault and a short circuit fault between signals of the motor controller to be tested.

[0154] It is understandable that the main function of the signal conditioning module is to pre-process the input signal to ensure that it is suitable for subsequent fault injection operations. This includes signal amplification, attenuation, filtering, isolation and other processing to ensure that fault injection does not cause unnecessary damage to the test system, while also being able to more accurately simulate signal changes in the actual working environment.

[0155] The fault injection module is the unit that actually performs the fault injection operation. It injects different types of faults into the motor controller under test by changing the circuit connection, simulating short circuit or open circuit, etc. These faults include but are not limited to short circuit to ground fault, short circuit to power fault, open circuit fault and short circuit between signals.

[0156] In the specific implementation, the tester sends a fault injection instruction through the host computer, specifying the fault type to be injected, duration and other parameters. The control module receives the instruction from the host computer, parses it and sends it to the signal conditioning module and the fault injection module. The control module may also be responsible for monitoring various parameters during the test to ensure the safety of the test. According to the instruction of the control module, the signal conditioning module performs necessary preprocessing on the input signal to match the requirements of the fault injection module. The fault injection module performs specific fault injection operations according to the instruction of the control module and the output of the signal conditioning module. For example, by changing the circuit connection to simulate a short circuit or open circuit fault to the ground, or by injecting additional current to simulate a high current fault, etc. During the fault simulation process, the motor controller under test monitors the operating status of the system in real time, and identifies and diagnoses possible faults through the built-in fault diagnosis algorithm. Once a fault is detected, the motor controller under test will send the diagnostic information to the host computer in a timely manner to evaluate the fault diagnosis capability of the controller. If so, when the fault diagnosis capability of the motor controller to be tested fails and the fault information cannot be fed back to the host computer, the host computer needs to adopt other strategies to indirectly evaluate or confirm whether the fault diagnosis capability of the motor controller fails. For example, the evaluation can be performed by the following methods:

[0157] Regular self-check and heartbeat signal:

[0158] The motor controller is designed to periodically send a "heartbeat" signal or self-test report to the host computer. This signal or report does not need to contain specific fault information, but can be used as a sign that the controller is working properly. If the host computer does not receive the heartbeat signal or self-test report within a predetermined time, it can be assumed that there may be a problem with the controller's fault diagnosis ability (or at least its communication ability).

[0159] Key parameters to monitor:

[0160] The host computer can continuously monitor the key operating parameters received from the motor controller (such as current, voltage, temperature, speed, etc.). If these parameters fluctuate abnormally or exceed the normal range, and the host computer does not receive the corresponding fault report, this may indicate that there is a problem with the controller's fault diagnosis ability.

[0161] Redundancy detection mechanism:

[0162] If system conditions permit, redundant sensors or detection elements can be introduced to monitor the status of the motor controller. These redundant elements can communicate directly with the host computer or pass information to the host computer through independent paths. When the main detection path (i.e. the motor controller's own fault diagnosis system) fails, the redundant detection mechanism can be used as a backup plan to identify the fault.

[0163] Manual intervention and regular inspection:

[0164] Regular manual inspection and maintenance includes checking the motor controller’s physical status, connectivity, and software updates. While this is not an automated method, it can help identify potential faults or issues and serve as an aspect of evaluating the controller’s troubleshooting capabilities.

[0165] Log analysis and historical data comparison:

[0166] The host computer can record and analyze historical data from the motor controller. By comparing current data with past data, any unusual patterns or trends can be identified, which may indicate problems with the controller's fault diagnosis capabilities.

[0167] In this embodiment, the test system achieves comprehensive testing and evaluation of the motor controller to be tested under fault conditions by introducing a fault injection component.

