Traction control unit fault diagnosis and processing test system and use method thereof

Abstract

The invention provides a traction control unit fault diagnosis and processing test system. The traction control unit fault diagnosis and processing test system comprises a high-speed simulation machine, a sensor simulation unit, a photoelectric conversion unit, a fault injection and signal observation unit and a traction control unit. According to the traction control unit fault diagnosis and processing test system provided by the invention, through fault modeling and semi-physical simulation test platform construction, simulation of each stage of a motor interphase short circuit fault in a laboratory low-voltage environment is realized; the irreversible damage to test equipment such as a motor caused by direct ground test simulation of an interphase short circuit fault is avoided, and the product development test cost and the safety risk are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of fault diagnosis, and in particular to a traction control unit fault diagnosis, processing and testing system and a method of using the same. Background Art

[0002] In recent years, permanent magnet synchronous motors have been gradually promoted and applied in railway transportation vehicles due to their advantages such as high efficiency and high power density. Due to the harsh operating environment of railway vehicles, the probability of motor failure will also increase greatly, especially if a two-phase short circuit fault occurs in a permanent magnet motor during high-speed train operation. At this time, the three-phase current is no longer symmetrical, and its high speed will bring a large back electromotive force, thereby causing a large torque pulsation. If it is not diagnosed in time and effective treatment measures are not taken, the motor will experience intensified vibration and severe heat generation, which will bring great safety hazards to train operation.

[0003] The development and verification of the permanent magnet synchronous motor short-circuit fault diagnosis and processing algorithm cannot be separated from a large number of tests. Reproducing the fault in the ground test will not only cause irreversible damage to the motor and other test equipment, increase the product development cost, but also pose a great safety hazard. Therefore, it is very necessary to develop a set of test systems with strong versatility, low cost and small safety hazards for the development and test verification of the permanent magnet motor interphase short-circuit fault diagnosis and processing algorithm.

[0004] At present, the verification of the permanent magnet motor interphase short circuit fault diagnosis and processing algorithm is generally to build the algorithm model in the Simulink environment, and use the motor model and short circuit module in the Simpower model library in MATLAB to construct the permanent magnet motor interphase short circuit fault model to perform offline simulation test verification of the algorithm. The simulation operation step size of this method is too large, and the error is large compared with the actual system operation rate, and it is impossible to achieve accurate verification of the fault diagnosis and processing algorithm. This patent constructs the Xilinx model of the permanent magnet synchronous motor interphase short circuit fault through the method of mathematical modeling, and downloads the model to the high-speed simulator, connects it with the EMU traction control unit TCU through the signal conversion module, realizes real-time simulation, and injects faults at any time through the host computer given instructions, so as to perform a complete test on the algorithm of the EMU permanent magnet synchronous motor interphase short circuit fault diagnosis and processing function. Summary of the invention

[0005] According to the technical problems mentioned in the above background technology, a traction control unit fault diagnosis, processing and testing system and a method of using the same are provided.

[0006] The technical means adopted by the present invention are as follows:

[0007] Traction control unit fault diagnosis and processing test system, including:

[0008] High-speed simulator, sensor simulation unit, photoelectric conversion unit, fault injection and signal observation unit and traction control unit;

[0009] The high-speed simulator is used to run the inverter model, the normal and fault models of the permanent magnet synchronous motor;

[0010] The sensor simulation unit is used to transfer the intermediate voltage, inverter current and speed signal output by the simulator to the signal acquisition board of the traction control unit;

[0011] The photoelectric conversion unit is used to convert the pulse light signal emitted by the traction control unit into a pulse electrical signal required for turning on or off the inverter IGBT;

[0012] The fault injection and signal observation unit injects faults at any time by simulating the host computer, and observes the results of the simulation model operation at the same time;

[0013] The traction control unit is a hardware unit that performs operation control, fault diagnosis and processing control on the train traction inverter and traction motor; when the traction control unit changes, the model parameters in the high-speed simulator are changed accordingly through the host computer.

