Commercial all-in-one motor controller performance test system

Abstract

The invention provides a commercial all-in-one motor controller performance test system. The system comprises a measurement and control subsystem, a simulation load and a main drive motor, an industrial personal computer in the measurement and control subsystem communicates with the simulation load, and the simulation load is used for simulating a mechanical load and an electromagnetic load of the main drive motor under a real working condition according to a first control instruction sent by the industrial personal computer and providing a required load environment for the main drive motor; a programmable bidirectional analog electronic load in the analog load is connected with a DCDC converter of the tested all-in-one motor controller, and a power conversion circuit in the programmable bidirectional analog electronic load is used for converting electric energy output by the DCDC converter into different forms of energy for consumption in the test process. And when the electric energy in the energy storage unit reaches a preset threshold value, the electric energy is fed back to the commercial all-in-one motor controller performance test system. According to the scheme, the problem that an existing commercial all-in-one motor controller test system is low in energy utilization efficiency is solved.

Description

Technical Field

[0001] This application relates to automotive electronics and automated testing technologies, and more particularly, to a performance testing system for commercial multi-in-one motor controllers. Background Art

[0002] With the acceleration of the electrification trend, multi-in-one motor controllers have become key electrified components due to their integration of multiple functional modules (such as main drive motor control, air pump control, oil pump control, DCDC conversion, power distribution control, etc.). Before mass production, these controllers must undergo strict functional and performance tests to ensure their stability and reliability in complex operating environments. Most traditional testing systems are designed based on laboratory environments and are mainly used for small-batch or R & D stage testing. These systems usually have basic functions such as motor simulation, temperature detection, voltage and current measurement.

[0003] When existing commercial multi-in-one motor controller testing systems perform performance tests on motor controllers, such as overload tests and peak current cycle tests, a large amount of energy loss often occurs. This part of the energy is usually dissipated in the form of heat and cannot be effectively utilized or recycled, resulting in energy waste. And during the testing process, especially when simulating the output of the motor controller under different working conditions, traditional testing equipment such as fixed-resistance electronic loads and fixed-current electronic loads can only passively consume energy and cannot feed this part of the energy back to the power grid or be used for the power supply of other devices. This energy consumption mode not only increases the testing cost but also has an unnecessary negative impact on the environment.

[0004] In summary, with the continuous improvement of the performance and quality requirements for electric commercial vehicles and the increasing attention to energy conservation and emission reduction, the existing commercial multi-in-one motor controller performance testing systems cannot meet the demand for energy feedback, thereby restricting the energy utilization efficiency of the testing systems. Summary of the Invention

[0005] The main objective of this application is to provide a performance testing system for commercial multi-in-one motor controllers to at least solve the problem of low energy utilization efficiency of the existing commercial multi-in-one motor controller testing systems.

[0006] To achieve the above object, according to one aspect of the present application, there is provided a performance test system for a commercial all-in-one motor controller, including a measurement and control subsystem, a simulated load, and a main drive motor. The measurement and control subsystem includes an industrial computer. The simulated load includes a programmable bidirectional analog electronic load, and the programmable bidirectional analog electronic load includes a power conversion circuit, an energy storage unit, and a control circuit. Among them, the industrial computer communicates with the simulated load, and the simulated load is used to simulate the mechanical load and electromagnetic load of the main drive motor under real working conditions according to the first control instruction issued by the industrial computer, and provide the required load environment for the main drive motor. The programmable bidirectional analog electronic load is connected to the DCDC converter of the multi-functional motor controller under test. The power conversion circuit is used to convert the electric energy output by the DCDC converter into different forms of energy for consumption during the test, and feedback the electric energy to the performance test system of the commercial all-in-one motor controller when the electric energy in the energy storage unit reaches a preset threshold. The control circuit is used to control the working state of the power conversion circuit.

[0007] Optionally, the simulated load further includes a distributed electric field sensor, and the distributed electric field sensor is deployed on the housing of the multi-functional motor controller under test for real-time monitoring of the insulation performance of the insulating material in the multi-functional motor controller under test.

[0008] Optionally, the performance test system for the commercial all-in-one motor controller further includes a dynamometer subsystem, and the dynamometer subsystem includes a companion motor and a companion motor controller. The companion motor controller is electrically connected to the companion motor and is used to control the speed and torque of the companion motor. The companion motor is used to simulate the torque load and speed load of the main drive motor under actual operating conditions.

[0009] Optionally, the dynamometer subsystem further includes a torsional sensor, a first coupling, and a second coupling. Among them, the input shaft end of the torsional sensor is connected to the main drive motor through the first coupling, and the output shaft end of the torsional sensor is connected to the companion motor through the second coupling, and is used to measure the torque output by the main drive motor and the torque borne by the companion motor, as well as the torsional angle of the shaft between the main drive motor and the companion motor.

[0010] Optionally, the dynamometer subsystem communicates with the industrial computer. The dynamometer subsystem transmits the measured data to the industrial computer for analysis, and the industrial computer issues a second control instruction to the dynamometer subsystem to control the dynamometer subsystem.

[0011] Optionally, the tested all-in-one motor controller also includes an oil pump controller and an air pump controller, and the simulated load also includes a first asynchronous motor, a second asynchronous motor, a first excitation motor and a second excitation motor, wherein the power output shaft of the first asynchronous motor is connected to the oil pump controller, the terminal of the rotor winding of the first asynchronous motor is connected to the first excitation motor, the power output shaft of the second asynchronous motor is connected to the air pump controller, and the terminal of the rotor winding of the second asynchronous motor is connected to the second excitation motor.