[0168] On the basis of any of the above embodiments, the motor controller to be tested is a fully redundant motor controller; the electronic load module includes a first electronic load submodule and a second electronic load submodule;

[0169] The fully redundant motor controller is used to generate a first voltage signal and a second voltage signal according to the first working condition test instruction;

[0170] The first electronic load submodule is used to simulate the motor current behavior according to the first voltage signal collected from the fully redundant motor controller, and send the generated first simulated current signal to the control module;

[0171] The second electronic load submodule is used to simulate the motor current behavior according to the second voltage signal collected from the fully redundant motor controller, and send the generated second simulated current signal to the control module;

[0172] The control module is specifically used to generate a first operating parameter and a second operating parameter and send them to the host computer; the first operating parameter includes the first analog current signal; the second operating parameter includes the second analog current signal;

[0173] The host computer is further used to generate a power level HIL test result of the fully redundant motor controller under the first test condition according to the first operating parameter and the second operating parameter.

[0174] It should be noted that the fully redundant motor controller is an executive motor controller with redundant design. Redundant design means adding additional hardware or software components to the system so that when the main component fails, these backup components can take over the control task, thereby ensuring the continuity and reliability of the system. This embodiment describes the operation process of a hardware-in-the-loop HIL test system for a fully redundant motor controller. In view of the characteristics of the two sets of components in the redundant system, the electronic load module in this embodiment and the motor model in the control module for determining the analog position signal based on the analog current signal are correspondingly set to two.

[0175] In a specific implementation, the fully redundant motor controller generates two independent voltage signals, a first voltage signal and a second voltage signal, according to a given first operating condition test instruction. These two signals represent the outputs that the controller may generate under a redundant configuration. The first electronic load submodule is responsible for collecting the first voltage signal and simulating the current behavior of the motor based on this signal. The simulated current signal (i.e., the first simulated current signal) reflects the possible current response of the motor when it receives the voltage signal. This signal is then sent to the control module. The second electronic load submodule is responsible for collecting the second voltage signal and simulating the corresponding current behavior, generating a second simulated current signal and sending it to the control module. The control module receives the first simulated current signal and the second simulated current signal from the two electronic load submodules and sends them to the host computer. Each set of operating parameters includes a simulated current signal, which provides a data basis for subsequent test evaluation.

[0176] It is also very important for fully redundant motor controllers to test whether the redundant system can switch seamlessly when a fault occurs to ensure the continuous operation of the system. As an example of testing whether the redundant system can switch seamlessly when a fault occurs, during the test, the fault injection module can be used to simulate the failure of the main control unit (such as disconnecting the power supply, sending an error signal, etc.); the host computer monitors the operating parameters in real time and immediately records the current status after detecting the failure of the main control unit; then, the redundancy mechanism of the fully redundant motor controller is automatically activated, and the backup control unit takes over the control task; the backup control unit continues to generate voltage signals according to the first working condition test instruction, and simulates the motor current behavior through the electronic load module; the host computer continues to receive the operating parameters from the control module and verifies whether the backup control unit has successfully taken over and the system is running smoothly. This includes checking whether the system operating parameters are stable and whether they meet the expected values.