[0014] Furthermore, the high-speed simulator includes: a processor board DS1006 and a high-speed simulation board DS5203; the high-speed simulation board DS5203 realizes the operation of the inverter and permanent magnet synchronous motor models, receives pulse instructions issued by the traction control unit through the hardware interface of the board, and outputs signals such as voltage, current, and speed obtained by calculation in the model to the traction control unit;

[0015] The processor board DS1006 realizes data interaction between the high-speed simulation board and the host computer, transfers the received fault injection instructions and configured parameters of the host computer to the main circuit model in the high-speed simulation board, and transfers the running results of the model in the high-speed simulation board to the host computer for display.

[0016] The present invention also includes a method for using a traction control unit fault diagnosis and processing test system, comprising the following steps:

[0017] A model is built for the interphase short-circuit process of a permanent magnet synchronous motor; the interphase short-circuit process of the permanent magnet synchronous motor includes: normal operation, two-phase short-circuit and three-phase short-circuit; after the model is built, the model is downloaded to a high-speed simulator, and connected to the traction control unit TCU through a photoelectric conversion unit and a sensor simulation unit to achieve real-time simulation; fault injection is performed at any time through instructions given by the host computer, and the algorithm for diagnosing and processing the interphase short-circuit fault of the permanent magnet synchronous motor is tested.

[0018] Furthermore, in the process of modeling the interphase short circuit of the permanent magnet synchronous motor, it is considered that the current sensor in the actual main circuit is outside the short-circuited winding, that is, it does not detect the current of the short-circuited phase of the motor, but detects the current of the corresponding inverter. Therefore, the modeling transmits the current of the inverter to the traction control unit through the sensor simulation unit.

[0019] Further, when operating normally, the process includes the following steps:

[0020] Establishing a motor model during normal operation; the motor model during normal operation includes: a voltage equation, a flux equation, and a torque equation;

[0021] The voltage equation is:

[0022]

[0023] The magnetic flux equation is:

[0024]

[0025] Among them, u d 、u q and u0 represent the three-phase voltage u output by the inverter through 3s / 2r transformation. a 、u b 、u c The corresponding d-axis, q-axis and zero-axis voltages when converted to the dq0 coordinate system; i d 、i q Respectively represent the motor d-axis current and q-axis current; R s Indicates the motor stator resistance; L d , L q They represent the motor d-axis inductance and q-axis inductance respectively; ψ f represents the permanent magnet flux; ω represents the motor angular velocity; ψ d , q They represent the motor d-axis flux and q-axis flux respectively; T e Indicates the motor torque; n p Indicates the number of motor rotor pole pairs;

[0026] Establish inverter current and short-circuit current models during normal operation;

[0027]

[0028] Among them, R f Represents the short-circuit resistance between phase B and phase C; i f Indicates the short-circuit current on the short-circuit resistor between the two phases BC, which is 0 in normal operation; i a_inv 、i b_inb 、i c_inv Respectively represent the three-phase current of the inverter; ia 、i b 、i c They represent the three-phase currents of the motor respectively; during normal operation, the three-phase currents of the inverter are equal to the corresponding three-phase currents of the motor.

[0029] Establish the inverter output three-phase voltage model during normal operation:

[0030]

[0031] Among them, u a 、u b 、u c Respectively represent the three-phase voltage output by the inverter; u dc It represents the voltage of the intermediate DC loop at the front end of the inverter; T1, T2, T3, T4, T5, and T6 represent the IGBT switch tubes of the upper and lower bridge arms of phase A, upper and lower bridge arms of phase B, and upper and lower bridge arms of phase C of the inverter respectively.

[0032] Furthermore, when there is a two-phase short circuit, there are two cases; the two cases include: a model before the inverter blocks the pulse and a model after the inverter blocks the pulse;

[0033] When the inverter has not yet blocked the pulse, due to the motor dq axis voltage u d 、u q The motor model is the same as that in normal operation, and the inverter and short-circuit current models are:

[0034]

[0035] Among them, R f It is the short-circuit resistance between the two phases when the two phases BC are short-circuited.