[0012] Optionally, the industrial computer is installed with host computer software, which is used to write test sequence program files suitable for different tested machine models. The industrial computer communicates with the tested all-in-one motor controller through a CAN bus, and is used to receive and parse at least one of the following parameters of the tested all-in-one motor controller: temperature parameters, bus voltage parameters, motor speed parameters, three-phase voltage and current parameters, main drive output current parameters, and DCDC converter parameters.

[0013] Optionally, the commercial all-in-one motor controller performance testing system also includes a bidirectional high-voltage DC power supply, wherein the AC input terminal of the bidirectional high-voltage DC power supply is connected to the input terminal of the AC power supply for converting the AC power supply into high-voltage DC power, and the DC output terminal of the bidirectional high-voltage DC power supply is connected to the all-in-one motor controller under test for providing DC power to the all-in-one motor controller under test.

[0014] Optionally, the commercial all-in-one motor controller performance testing system further includes a water cooling subsystem, which is connected to the all-in-one motor controller under test and is used to control the temperature of the all-in-one motor controller under test within a preset range during the test.

[0015] Optionally, the measurement and control subsystem also includes a power analyzer and a multimeter, the power analyzer is used to measure relevant power parameters of electrical equipment in the commercial all-in-one motor controller performance test system, and the multimeter is used to measure relevant electrical parameters of the electrical equipment, wherein the power analyzer and the multimeter are respectively connected to the industrial computer, and the industrial computer is used to send a third control instruction to the power analyzer and the multimeter to control the measurement of the power analyzer and the multimeter, and the power analyzer and the multimeter are used to transmit the measured relevant power parameters and the relevant electrical parameters to the industrial computer for analysis.

[0016] Applying the technical solution of the present application, a performance test system for a commercial multi-in-one motor controller includes a measurement and control subsystem, a simulated load, and a main drive motor. The measurement and control subsystem includes an industrial computer, and the simulated load includes a programmable bidirectional analog electronic load. The programmable bidirectional analog electronic load includes a power conversion circuit, an energy storage unit, and a control circuit. Among them, the industrial computer communicates with the simulated load, and the simulated load is used to simulate the mechanical load and electromagnetic load of the main drive motor under real working conditions according to the first control instruction issued by the industrial computer, and provide the required load environment for the main drive motor. The programmable bidirectional analog electronic load is connected to the DCDC converter of the multi-in-one motor controller under test. The power conversion circuit is used to convert the electric energy output by the DCDC converter into different forms of energy for consumption during the test, and feedback the electric energy to the performance test system of the commercial multi-in-one motor controller when the electric energy in the energy storage unit reaches a preset threshold. The control circuit is used to control the working state of the power conversion circuit. In this solution, by introducing a programmable bidirectional analog electronic load into the multi-in-one motor controller test, the energy output by the DCDC converter is absorbed and converted, and the stored energy is fed back to the performance test system of the commercial multi-in-one motor controller. The programmable bidirectional analog electronic load supports bidirectional energy flow, can absorb the energy of the DCDC converter as a load, and can also feed back the energy to the performance test system when needed, realizing the recycling of energy, improving the energy utilization efficiency, and thus solving the problem of low energy utilization efficiency of the existing commercial multi-in-one motor controller test system. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings forming a part of this application are used to provide a further understanding of this application. The schematic embodiments of this application and their descriptions are used to explain this application and do not constitute an improper limitation to this application. In the drawings:

[0018] Figure 1 shows a schematic structural diagram of a performance test system for a commercial multi-in-one motor controller provided in an embodiment of the present application;

[0019] Figure 2 shows a structural diagram of a specific performance test system for a commercial multi-in-one motor controller provided in an embodiment of the present application.

[0020] Among them, the above-mentioned accompanying drawings include the following reference numerals:

[0021] 01, performance test system for commercial multi-in-one motor controller; 10, measurement and control subsystem; 20, simulated load; 30, main drive motor; 110, industrial computer; 210, programmable bidirectional analog electronic load; 2110, power conversion circuit; 2111, energy storage unit; 2112, control circuit; 02, multi-in-one motor controller under test; 021, DCDC converter. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] It should be noted that, without conflict, the embodiments in this application and the features in the embodiments may be combined with each other. The following will detail this application with reference to the accompanying drawings and in combination with the embodiments.

[0023] To enable those skilled in the art to better understand the solution of this application, the following will clearly and completely describe the technical solutions in the embodiments of this application with reference to the accompanying drawings in the embodiments of this application. Obviously, the described embodiments are only a part rather than all of the embodiments of this application. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of this application.

[0024] It should be noted that the terms "first", "second", etc. in the specification and claims of this application and the above-mentioned drawings are used to distinguish similar objects and do not necessarily need to be used to describe a specific order or sequence. It should be understood that such used data may be interchanged under appropriate circumstances so as to implement the embodiments of this application described herein. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units does not necessarily limit to those clearly listed steps or units, but may include other steps or units not clearly listed or inherent to these process, method, product or device.

[0025] As introduced in the background art, the test system in the prior art can only passively consume energy and cannot feed back this part of energy to the power grid or use it for power supply of other devices, thus unable to meet the demand for energy feedback, and further limiting the energy utilization efficiency of the test system. To solve the problem of low energy utilization efficiency of the commercial multi-in-one motor controller test system in the prior art, the embodiments of this application provide a commercial multi-in-one motor controller performance test system.

[0026] The following will clearly and completely describe the technical solutions in the embodiments of this invention with reference to the accompanying drawings in the embodiments of this invention.