[0177] like Figure 4 As shown, Figure 4A schematic diagram of the structure of a test system for a fully redundant motor controller provided in an embodiment of the present application. It includes a three-phase power supply, an uninterruptible power supply, a bidirectional DC power supply, a programmable DC power supply module, a real-time control system (i.e., the above-mentioned control module), an electronic load module, a fully redundant motor controller under test, a signal conditioning module, a fault injection module, and a host computer. When the three-phase AC power is connected to the HIL test system, the uninterruptible power supply is first powered. The uninterruptible power supply powers the bidirectional DC power supply, the programmable DC power supply module, and the real-time control system. The uninterruptible power supply can continue to power the HIL system after the power is cut off outside the cabinet. The bidirectional DC power supply can power the electronic load module and receive the electric energy fed back by the electronic load module. The programmable DC power supply module provides two KL15 interfaces and a KL30 interface to power the fully redundant motor controller. The real-time control system includes a motor model algorithm and an incremental encoder (ABZ) type / PWM type / Hall switch type / sine-cosine type / The rotary transformer position signal simulation interface (common motor position signal interface modules can be switched with each other, and there is no need to redevelop the position signal interface module when testing different controllers. In addition, since the real-time control system provides a signal interface, the control board and power board of the motor controller can be tested separately), the electronic load module includes an electronic load module 1 and an electronic load module 2, each electronic load module includes a resistive-inductive load network, a three-phase inverter bridge and a current follower, and the fault injection module includes a small current fault injection and a large current fault injection, which can realize a short circuit fault to ground, a short circuit fault to electricity, an open circuit fault and a short circuit fault between signals. When testing the fully redundant motor controller, the host computer sends a torque command to the fully redundant motor controller and the real-time control system according to the working conditions. After receiving the torque command, the fully redundant motor controller opens the switch tube (i.e., the power switch) on the power board of the controller in an orderly manner after calculation by the motor control algorithm; at the same time, after receiving the torque command, the real-time control system uses the incremental encoder (ABZ) type / PWM type / Hall switch type / sine-cosine type / rotary transformer position signal simulation interface to calculate the position signal, i.e., the above-mentioned simulated position signal. The electronic load module collects the dual three-phase voltage signal on the power board and sends the voltage signal to the real-time control system. The dual three-phase motor model algorithm in the real-time control system receives the dual three-phase voltage signal and position signal, calculates the dual three-phase current signal, and sends it to the electronic load module. The electronic load module follows the current according to the received dual three-phase current command, controls the three-phase inverter bridge to make the current flow through the resistive load network, and realizes the simulation of the dual three-phase current of the fully redundant motor. The real-time control system feeds back the operating parameters including the position signal and the dual three-phase current signal to the host computer, and the host computer gives the motor torque command at the next moment according to the working conditions. At the same time, the host computer can control the fully redundant motor controller, and then control the motor model to recycle the power loss of the electronic load module and feed it back to the uninterruptible power supply, greatly reducing energy consumption.

[0178] In this embodiment, the entire test process verifies and evaluates the output of the fully redundant motor controller by simulating the actual motor operating environment.

[0179] Based on any of the above embodiments, the motor controller to be tested includes an external power board;

[0180] The control module is communicatively connected with the power board;

[0181] The host computer is further used to send a second working condition test instruction to the control module according to a preset second test working condition;

[0182] The control module is further configured to send a modulation signal to the power board according to the second operating condition test instruction;

[0183] The power board is used to generate a third voltage signal according to the modulation signal;

[0184] The electronic load module is further used to simulate the motor current behavior according to the third voltage signal collected from the power board, and send the third voltage signal and the modulated current signal generated by simulating the motor current behavior to the host computer through the control module;

[0185] The host computer is further used to generate a test result of the power board under the second test condition according to the third voltage signal and the modulated current signal.

[0186] It should be noted that, in this embodiment, the power board is external to the motor controller, and the power board is connected to the controller body as an independent module, and the power board is tested separately through the power-level hardware-in-the-loop HIL test system.

[0187] It should be understood that the second test condition is specifically designed for external power boards and is intended to evaluate the performance of the power board under different operating conditions. These conditions may be directly related to the power board's electrical characteristics, thermal management, efficiency, and compatibility with other system components. Specifically, the second test condition may include the following aspects:

[0188] Electrical performance test:

[0189] Voltage range: Test the output voltage stability and accuracy of the power board under different input voltages.

[0190] Current carrying capacity: Evaluate the stability and heat dissipation capability of the power board under continuous high current load.

[0191] Switching frequency: Test the efficiency and response speed of the power board at different PWM switching frequencies.

[0192] Thermal Management Tests:

[0193] Temperature Cycle: Simulates the operation of the power board under extreme temperature conditions to evaluate its thermal stability and thermal protection mechanism.

[0194] Heat dissipation efficiency: Measure the temperature rise of the power board under different loads to evaluate its heat dissipation design and heat conduction efficiency.

[0195] Fault simulation and protection:

[0196] Overcurrent protection: simulates current overload conditions to test whether the overcurrent protection mechanism of the power board is effective.

[0197] Short-circuit protection: simulate output short-circuit conditions to verify the short-circuit protection capability of the power board.