[0036] When the inverter is blocked, two cases are modeled:

[0037] When|u ab | dc When the voltage drop caused by the back electromotive force of the permanent magnet synchronous motor fails to exceed the intermediate DC circuit voltage, the A-phase winding is equivalent to an open circuit state, and the B-phase and C-phase windings are connected through the short-circuit resistor R f A loop is formed, and the motor voltage and current equations are as follows:

[0038]

[0039] Among them, u bc =R f i f , θ represents the motor rotor position angle, u ab 、u bc They are the line voltage between the motor's AB phases and the line voltage between the motor's BC phases.​

[0040] At this time, the inverter current and short-circuit current model are:

[0041]

[0042] When|u ad |>=u dc When the voltage drop caused by the back electromotive force of the permanent magnet synchronous motor exceeds the voltage of the intermediate DC circuit, the motor winding reversely charges the intermediate DC circuit through the diode of the inverter. At this time, the motor model is consistent with the normal state, but u in the voltage equation is d 、u q , u0 is the line voltage u ab 、u bc Obtained by 3s / 2r transformation, where

[0043] At this time, the inverter current and short-circuit current models are:

[0044]

[0045] Furthermore, when there is a three-phase short circuit, the traction control unit will send a zero vector pulse to the inverter to switch the permanent magnet synchronous motor into three-phase short circuit operation; the three-phase short circuit motor model, inverter current and short circuit current model are consistent with normal operation, but the line voltage output by the inverter to the three-phase motor is different. At this time, u ab =u dc =0.

[0046] Compared with the prior art, the present invention has the following advantages:

[0047] 1. The traction control unit fault diagnosis and processing test system provided by the present invention is constructed through fault modeling and semi-physical simulation test platform, which realizes the simulation of various stages of motor interphase short-circuit fault in a low-voltage laboratory environment, avoids the irreversible damage to motors and other test equipment caused by directly simulating interphase short-circuit faults in ground tests, and reduces product development test costs and safety risks.

[0048] 2. The present invention constructs a motor interphase short-circuit fault model through the Xilinx mathematical modeling method and runs it in a high-speed simulator. The running step can reach 10ns level, realizing real-time simulation test of the fault diagnosis and processing functions of the traction control unit, avoiding the problems of large simulation step (10us level), slow simulation rate and incomplete testing when building a fault model and fault diagnosis and processing algorithms in an ordinary MATLAB environment for pure model simulation.

[0049] In summary, the application of the technical solution of the present invention can simulate the phase-to-phase short-circuit fault of the permanent magnet synchronous motor in a safe laboratory low-voltage environment, and realize real-time simulation testing of the fault diagnosis and processing functions of the traction control unit, which solves the problems of high test cost, high safety risks, low precision, slow rate and incomplete testing of pure model simulation in ground tests.

[0050] Based on the above reasons, the present invention can be widely promoted in the development and testing process of traction electric drive system control units in locomotives, motor vehicles, urban rails, subways and other fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0052] Figure 1 The figure is an equivalent schematic diagram of the circuit connection between the inverter and the permanent magnet synchronous motor when the present invention is operating normally.

[0053] Figure 2 The figure is an equivalent schematic diagram of the circuit connection between the inverter and the permanent magnet synchronous motor when two phases are short-circuited in the present invention.

[0054] Figure 3 The figure is an equivalent schematic diagram of the circuit connection between the inverter and the permanent magnet synchronous motor when the three phases are short-circuited according to the present invention.

[0055] Figure 4 It is a schematic diagram of the system structure of the present invention.

[0056] Figure 5 The present invention provides a two-phase short circuit fault diagnosis and processing flow for the traction control unit.

[0057] Figure 6 This is a model diagram of the main circuit and permanent magnet synchronous motor of the present invention.

[0058] Figure 7 This is the interface configuration model diagram of the present invention. DETAILED DESCRIPTION

[0059] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0060] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0061] The present invention provides a method for using a traction control unit fault diagnosis and processing test system, comprising the following steps: modeling a permanent magnet synchronous motor interphase short circuit process; the permanent magnet synchronous motor interphase short circuit process includes: normal operation, two-phase short circuit and three-phase short circuit; after the model is built, the model is downloaded to a high-speed simulator, and connected to a traction control unit TCU through a photoelectric conversion unit and a sensor simulation unit to achieve real-time simulation; a fault is injected at any time by giving instructions through a host computer, and an algorithm for the permanent magnet synchronous motor interphase short circuit fault diagnosis and processing function is tested.