[0027] Figure 1 is a schematic structural diagram of a commercial multi-in-one motor controller performance test system according to the embodiments of this application. As Figure 1As shown in the figure, the commercial all-in-one motor controller performance test system 01 includes a measurement and control subsystem 10, a simulated load 20, and a main drive motor 30. The measurement and control subsystem 10 includes an industrial control computer 110. The simulated load 20 includes a programmable bidirectional analog electronic load 210. The programmable bidirectional analog electronic load 210 includes a power conversion circuit 2110, an energy storage unit 2111, and a control circuit 2112. Among them, the industrial control computer 110 communicates with the simulated load 20. The simulated load 20 is used to simulate the mechanical load and electromagnetic load of the main drive motor 30 under real working conditions according to the first control instruction issued by the industrial control computer 110, and provide the required load environment for the main drive motor 30. The programmable bidirectional analog electronic load 210 is connected to the DCDC converter 021 of the multi-functional motor controller 02 to be measured. The power conversion circuit 2110 is used to convert the electric energy output by the DCDC converter 021 into different forms of energy for consumption during the test, and feedback the electric energy to the commercial all-in-one motor controller performance test system 01 when the electric energy in the energy storage unit 2111 reaches a preset threshold. The control circuit 2112 is used to control the working state of the power conversion circuit.

[0028] Specifically, the commercial multi-in-one motor controller performance test system provided in this embodiment (hereinafter referred to as the test system) includes a measurement and control subsystem, a simulated load, and a main drive motor. The measurement and control subsystem includes an industrial computer, which plays a role of control and monitoring in the system, responsible for issuing instructions and collecting and processing data. The industrial computer communicates with the simulated load and sends a first control instruction to the simulated load. The simulated load, based on this first control instruction, simulates the mechanical load (such as friction, resistance, etc.) and electromagnetic load (such as back electromotive force, etc.) that the main drive motor would encounter in the actual working scenario, providing a near-real load environment for the main drive motor to accurately test. The simulated load includes a programmable bidirectional analog electronic load, which includes a power conversion circuit, an energy storage unit, and a control circuit. Among them, the power conversion circuit converts the input electrical energy (the electrical energy from the DCDC converter of the multi-in-one motor controller under test) into other forms of energy according to the test requirements, such as heat energy, etc., and consumes it. And when the electrical energy in the energy storage unit is sufficient (reaching the preset threshold), it feeds the electrical energy back into the test system to achieve the bidirectional flow of electrical energy. The energy storage unit is used to temporarily store electrical energy. During the test process, when there is excess electrical energy generated, it stores it. When the stored electrical energy reaches the preset threshold, it cooperates with the power conversion circuit to feed the electrical energy back to the test system to achieve the recycling of energy. The control circuit plays a regulatory role, precisely controlling the working state of the power conversion circuit, determining when to perform electrical energy conversion, the conversion method, and the timing of energy feedback, etc., to ensure that the entire programmable bidirectional analog electronic load operates stably according to the predetermined program and test requirements. On the one hand, by receiving the instructions from the industrial computer, the programmable bidirectional analog electronic load can flexibly simulate various load characteristics, and can simulate different types of static load characteristics such as resistive, inductive, capacitive, etc., and can also simulate the dynamic characteristics of the load changing with time in the actual working conditions, such as sudden changes and gradual changes of the load. On the other hand, the programmable bidirectional analog electronic load can not only absorb electrical energy to simulate the energy consumption of the load, but also feed the stored electrical energy back into the test system under specific conditions.

[0029] By introducing the programmable bidirectional analog electronic load into the multi-in-one motor controller test, the power conversion circuit of the programmable bidirectional analog electronic load converts the electrical energy output by the DCDC converter into an energy form that can be consumed in the test, and stores the electrical energy in the energy storage unit, and feeds back the electrical energy when the electrical energy reaches the preset threshold, achieving the bidirectional flow and reasonable utilization of energy, avoiding the unnecessary waste of electrical energy, reducing the test cost, realizing the recycling of energy, and improving the energy utilization efficiency.

[0030] It should be noted that the industrial computer communicates with the above-mentioned simulated load, that is, the industrial computer establishes a communication connection with each device in the simulated load, that is, the industrial computer communicates with the programmable bidirectional simulated electronic load in the simulated load. The subsequent content explains that the simulated load also includes a distributed electric field sensor, a first asynchronous motor, a second asynchronous motor, a first excitation motor and a second excitation motor, which means that the industrial computer also establishes a communication relationship with the distributed electric field sensor, the first asynchronous motor, the second asynchronous motor, the first excitation motor and the second excitation motor in the simulated load.

[0031] Furthermore, the simulated load also includes a distributed electric field sensor, which is deployed and installed on the housing of the all-in-one motor controller under test and is used to monitor the insulation performance of the insulating material in the all-in-one motor controller under test in real time.

[0032] Specifically, a distributed electric field sensor is a device that can sense the distribution of the electric field and obtain relevant information by detecting changes in the intensity and distribution of the electric field. The distributed electric field sensor is deployed and installed on the shell of the multi-in-one motor controller under test. This installation method facilitates direct perception of the electric field conditions near the shell of the multi-in-one motor controller under test, because the electrical conditions inside the multi-in-one motor controller under test will be reflected to a certain extent in the electric field distribution around the shell. The main function of the distributed electric field sensor is to monitor the insulation performance of the insulating material in the multi-in-one motor controller under test in real time. During the operation of the multi-in-one motor controller under test, the insulation performance of the insulating material is crucial. If the insulating material is aged or damaged, the electric field distribution will change abnormally. The distributed electric field sensor continuously monitors the electric field distribution around the shell, and once the local electric field distortion exceeds the threshold, the withstand voltage test is triggered. Specifically, when the multi-in-one motor controller under test is running, when the insulating material is damaged (such as aging, moisture, tiny cracks, etc.), the electric field distribution will change, and the originally uniform electric field will have irregular changes in intensity and direction in the local area, which is the local electric field distortion. In order to determine whether the local electric field distortion has reached a dangerous level, a threshold is pre-set, which is determined based on the insulation design requirements of the all-in-one motor controller under test, the operating environment and other factors. When the degree of local electric field distortion (such as the proportion of electric field strength exceeding the normal range, the angle of deviation of the electric field direction and other indicators) monitored by the distributed electric field sensor exceeds the threshold, it means that the condition of the insulation material has reached a level that may cause electrical failure (such as breakdown of the insulation layer causing a short circuit).