[0198] Overheat protection: When the temperature exceeds the safety threshold, test whether the power board can cut off the output in time to protect itself and the motor.

[0199] Compatibility Test:

[0200] Communication with control module: Verify the accuracy and stability of the communication protocol and data transmission between the power board and the control module.

[0201] Integration with other system components: Test the integration performance and compatibility of the power board in the entire motor control system.

[0202] It is understandable that the modulation signal may be a PWM (Pulse Width Modulation) signal, that is, a pulse width modulation signal, which controls the average level of the output signal by changing the width of the pulse.

[0203] The power semiconductor devices (such as MOSFETs) on the power board perform switching operations according to the duty cycle of the PWM signal. When these devices are turned on, they allow current to pass, thereby generating a voltage drop across the load (such as an analog motor - electronic load module). The size and shape of this voltage drop (i.e., the third voltage signal) depends on the duty cycle of the PWM signal, the characteristics of the power semiconductor device, and the impedance of the load.

[0204] The modulated current signal is a current signal generated by the electronic load module based on the third voltage signal to simulate the motor current behavior. The electronic load module can send the third voltage signal to the control module, so that the control module inputs the third voltage signal into the motor model for calculation, and obtains the current parameter of the electronic load module to simulate the motor current behavior. The electronic load module simulates the motor current behavior according to the current parameter and generates the modulated current signal.

[0205] In addition, the present application embodiment also provides a method for testing a control board separately. Figure 5 As shown, Figure 5A structural schematic diagram of a separate test control board provided in an embodiment of the present application. When the control board is tested separately, the control module needs to be connected to the control board first. When the control board is automatically tested, the host computer uses the Teststand test platform to call the Veristand project to send a test signal to the control module. After the control module receives the test signal, it sends an instruction (including position, speed, and torque information) to the control board. After the control board receives the instruction, it processes the internal motor control algorithm and sends a PWM signal to the control module. After the power board model in the control module receives the PWM signal, it opens the power switch in an orderly manner to generate a corresponding three-phase AC signal. The control module sends a three-phase AC signal and a position simulation signal to the control board. After the control board receives the three-phase AC signal and the position simulation signal, it processes the internal motor controller algorithm and sends a corresponding test signal or result to the control module. The control module sends the test signal or result sent by the control board to the host computer, and the host computer processes it into a test report.

[0206] In this embodiment, by measuring and analyzing the third voltage signal generated by the power board and the modulated current signal generated by the electronic load module simulating the motor current behavior, the host computer can comprehensively evaluate the performance of the power board under various working conditions and implement individual testing of the power board.

[0207] Based on any of the above embodiments, the host computer is equipped with an automated testing platform and engineering software;

[0208] The automated testing platform is used to obtain test data input by the user;

[0209] The engineering software is used to generate test instructions based on the test data.

[0210] It should be noted that the automated test platform can be the Teststand automated test platform, and the engineering software can be the Veristand engineering. TestStand is a software platform independently developed and researched by National Instruments (NI). NI TestStand is an immediately executable test management software that can help users develop automated test and verification systems faster. NI TestStand can be used to develop, execute, and deploy test system software. In addition, users can also develop test sequences using test code modules written in any programming language. Test sequences can specify execution flows, generate test reports, perform database records, and connect to other company systems. Finally, users can deploy test systems in production with the help of an easy-to-use operating interface. Veristand engineering is an engineering project based on the VeriStand software developed by the above-mentioned NI company. VeriStand is a software platform for real-time testing, verification, and deployment of control systems. It supports the construction of multiple test environments from model-in-the-loop (MIL), software-in-the-loop (SIL) to hardware-in-the-loop (HIL).

[0211] Veristand and Teststand are highly compatible and easy to use, which greatly reduces the learning time cost of developers and testers. Veristand projects manage and configure the power level HIL test system of the motor controller. Teststand calls Veristand projects for automated testing, replacing the manual control of Veristand projects, which greatly improves the test efficiency. The Teststand automated testing platform includes an automated testing framework, a test case editing module, a test case execution module, and a test report output module. The following is a detailed introduction to each module.