[0062] As a preferred embodiment, in the present application, in the process of modeling the interphase short circuit of the permanent magnet synchronous motor, it is considered that the current sensor in the actual main circuit is outside the short-circuited winding, that is, it does not detect the current of the short-circuited phase of the motor, but detects the current of the corresponding inverter. Therefore, the modeling transmits the current of the inverter to the traction control unit through the sensor simulation unit.

[0063] When operating normally, the circuit connection diagram of the inverter and the permanent magnet synchronous motor is as follows: Figure 1 As shown, the process includes the following steps:

[0064] Establishing a motor model during normal operation; the motor model during normal operation includes: a voltage equation, a flux equation, and a torque equation;

[0065] The voltage equation is:

[0066]

[0067] The magnetic flux equation is:

[0068]

[0069] Among them, u d 、u qand u0 represent the three-phase voltage u output by the inverter through 3s / 2r transformation. a 、u b 、u c The corresponding d-axis, q-axis and zero-axis voltages when converted to the dq0 coordinate system; i d 、i q Respectively represent the motor d-axis current and q-axis current; R s Indicates the motor stator resistance; L d , L q They represent the motor d-axis inductance and q-axis inductance respectively; ψ f represents the permanent magnet flux; ω represents the motor angular velocity; ψ d , q They represent the motor d-axis flux and q-axis flux respectively; T e Indicates the motor torque; n p Indicates the number of motor rotor pole pairs;

[0070] Establish inverter current and short-circuit current models during normal operation;

[0071]

[0072] Among them, i f Indicates the short-circuit current on the short-circuit resistor between the two phases BC, which is 0 in normal operation; i a_inv 、i b_inv 、i c_inv Respectively represent the three-phase current of the inverter; i a 、i b 、i c They represent the three-phase currents of the motor respectively; during normal operation, the three-phase currents of the inverter are equal to the corresponding three-phase currents of the motor.

[0073] Establish the inverter output three-phase voltage model during normal operation:

[0074]

[0075] Among them, u a 、u b 、u c Respectively represent the three-phase voltage output by the inverter; u dc It represents the voltage of the intermediate DC loop at the front end of the inverter; T1, T2, T3, T4, T5, and T6 represent the IGBT switch tubes of the upper and lower bridge arms of phase A, upper and lower bridge arms of phase B, and upper and lower bridge arms of phase C of the inverter respectively.

[0076] When two phases are short-circuited, taking the short-circuit of phases B and C as an example, the circuit connection diagram of the inverter and the permanent magnet synchronous motor is as follows: Figure 2 As shown, the ends of phase B and phase C are connected by short-circuit resistor R fConnection. It is divided into two cases; the two cases include: the model before the inverter blocks the pulse and the model after the inverter blocks the pulse;

[0077] When the inverter has not yet blocked the pulse, due to the motor dq axis voltage u d 、u q The motor model is the same as that in normal operation, and the inverter and short-circuit current models are:

[0078]

[0079] Among them, R f It is the short-circuit resistance between the two phases when the two phases BC are short-circuited.

[0080] When blocking pulses for the inverter, two cases are modeled:

[0081] When|u ab | dc When the voltage drop caused by the back electromotive force of the permanent magnet synchronous motor fails to exceed the intermediate DC circuit voltage, the A-phase winding is equivalent to an open circuit state, and the B-phase and C-phase windings are connected through the short-circuit resistor R f A loop is formed, and the motor voltage and current equations are as follows:

[0082]

[0083] Among them, u bc =R f i f , θ represents the motor rotor position angle, u ab 、u bc They are the line voltage between the motor's AB phases and the line voltage between the motor's BC phases.

[0084] At this time, the inverter current and short-circuit current model are:

[0085]

[0086] When|u ab |>=u dc When the voltage drop caused by the back electromotive force of the permanent magnet synchronous motor exceeds the voltage of the intermediate DC circuit, the motor winding reversely charges the intermediate DC circuit through the diode of the inverter. At this time, the motor model is consistent with the normal state, but u in the voltage equation is d 、u q , u0 is the line voltage u ab 、u bc Obtained by 3s / 2r transformation, where

[0087] At this time, the inverter current and short-circuit current models are: ​

[0088]

[0089] When a two-phase short-circuit fault is detected, the traction control unit will send a zero vector pulse to the inverter to switch the permanent magnet synchronous motor into three-phase short-circuit operation, thereby avoiding problems such as vibration and heating caused by unbalanced operation of the motor. At this time, the equivalent circuit connection diagram of the inverter and the permanent magnet synchronous motor is as follows: Figure 3 The three-phase short-circuit motor model, inverter current and short-circuit current model are consistent with those in normal operation, but the line voltage output by the inverter to the three-phase motor is different. At this time, u ab =u bc =0.