[0033] Once the local electric field distortion exceeds the threshold, the withstand voltage test is triggered. The purpose of the withstand voltage test is to apply a test voltage higher than the normal operating voltage to the all-in-one motor controller under test for a period of time to detect the insulation performance of the device under high voltage. Through the withstand voltage test, it can be further confirmed whether the insulating material can still withstand the normal operating voltage and the impact of higher voltages, and whether there are potential insulation problems in the all-in-one motor controller under test, so as to take maintenance, repair or replacement measures in time to prevent the all-in-one motor controller under test from being damaged due to insulation problems during operation, and ensure the safe and reliable operation of the entire test system.

[0034] The distributed electric field sensor does not need to make physical contact with the internal electrical components of the all-in-one motor controller under test. It can sense the internal electric field conditions by simply installing it on the outer casing. On the one hand, it avoids physical damage to the all-in-one motor controller under test due to contact. On the other hand, it also prevents the introduction of additional impurities and changes in the original electric field distribution due to contact. In addition, the distributed electric field sensor can reflect the insulation status of the all-in-one motor controller under test in real time. For example, when simulating high-load conditions, if the insulation material performance degrades due to factors such as heat, the distributed electric field sensor can quickly detect the electric field distortion and issue an early warning. Moreover, there is no need to perform insulation testing separately after the test is completed, which reduces the testing process and time cost, and facilitates a quick and comprehensive evaluation of the performance and insulation status of the all-in-one motor controller under test.

[0035] In some embodiments, the above-mentioned commercial all-in-one motor controller performance testing system also includes a dynamometer subsystem, the above-mentioned dynamometer subsystem includes a companion test motor and a companion test motor controller, the above-mentioned companion test motor controller is electrically connected to the above-mentioned companion test motor, and is used to control the speed and torque of the above-mentioned companion test motor, and the above-mentioned companion test motor is used to simulate the torque load and speed load of the above-mentioned main drive motor under actual operating conditions.

[0036] Specifically, the function of the accompanying motor is to simulate the torque load and speed load that the main drive motor will encounter during actual operation. In actual working conditions, the torque and speed of the main drive motor will change with the working conditions. The accompanying motor simulates the torque load and speed load of the main drive motor under different working conditions by adjusting its own speed and torque. For example, when the main drive motor is in different stages such as starting, accelerating, and climbing slopes, the accompanying motor can be adjusted accordingly to provide a load environment close to the real one for the test. More specifically, the accompanying motor can simulate the torque load borne by the main drive motor under different working conditions by controlling the output torque. For example, when the main drive motor is in the accelerating or climbing state and needs to output a large torque, the accompanying motor can simulate this torque demand to test the performance of the main drive motor when outputting a high torque. In addition, the accompanying motor can run at different speeds according to the test requirements, so as to simulate the load conditions of the main drive motor under various speed working conditions. For example, when the main drive motor is in the high-speed and low-speed states, the speeds of the main drive motor are different. The accompanying motor can adjust its speed to simulate the working state of the main drive motor at different speeds, so as to test indicators such as the speed control accuracy and efficiency of the main drive motor.

[0037] The accompanying motor controller can accurately control the speed and torque of the accompanying motor. Through this control, the accompanying motor can highly simulate the torque load and speed load faced by the main drive motor during actual operation, making the test environment closer to the real working state, so as to obtain more accurate and valuable test results and improve the reference value of the test results for actual applications.

[0038] In some embodiments of the present application, the above-mentioned dynamometer subsystem further includes a torsion sensor, a first coupling and a second coupling. Among them, the input shaft end of the above-mentioned torsion sensor is connected to the above-mentioned main drive motor through the above-mentioned first coupling, and the output shaft end of the above-mentioned torsion sensor is connected to the above-mentioned accompanying motor through the above-mentioned second coupling, and is used to measure the torque output by the above-mentioned main drive motor and the torque borne by the above-mentioned accompanying motor, as well as the torsional angle of the shaft between the above-mentioned main drive motor and the above-mentioned accompanying motor.

[0039] The input shaft end of the torsion sensor is connected to the main drive motor through the first coupling, and the output shaft end is connected to the accompanying motor through the second coupling. This connection method makes the main drive motor, the torsion sensor and the accompanying motor form a coherent transmission system. Through the above connection method, the torsion sensor can measure the torque output by the main drive motor to obtain the power output situation of the main drive motor under different working conditions. At the same time, the torsion sensor measures the torque borne by the accompanying motor to reflect the actual force condition of the simulated load of the accompanying motor. In addition, the torsion sensor also measures the torsional angle of the shaft between the main drive motor and the accompanying motor, which is used to evaluate the elastic deformation, transmission accuracy, etc. of the transmission system, facilitate the optimization of the system design, and prevent failures.