[0212] Automated testing framework: Teststand provides an automated testing framework based on a graphical library. By defining test processes and steps, you can quickly build an automated testing framework.

[0213] Test case editing module: Teststand provides graphical libraries such as calibration tool library, data evaluation library, fault injection library, action library, variable acquisition library, and inspection library, and supports calling third-party devices. When editing test cases, testers can import graphical libraries, obtain operation variables, and modify the values ​​of operation variables by dragging according to the test requirements of the fully redundant motor controller, and then complete the test case editing.

[0214] Execute test case module: In Teststand, you can change the execution order of test cases, execute a single test case, or execute multiple test cases according to test requirements.

[0215] Test report output module: Teststand automatically generates test reports, which record the test steps and can be freely edited. Reports in formats such as html, csv, txt and atml can be generated.

[0216] Specifically, the automated test platform provides a user interface (UI) that allows testers to input various test parameters and data. These data may include specific parameters of the test conditions (such as voltage range, current limit, speed requirements, etc.), test time, number of tests, etc. In addition to receiving input from testers, the automated test platform is also responsible for the management of the entire test process. It can automatically execute a series of test steps according to the test plan set by the tester, including sending test instructions, monitoring the test process, collecting test data, etc.

[0217] Engineering software usually contains a series of complex algorithms and models to simulate the dynamic behavior of the motor, calculate the expected test results, etc. These algorithms and models ensure the accuracy and effectiveness of the test instructions. It receives user input data from the automated test platform and generates specific test instructions based on these data. These test instructions will be sent to the control module to control the output of the power board and simulate the operating conditions of the motor.

[0218] In this embodiment, the automated test platform and engineering software are integrated in the host computer, providing strong support for the test of the motor controller. This integration not only improves the automation and efficiency of the test, but also ensures the accuracy and reliability of the test results. Through the user-friendly interface and powerful algorithm support, testers can easily set test parameters, monitor the test process, and quickly obtain test results.

[0219] The present application also provides a testing device, which includes the testing system as described in any of the above embodiments.

[0220] In several embodiments provided in the present application, it should be understood that the disclosed devices and methods can also be implemented in other ways. The device embodiments described above are merely schematic. For example, the flowcharts and block diagrams in the accompanying drawings show the possible architecture, functions and operations of the devices, methods and computer program products according to multiple embodiments of the present application. In this regard, each box in the flowchart or block diagram can represent a module, a program segment or a part of a code, and the module, a program segment or a part of a code contains one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order from the order marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or flowchart, and the combination of boxes in the block diagram and / or flowchart can be implemented with a dedicated hardware-based system that performs a specified function or action, or can be implemented with a combination of dedicated hardware and computer instructions.

[0221] In addition, the functional modules in the various embodiments of the present application may be integrated together to form an independent part, or each module may exist separately, or two or more modules may be integrated to form an independent part.

[0222] If the functions are implemented in the form of software function modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application can be essentially or partly embodied in the form of a software product that contributes to the prior art. The computer software product is stored in a storage medium, including several instructions to enable a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in each embodiment of the present application. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk.

[0223] The above description is only an embodiment of the present application and is not intended to limit the scope of protection of the present application. For those skilled in the art, the present application may have various changes and variations. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present application should be included in the scope of protection of the present application. It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings.

[0224] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

[0225] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

Claims

1. A power level hardware-in-the-loop (HIL) test system for executing a motor controller, characterized in that: The test system is connected to the motor controller to be tested, and the test system includes a host computer, a control module, and an electronic load module; The host computer is used to send a first working condition test instruction to the motor controller to be tested according to a preset first test working condition; The motor controller to be tested is used to generate a voltage signal according to the first working condition test instruction; The electronic load module is used to simulate the motor current behavior according to the voltage signal collected from the motor controller to be tested, and send the generated simulated current signal to the control module; The control module is used to generate operating parameters and send them to the host computer; the operating parameters include the analog current signal; The host computer is further used to generate a power level HIL test result of the motor controller to be tested under the first test condition according to the operating parameters.