[0090] As a preferred embodiment of the present application, the present invention also discloses a traction control unit fault diagnosis and processing test system, such as Figure 4 As shown, including:

[0091] High-speed simulator, sensor simulation unit, photoelectric conversion unit, fault injection and signal observation unit and traction control unit;

[0092] The high-speed simulator is used to run the inverter model, the normal and fault models of the permanent magnet synchronous motor;

[0093] The sensor simulation unit is used to transfer the intermediate voltage, inverter current and speed signal output by the simulator to the signal acquisition board of the traction control unit;

[0094] The photoelectric conversion unit is used to convert the pulse light signal emitted by the traction control unit into a pulse electrical signal required for turning on or off the inverter IGBT;

[0095] The fault injection and signal observation unit injects faults at any time by simulating the host computer, and observes the results of the simulation model operation at the same time;

[0096] The traction control unit is a hardware unit that performs operation control, fault diagnosis and processing control on the train traction inverter and traction motor, and is the test object of this test system. When the traction control unit changes, the model parameters in the high-speed simulator are changed accordingly through the host computer.

[0097] The high-speed simulator includes: a processor board DS1006 and a high-speed simulation board DS5203; the high-speed simulation board DS5203 realizes the operation of the inverter and permanent magnet synchronous motor models, receives pulse instructions issued by the traction control unit through the hardware interface of the board, and outputs signals such as voltage, current, and speed obtained by calculation in the model to the traction control unit;

[0098] The processor board DS1006 realizes data interaction between the high-speed simulation board and the host computer, transfers the received fault injection instructions and configured parameters of the host computer to the main circuit model in the high-speed simulation board, and transfers the running results of the model in the high-speed simulation board to the host computer for display.

[0099] Embodiment 1:

[0100] An embodiment of the present invention provides a method for using a traction control unit fault diagnosis and processing test system, comprising the following steps:

[0101] Main circuit modeling: Use modules in the Xilinx module library to model the inverter and permanent magnet synchronous motor.

[0102] Interface configuration; includes two parts: one is to configure the hardware interface of the high-speed simulation board, including PWM pulse signal interface, motor speed signal interface, voltage and current analog signal interface; the other is to configure the data transmission interface between the high-speed simulation board and the processor board, including fault injection instruction interface, main circuit and motor parameter configuration interface, model operation result (voltage, current, speed, etc.) data transmission interface.

[0103] Model download and operation: Download the model to a high-speed simulator via Ethernet and run it.

[0104] Parameter setting: The parameters of the traction control unit under test corresponding to the control object (such as the capacitance of the intermediate support capacitor, the resistance, inductance, permanent magnet flux linkage, number of pole pairs, etc. of the permanent magnet synchronous motor) are transmitted to the model in the simulation machine through the host computer.

[0105] Fault injection: Run the entire fault diagnosis and test system and inject a two-phase short-circuit fault at any time through the host computer.

[0106] Fault diagnosis and processing: The traction control unit performs fault diagnosis and processing based on the inverter three-phase current data fed back by the simulation system. Figure 5 As shown: the traction inverter and motor operate normally, and the traction control unit does not detect any fault, then it sends out pulses normally, and the traction inverter is in normal operation. If the traction control unit detects a two-phase short-circuit fault, then it blocks the pulses, the traction inverter stops running, and the traction motor is in a two-phase short-circuit fault operation state. Then the traction control unit resets the fault, and uses a zero vector pulse to start the inverter, converting the traction motor to a three-phase short-circuit operation state.