[0040] In some specific embodiments, the dynamometer subsystem communicates with the industrial computer, the dynamometer subsystem transmits the measured data to the industrial computer for analysis, and the industrial computer sends a second control instruction to the dynamometer subsystem to control the dynamometer subsystem.

[0041] The dynamometer subsystem establishes a communication connection with the industrial computer. The dynamometer subsystem is responsible for the measurement task and transmits various types of data (such as torque, speed and other motor performance related data) to the industrial computer. The industrial computer has data processing capabilities and can parse the received data. The industrial computer generates a second control instruction based on the data analysis results, and then sends the second control instruction to the dynamometer subsystem to control the dynamometer subsystem and adjust its working state to ensure that the entire test system operates according to the predetermined requirements, so as to complete the effective test of the commercial all-in-one motor controller performance test system.

[0042] The dynamometer subsystem transmits the measurement data to the industrial computer for analysis. By using the powerful data processing capabilities of the industrial computer, it can accurately and efficiently analyze a large amount of complex motor performance data, quickly and accurately obtain motor performance indicators and operating status information, and provide a reliable basis for subsequent evaluation and decision-making. The industrial computer sends the second control instruction to the dynamometer subsystem based on the analysis results, and builds a closed-loop control system for measurement, analysis, and control. It can adjust the working parameters of the dynamometer subsystem in real time according to the motor operating status, so that the test system is always in the best operating state, ensuring test accuracy and stability, and improving test efficiency and quality.

[0043] In other embodiments, the multi-in-one motor controller under test also includes an oil pump controller and an air pump controller, and the simulated load also includes a first asynchronous motor, a second asynchronous motor, a first excitation motor and a second excitation motor, wherein the power output shaft of the first asynchronous motor is connected to the oil pump controller, the terminal of the rotor winding of the first asynchronous motor is connected to the first excitation motor, the power output shaft of the second asynchronous motor is connected to the air pump controller, and the terminal of the rotor winding of the second asynchronous motor is connected to the second excitation motor.

[0044] The multi - function motor controller under test includes an oil pump controller and an air pump controller. That is, this multi - function motor controller not only controls the functions of a conventional motor, but also controls auxiliary devices such as oil pumps and air pumps, reflecting its "multi - function integration" characteristic. The simulated load also includes a first asynchronous motor, a second asynchronous motor, a first excitation motor, and a second excitation motor. Asynchronous motors are commonly used in situations where high starting torque is required and the speed regulation performance requirements are not high. The excitation motor can change the magnetic field strength by adjusting the excitation current, thereby affecting the motor performance. The power output shaft of the first asynchronous motor is connected to the oil pump controller, which can transmit power to the oil pump to achieve the operation control of the oil pump; the terminal of its rotor winding is connected to the first excitation motor, and the magnetic field of the first asynchronous motor is adjusted through the first excitation motor, thereby adjusting the operating parameters such as the speed and torque of the motor to simulate the load conditions of the oil pump under different working conditions. The power output shaft of the second asynchronous motor is connected to the air pump controller to provide power for the operation of the air pump; the terminal of its rotor winding is connected to the second excitation motor. Similarly, the magnetic field of the second asynchronous motor can be adjusted through the second excitation motor to simulate the load characteristics of the air pump under different working conditions to test the control performance of the multi - function motor controller under test for the air pump.

[0045] By connecting the first asynchronous motor and the second asynchronous motor to the oil pump controller and the air pump controller respectively, and cooperating with the first excitation motor and the second excitation motor to adjust the magnetic field, it is possible to accurately simulate the complex and diverse load conditions of the oil pump and the air pump during actual operation. During the test process of the multi - function motor controller under test, it faces load changes close to the real working scenario, effectively evaluating its control performance for the oil pump and the air pump under different loads. Through the control of the oil pump and the air pump and the corresponding load simulation, the test dimensions of the multi - function motor controller under test are increased. It is no longer limited to the test of the control performance of a conventional motor, but can also test its performance in controlling specific auxiliary devices (oil pump, air pump), comprehensively evaluating the comprehensive control ability of the multi - function motor controller and improving the integrity and effectiveness of the test.

[0046] In some embodiments, the above - mentioned industrial control computer is installed with upper - computer software. The above - mentioned upper - computer software is used to write test sequence program files suitable for different models under test. The above - mentioned industrial control computer communicates with the above - mentioned multi - function motor controller under test through a CAN bus and is used to receive and analyze at least one of the following parameters of the above - mentioned multi - function motor controller under test: temperature parameter, bus voltage parameter, motor speed parameter, three - phase voltage and current parameters, main drive output current parameter, DCDC converter parameter.

[0047] Specifically, the host computer software installed in the industrial computer can write test sequence program files suitable for different models of tested machines. In other words, it can customize special test processes and plans for different models of all-in-one motor controllers to meet diverse test needs and improve the pertinence and effectiveness of the test. The industrial computer communicates with the all-in-one motor controller under test through the CAN bus. The CAN bus is a field bus with the advantages of high communication rate, strong reliability, and good real-time performance. It is suitable for data transmission between equipment in the field of industrial control. The industrial computer uses the CAN bus to receive and parse various parameters of the all-in-one motor controller under test, including temperature parameters, bus voltage parameters, motor speed parameters, three-phase voltage and current parameters, main drive output current parameters, DCDC converter parameters, etc. By obtaining these parameters, the operating status and performance of the all-in-one motor controller under test can be fully understood, providing data support for evaluating its performance and diagnosing potential faults.