2. The test system according to claim 1, characterized in that: The motor controller to be tested includes a power board; The motor controller to be tested is specifically used to control the power board to turn on the power switch to generate the voltage signal according to the first working condition test instruction.

3. The test system according to claim 1, characterized in that: The host computer is further used to send the first operating condition test instruction to the control module; The control module is further used to determine a simulated position signal according to the first operating condition test instruction; The electronic load module is specifically used to send the collected voltage signal to the control module; The control module is further used to determine a simulated current parameter according to the simulated position signal and the voltage signal, and send the simulated current parameter to the electronic load module; The electronic load module is specifically used to simulate the motor current behavior according to the simulated current parameters.

4. The test system according to claim 1, characterized in that: The test system is connected to the first power module; the test system also includes a second power module, a third power module, and a fourth power module; The first power module is used to transmit AC power to the second power module; The second power module is used to transmit AC power to the third power module, the fourth power module, and the control module; The third power supply module is used to rectify the AC power delivered by the second power supply module into DC power and then supply power to the electronic load module; The fourth power supply module is used to rectify the alternating current delivered by the second power supply module into direct current and then supply power to the motor controller to be tested.

5. The test system according to claim 4, characterized in that: The electronic load module includes a resistive-inductive load network for storing electrical energy; The host computer is also used to send an electric energy recovery instruction to the motor controller to be tested; The motor controller to be tested is further used to generate a recovery signal according to the electric energy recovery instruction; The electronic load module is further used to recover the electric energy stored in the resistive-inductive load network to the second power module through the third power module according to the recovery signal collected from the motor controller to be tested.

6. The test system according to claim 1, characterized in that: The test system also includes a fault injection component; The host computer is also used to send a fault test instruction to the fault injection component through the control module according to a preset fault condition; The fault injection component is used to perform fault simulation on the motor controller to be tested under the fault condition according to the fault test instruction; The motor controller to be tested is also used to perform fault diagnosis and send diagnostic information to the host computer; The host computer is also used to generate a fault test report of the motor controller to be tested according to the diagnostic information.

7. The test system according to claim 1, characterized in that: The motor controller to be tested is a fully redundant motor controller; the electronic load module includes a first electronic load submodule and a second electronic load submodule; The fully redundant motor controller is used to generate a first voltage signal and a second voltage signal according to the first working condition test instruction; The first electronic load submodule is used to simulate the motor current behavior according to the first voltage signal collected from the fully redundant motor controller, and send the generated first simulated current signal to the control module; The second electronic load submodule is used to simulate the motor current behavior according to the second voltage signal collected from the fully redundant motor controller, and send the generated second simulated current signal to the control module; The control module is specifically used to generate a first operating parameter and a second operating parameter and send them to the host computer; the first operating parameter includes the first analog current signal; the second operating parameter includes the second analog current signal; The host computer is further used to generate a power level HIL test result of the fully redundant motor controller under the first test condition according to the first operating parameter and the second operating parameter.

8. The test system according to claim 1, characterized in that: The motor controller to be tested includes an external power board; The control module is communicatively connected with the power board; The host computer is further used to send a second working condition test instruction to the control module according to a preset second test working condition; The control module is further configured to send a modulation signal to the power board according to the second operating condition test instruction; The power board is used to generate a third voltage signal according to the modulation signal; The electronic load module is further used to simulate the motor current behavior according to the third voltage signal collected from the power board, and send the third voltage signal and the modulated current signal generated by simulating the motor current behavior to the host computer through the control module; The host computer is further used to generate a test result of the power board under the second test condition according to the third voltage signal and the modulated current signal.

9. The test system according to any one of claims 1 to 8, characterized in that: The host computer is equipped with an automated testing platform and engineering software; The automated testing platform is used to obtain test data input by the user; The engineering software is used to generate test instructions based on the test data.

10. A testing device, characterized in that: The testing device comprises the testing system according to any one of claims 1-9.

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