[0107] Embodiment 2:

[0108] Figure 6The figure shows the module diagram of the inverter and permanent magnet synchronous motor model, which is mainly divided into the inverter main circuit model (i.e., the dq axis voltage and line voltage solution model), the normal operation and three-phase short-circuit current solution model, the B-phase and C-phase short-circuit fault current solution model, the current selection and flux torque solution model, and the 2r / 3s transformation and inverter current solution model.

[0109] In the figure, the green From module is the IGBT pulse signal received by the high-speed simulation board running the model from the traction control unit. The yellow From module is the parameter configuration signal and fault command signal given by the host computer and transferred to the main circuit and motor model through the main processor board. The blue and cyan Goto modules are the signals solved by the model and transferred to the host computer for observation through the main processor board. The signal of the cyan module is also output to the traction control unit through the hardware interface of the high-speed simulation card.

[0110] Embodiment 3:

[0111] Figure 7 The interface configuration model is shown in the figure. The From module and Goto module are Figure 6 Correspondingly, it includes the six-way inverter pulse interface configuration transmitted from the simulation machine hardware interface Digital In to the high-speed simulation board, the main circuit parameter and fault injection instruction interface configuration transmitted from the processor board register Register In to the high-speed simulation board, the data interface configuration for host computer observation transmitted from the high-speed simulation board register Register Out to the processor board, and the voltage and current data interface configuration transmitted from the high-speed simulation board hardware interface Digital Out to the traction control unit.

[0112] The serial numbers of the above-mentioned embodiments of the present invention are only for description and do not represent the advantages and disadvantages of the embodiments. In the above-mentioned embodiments of the present invention, the descriptions of each embodiment have their own emphasis. For the parts that are not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments. In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. Among them, the device embodiments described above are only schematic. For example, the division of the units can be a logical function division. There may be other division methods in actual implementation. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of units or modules, which can be electrical or other forms.

[0113] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple units. Some or all of the units may be selected according to actual needs to achieve the purpose of the present embodiment.

[0114] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0115] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions for 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 method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), mobile hard disk, magnetic disk or optical disk and other media that can store program codes.

[0116] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. Traction control unit fault diagnosis and processing test system, characterized in that: include: High-speed simulator, sensor simulation unit, photoelectric conversion unit, fault injection and signal observation unit and traction control unit; The high-speed simulator is used to run the inverter model, the normal and fault models of the permanent magnet synchronous motor; The sensor simulation unit is used to transfer the intermediate voltage, inverter current and speed signal output by the simulator to the signal acquisition board of the traction control unit; The photoelectric conversion unit is used to convert the pulse light signal emitted by the traction control unit into a pulse electrical signal required for turning on or off the inverter IGBT; The fault injection and signal observation unit injects faults at any time by simulating the host computer, and observes the results of the simulation model operation at the same time; The traction control unit is a hardware unit that performs operation control, fault diagnosis and processing control on the train traction inverter and traction motor; when the traction control unit changes, the model parameters in the high-speed simulator are changed accordingly through the host computer.

2. The traction control unit fault diagnosis and processing test system according to claim 1, characterized in that: The high-speed emulation machine comprises: a processor board DS1006 and a high-speed emulation board DS5203; The high-speed simulation board DS5203 realizes the operation of the inverter and permanent magnet synchronous motor models, receives pulse instructions from the traction control unit through the hardware interface of the board, and outputs the voltage, current, speed and other signals calculated in the model to the traction control unit; The processor board DS1006 realizes data interaction between the high-speed simulation board and the host computer, transfers the received fault injection instructions and configured parameters of the host computer to the main circuit model in the high-speed simulation board, and transfers the running results of the model in the high-speed simulation board to the host computer for display.

3. A method for using a traction control unit fault diagnosis and processing test system, using the system described in claims 1-2, characterized in that: The following steps are involved: Modeling of the interphase short-circuit process of permanent magnet synchronous motor; The interphase short circuit process of the permanent magnet synchronous motor includes: normal operation, two-phase short circuit and three-phase short circuit; After the model is built, it is downloaded to a high-speed simulator and connected to the traction control unit TCU through a photoelectric conversion unit and a sensor simulation unit to achieve real-time simulation. Faults are injected at any time by giving instructions from the host computer to test the algorithm for diagnosing and processing the interphase short-circuit fault of the permanent magnet synchronous motor.