[0048] Through the above design, the host computer software can write test sequence program files suitable for different models of tested machines, so that the test system can flexibly respond to the test requirements of various models of all-in-one motor controllers. There is no need to develop a separate test system for each model, which improves the versatility and reusability of the test system and reduces development costs and time costs. The CAN bus is used for communication between the industrial computer and the all-in-one motor controller under test. The high reliability, high speed and strong anti-interference ability of the CAN bus are used to ensure efficient and stable data transmission, and ensure that various parameters can be accurately and timely transmitted to the industrial computer during the test. The industrial computer can receive and analyze various parameters such as temperature, bus voltage, motor speed, etc., and fully cover the key operating indicators of the all-in-one motor controller under test, providing rich and accurate data support for in-depth evaluation of the performance of the all-in-one motor controller under test, monitoring the operating status, and diagnosing potential faults, thereby improving the accuracy and completeness of the test system's evaluation of the motor controller's performance.

[0049] In some embodiments of the present application, the above-mentioned commercial all-in-one motor controller performance testing system also includes a bidirectional high-voltage DC power supply, the AC input end of the above-mentioned bidirectional high-voltage DC power supply is connected to the input end of the AC power, and is used to convert the above-mentioned AC power into high-voltage DC power, and the DC output end of the above-mentioned bidirectional high-voltage DC power supply is connected to the above-mentioned all-in-one motor controller under test, and is used to provide DC power for the above-mentioned all-in-one motor controller under test.

[0050] The AC input of the bidirectional high-voltage DC power supply is connected to the input of the mains power, and can convert the input mains power (usually AC power) into high-voltage DC power. The converted high-voltage DC power is connected to the all-in-one motor controller under test through the DC output terminal to provide it with the DC power required for operation. The bidirectional high-voltage DC power supply can convert the mains power into stable high-voltage DC power, providing a stable and suitable DC power supply for the all-in-one motor controller under test, ensuring that the motor controller can operate stably during the test process and avoiding the accuracy of the test results affected by unstable power supply. It meets the needs of the all-in-one motor controller for DC power supply, enables the test system to simulate the power supply environment in its actual work, ensures that the test conditions are close to the real application scenarios, and improves the reference value of the test results for actual applications.

[0051] In some embodiments, the commercial all-in-one motor controller performance testing system further includes a water cooling subsystem, which is connected to the all-in-one motor controller under test and is used to control the temperature of the all-in-one motor controller under test within a preset range during the test.

[0052] The water cooling subsystem is connected to the multi-in-one motor controller under test. During the test, the multi-in-one motor controller under test will generate heat during operation. The role of the water cooling subsystem is to remove the heat through heat exchange and other means, and control the temperature of the multi-in-one motor controller under test within a preset range to ensure that it operates under appropriate temperature conditions. The setting of the water cooling subsystem avoids the multi-in-one motor controller under test from overheating due to long-term operation during the test. Excessive temperature may cause the performance of the motor controller to decline, the aging of electronic components to accelerate, or even damage it. The water cooling subsystem maintains a suitable temperature to ensure its stable operation, so that the test can proceed smoothly. In addition, temperature has a significant impact on the performance of the multi-in-one motor controller under test. Controlling the temperature within a preset range can eliminate the interference of temperature factors on the test results, ensure that the test data can truly reflect the performance of the multi-in-one motor controller under test, and improve the accuracy and reliability of the test results. In addition, the appropriate operating temperature can reduce the loss of internal components of the motor controller due to thermal stress, reduce the probability of failure, and extend its service life. In the long run, it helps to improve the overall efficiency and economy of the equipment.

[0053] In some embodiments, the measurement and control subsystem also includes a power analyzer and a multimeter. The power analyzer is used to measure relevant power parameters of electrical equipment in the commercial all-in-one motor controller performance test system, and the multimeter is used to measure relevant electrical parameters of the electrical equipment. The power analyzer and the multimeter are respectively connected to the industrial computer, and the industrial computer is used to send a third control instruction to the power analyzer and the multimeter to control the measurement of the power analyzer and the multimeter. The power analyzer and the multimeter are used to transmit the measured relevant power parameters and the relevant electrical parameters to the industrial computer for analysis.

[0054] Specifically, the power analyzer is responsible for measuring the relevant power parameters of the electrical equipment in the test system, such as active power, reactive power, etc.; the multimeter is used to measure the relevant electrical parameters of the electrical equipment, such as voltage, current, resistance, etc. The power analyzer and the multimeter are both connected to the industrial computer, which issues third control instructions to the power analyzer and the multimeter to control the measurement process, such as setting measurement parameters, starting or stopping measurement, etc. The power analyzer and the multimeter transmit the measured relevant power parameters and relevant electrical parameters to the industrial computer, which is then analyzed and processed by the industrial computer. The power analyzer and the multimeter have professional measurement capabilities and can accurately obtain the power and electrical parameters of electrical equipment, providing accurate data support for the comprehensive evaluation of the performance of commercial all-in-one motor controllers. The power analyzer and the multimeter are controlled by the industrial computer to realize the automation of the measurement process. The measurement instructions can be flexibly set according to the test requirements to improve the measurement efficiency and reduce manual operation errors. The measured data is transmitted to the industrial computer for analysis, which facilitates the integration and analysis of different types of parameters. This enables a more systematic and in-depth understanding of the operating status and performance of the all-in-one motor controller and related electrical equipment under test, providing a basis for optimized design and fault diagnosis.

[0055] In order to enable those skilled in the art to more clearly understand the technical solution of the present application, the implementation process of the commercial all-in-one motor controller performance testing system of the present application will be described in detail below in combination with specific embodiments.

[0056] This embodiment relates to a specific commercial all-in-one motor controller performance test system, such as Figure 2 As shown, it includes a measurement and control subsystem, a simulated load, a main drive motor, a dynamometer subsystem, a bidirectional high-voltage DC power supply and a water cooling subsystem. The measurement and control subsystem includes an industrial computer, a power analyzer and a multimeter. The simulated load includes a programmable bidirectional simulated electronic load, a distributed electric field sensor, a first asynchronous motor, a second asynchronous motor, a first excitation motor and a second excitation motor. The dynamometer subsystem includes a companion motor, a companion motor controller, a torsion sensor, a first coupling and a second coupling.

[0057] Specifically, the power supply of the entire test system is a bidirectional high-voltage DC power supply. The AC input of the bidirectional high-voltage DC power supply is connected to the mains power, which converts the mains power into high-voltage DC power. The DC output is connected to the multi-in-one motor controller under test to provide it with a stable DC power supply to ensure stable power supply during the test. The industrial computer of the measurement and control subsystem is the core control unit, which has communication interfaces such as RS232, RS485, and CAN. It communicates with the multi-in-one motor controller under test through the CAN bus, receives and analyzes temperature parameters, bus voltage parameters, motor speed parameters, three-phase voltage and current parameters, main drive output current parameters, DCDC converter and other parameters. The power analyzer is connected to the industrial computer and is used to measure the relevant power parameters of the electrical equipment in the test system, such as power, power factor, etc., to provide data for evaluating the energy consumption and efficiency of the equipment; the multimeter is also connected to the industrial computer and is responsible for measuring the relevant electrical parameters of the electrical equipment, such as voltage, current, resistance, etc., to assist in a comprehensive understanding of the electrical characteristics of the equipment.

[0058] This embodiment can introduce adaptive test parameter optimization, and can automatically adjust the test conditions, such as the peak value of the output current, the set value of the programmable bidirectional analog electronic load, etc., according to the model, specifications and known performance parameters of the tested all-in-one motor controller, so as to achieve the best test effect. By reducing unnecessary test steps and optimizing the test sequence, the test time can be significantly shortened. The adaptive test parameter optimization is based on a preset algorithm, which comprehensively considers the type of the tested all-in-one motor controller, the expected use environment, historical test data, etc., and stores all test parameters and results, as well as the characteristics of different tested all-in-one motor controller models through a built-in database. The preset algorithm dynamically adjusts the test parameters based on this information. For example, when it is detected that a certain model of all-in-one motor controller is prone to failure under specific conditions, the number of tests for the condition can be automatically increased and the test parameters can be refined.

[0059] The main drive motor is installed on the test bench and is the power output source. The main drive motor is connected to the main controller of the multi-in-one motor controller under test. The main controller can accurately control the operating state of the main drive motor, including parameters such as speed and torque, according to actual needs, such as acceleration, deceleration, and steering. At the same time, the main controller can monitor the working state of the main drive motor in real time, such as current, voltage, temperature and other information. The torsion sensor in the dynamometer subsystem is connected to the main drive motor and the accompanying test motor through the first coupling and the second coupling respectively, and measures the output torque of the main drive motor, the torque borne by the accompanying test motor, and the torsion angle of the shaft between the two motors to reflect the power transmission situation. The accompanying test motor cooperates with the main drive motor to simulate the actual load condition. The dynamometer subsystem communicates with the measurement and control subsystem through RS485. The dynamometer subsystem is responsible for the measurement task and transmits the various data obtained (such as torque, speed and other motor performance related data) to the industrial computer. The industrial computer has data processing capabilities and can parse the received data. The industrial computer generates a control instruction (i.e., a second control instruction) based on the data analysis results, and then sends the control instruction to the dynamometer subsystem to control the dynamometer subsystem and adjust its working state to ensure that the entire test system operates according to predetermined requirements, so as to complete the effective test of the commercial all-in-one motor controller performance test system.

[0060] The two groups of asynchronous motors (the first asynchronous motor and the second asynchronous motor) in the simulated load are respectively connected to the oil pump controller and the air pump controller of the multi-in-one motor controller under test, and the corresponding excitation motors (the first excitation motor and the second excitation motor) adjust the magnetic field to simulate the oil pump and air pump load conditions, and test the control performance of the multi-in-one motor controller under test on different devices. The two groups of asynchronous motors and the corresponding excitation motors communicate with the industrial computer through RS232. The industrial computer, as the control core, can perform unified start, stop, speed setting and other control operations on the two groups of asynchronous motors and the excitation motors through RS232 communication, and monitor the running status of the motors in real time, such as speed, current, voltage and other parameters. The industrial computer can accurately send control instructions to the two groups of asynchronous motors and the corresponding excitation motors according to actual requirements, so that the two groups of asynchronous motors and the corresponding excitation motors can operate according to the set parameters to ensure the stability and accuracy of the system.