4. The method for using the traction control unit fault diagnosis and processing test system according to claim 3, characterized in that: In the process of modeling the interphase short circuit of the permanent magnet synchronous motor, it is considered that the current sensor in the actual main circuit is outside the short-circuited winding, that is, it does not detect the current of the short-circuited phase of the motor, but detects the current of the corresponding inverter. Therefore, the modeling transmits the current of the inverter to the traction control unit through the sensor simulation unit.

5. The method for using the traction control unit fault diagnosis and processing test system according to claim 3, characterized in that: When operating normally, the process includes the following steps: Establishing a motor model during normal operation; the motor model during normal operation includes: a voltage equation, a flux equation, and a torque equation; The voltage equation is: The magnetic flux equation is: Among them, u d 、u q and u0 represent the three-phase voltage u output by the inverter through 3s / 2r transformation. a 、u b 、u c The corresponding d-axis, q-axis and zero-axis voltages when converted to the dq0 coordinate system; i d 、i q Respectively represent the motor d-axis current and q-axis current; R s Indicates the motor stator resistance; L d , L q They represent the motor d-axis inductance and q-axis inductance respectively; ψ f represents the permanent magnet flux; ω represents the motor angular velocity; ψ d , q They represent the motor d-axis flux and q-axis flux respectively; T e Indicates the motor torque; n p Indicates the number of motor rotor pole pairs; Establish inverter current and short-circuit current models during normal operation; Among them, i f Indicates the short-circuit current on the short-circuit resistor between the two phases BC, which is 0 in normal operation; i a_inv 、i b_inv 、i c_inv Respectively represent the three-phase current of the inverter; i a 、i b 、i c Respectively represent the three-phase current of the motor; in normal operation, the three-phase current of the inverter is equal to the corresponding three-phase current of the motor; Establish the inverter output three-phase voltage model during normal operation: Among them, u a 、u b 、u c Respectively represent the three-phase voltage output by the inverter; u dc It represents the voltage of the intermediate DC loop at the front end of the inverter; T1, T2, T3, T4, T5, and T6 represent the IGBT switch tubes of the upper and lower bridge arms of phase A, upper and lower bridge arms of phase B, and upper and lower bridge arms of phase C of the inverter respectively.

6. The method for using the traction control unit fault diagnosis and processing test system according to claim 3, characterized in that: When two phases are short-circuited, there are two cases: the model before the inverter blocks the pulse and the model after the inverter blocks the pulse. When the inverter has not yet blocked the pulse, due to the motor dq axis voltage u d 、u q The motor model is the same as that in normal operation, except that the inverter current and short-circuit current models are: Among them, R f It is the short-circuit resistance between the two phases when the two phases BC are short-circuited; When the inverter is blocked, two cases are modeled: ①When |u ab | dc When the voltage drop caused by the back electromotive force of the permanent magnet synchronous motor fails to exceed the intermediate DC circuit voltage, the A-phase winding is equivalent to an open circuit state, and the B-phase and C-phase windings are connected through the short-circuit resistor R f A loop is formed, and the motor voltage and current equations are as follows:​ Among them, u bc =R f i f , θ represents the motor rotor position angle, u ab 、u bc They are the line voltage between the AB phase and the line voltage between the BC phase of the motor respectively; At this time, the inverter current and short-circuit current model are: ②When |u ab |>=u sc When the voltage drop caused by the back electromotive force of the permanent magnet synchronous motor exceeds the voltage of the intermediate DC circuit, the motor winding reversely charges the intermediate DC circuit through the diode of the inverter. At this time, the motor model is consistent with the normal state, but u in the voltage equation is d 、u q , u0 is the line voltage u ab 、u bc Obtained by 3s / 2r transformation, where At this time, the inverter current and short-circuit current models are:

7. The method for using the traction control unit fault diagnosis and processing test system according to claim 3, characterized in that: When a two-phase short-circuit fault is detected, the traction control unit will send a zero vector pulse to the inverter to switch the permanent magnet synchronous motor into three-phase short-circuit operation; the three-phase short-circuit motor model, inverter current and short-circuit current model are consistent with normal operation, but the line voltage output by the inverter to the three-phase motor is different. At this time, u ab =u bc =0.

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