[0061] The power distribution controller in the multi-in-one motor controller under test interacts with external devices through the I / O interface for simple digital or analog signal interaction. The CAN bus is used for high-speed and reliable serial communication between the power distribution controller and other devices (such as industrial computers, etc.). The power distribution controller can send its own operating parameters (such as voltage, current, power, etc.) and fault information to other devices through the CAN bus, and receive control instructions, configuration parameters, etc. from other devices at the same time, so as to realize information sharing and collaborative control between the power distribution system and the entire test system. The programmable bidirectional analog electronic load in the simulated load includes a power conversion circuit, an energy storage unit and a control circuit. The power conversion circuit converts the electric energy from the DCDC converter of the multi-in-one motor controller under test into other forms of energy, such as heat energy, etc., according to the test requirements, and feeds the electric energy back to the test system when the electric energy in the energy storage unit reaches the preset threshold, so as to realize the bidirectional flow of electric energy. During the test process, when excess electric energy is generated, it is stored in the energy storage unit. When the stored electric energy reaches the preset threshold, the electric energy is fed back to the test system in conjunction with the power conversion circuit to realize the recycling of energy. The control circuit plays a regulatory role, accurately controls the working state of the power conversion circuit, determines when to perform power conversion, the conversion method, and the timing of energy feedback, etc., to ensure that the entire programmable bidirectional analog electronic load operates stably according to the predetermined program and test requirements. The programmable bidirectional analog electronic load communicates with the industrial computer through RS232. On the one hand, by receiving instructions from the industrial computer, the programmable bidirectional analog electronic load can flexibly simulate various load characteristics, such as different types of static load characteristics such as resistance, inductance, and capacitance, and can also simulate the dynamic characteristics of the load changing over time in actual working conditions, such as sudden changes and gradual changes in the load. On the other hand, the programmable bidirectional analog electronic load can absorb electrical energy to simulate the energy consumption of the load, and can also feed back the stored electrical energy to the test system under certain conditions.

[0062] Programmable bidirectional analog electronic load capability feedback can be achieved by following the steps below:

[0063] Step 1: Connect the device under test to the programmable electronic load.

[0064] Connect the output of the DCDC converter of the all-in-one motor controller to the input of the programmable bidirectional analog electronic load. Ensure the polarity is correct and avoid reverse connection. Use the appropriate specification of the connecting wire and ensure that the wire diameter is large enough to carry the maximum expected current to avoid heating or voltage drop due to excessive current.

[0065] Step 2: Set the load mode and dynamic change curve.

[0066] The load modes are as follows:

[0067] Constant voltage mode: Suitable for testing the energy feedback capability of the all-in-one motor controller under test at a constant voltage. Set the voltage target value of the programmable bidirectional analog electronic load so that it absorbs current to maintain that voltage.

[0068] Constant Current Mode: Suitable for testing the performance of the all-in-one motor controller under constant current. Set the current value and the programmable bidirectional analog electronic load will adjust the voltage to maintain that current.

[0069] Constant Power Mode: Suitable for testing the performance of the all-in-one motor controller under test at a fixed power. The programmable bidirectional simulated electronic load will dynamically adjust the voltage and current to maintain the set power.

[0070] Step 3: Measure feedback energy and electrical parameters.

[0071] Start the test: Make sure all devices are connected correctly, turn on the programmable bidirectional simulated electronic load and power analyzer, and gradually increase the load to avoid sudden changes. Start the test program, observe whether the programmable bidirectional simulated electronic load responds correctly, and adjust the device under test to enter the energy feedback mode.

[0072] Real-time monitoring: Use a power analyzer to monitor voltage, current, power and energy in real time.

[0073] Data Collection: During the test, key parameters are collected, including maximum, minimum and average values, as well as the total amount of energy.

[0074] Electronic loads can be calibrated regularly to ensure their measurement accuracy and avoid test result deviations due to equipment errors. Equipment power analyzers should also be calibrated regularly, especially in high-power or high-frequency applications. An appropriate sampling rate should be set to ensure that fast-changing parameters are captured to avoid data loss.

[0075] The distributed electric field sensor in the simulated load is deployed and installed on the shell of the multi-in-one motor controller under test. By continuously monitoring the electric field distribution around the shell, when the multi-in-one motor controller under test is running, when the insulation material is damaged (such as aging, moisture, tiny cracks, etc.), the electric field distribution will change, and the originally uniform electric field will show irregular changes in intensity and direction in the local area, which is the local electric field distortion. When the degree of local electric field distortion (such as the proportion of electric field intensity exceeding the normal range, the angle of deviation of the electric field direction, etc.) monitored by the distributed electric field sensor exceeds the preset threshold, it means that the condition of the insulation material has reached the level that may cause electrical failure (such as breakdown of the insulation layer causing a short circuit), then the withstand voltage test will be triggered, and a test voltage higher than the normal operating voltage will be applied to the multi-in-one motor controller under test for a period of time, so as to detect the insulation performance of the equipment under high voltage. Through the withstand voltage test, it can be further confirmed whether the insulating material can still withstand the normal operating voltage and the impact of higher voltage, and whether there is a potential insulation problem in the tested all-in-one motor controller, so as to take maintenance, repair or replacement measures in time to prevent the tested all-in-one motor controller from being damaged due to insulation problems during operation, and ensure the safe and reliable operation of the entire test system. The distributed electric field sensor communicates with the industrial computer through RS232. The industrial computer can send instructions to the distributed electric field sensor to realize remote control of the distributed electric field sensor, such as setting the sampling frequency, measurement range, working mode and other parameters of the distributed electric field sensor to adapt to different measurement requirements and environmental conditions. The distributed electric field sensor transmits the real-time collected electric field strength, electric field distribution and other information at different locations to the industrial computer. As a data processing and storage center, the industrial computer can integrate and analyze a large amount of electric field data. The distributed electric field sensor communicates with the industrial computer, and the industrial computer can process and analyze the data collected by the distributed electric field sensor in real time, and improve the accuracy of electric field measurement through algorithm correction, filtering and other operations. At the same time, automated data transmission and processing reduces manual intervention and improves measurement efficiency. Through RS232 communication, distributed electric field sensors can be easily added or replaced. The industrial computer can quickly identify and configure new distributed electric field sensors, making the entire test system more flexible and scalable.

[0076] In addition, the high-frequency pulse injection method can be combined to inject a slight high-frequency signal (such as 1kHz / 10V) through the bus of the all-in-one motor controller under test, and the leakage current can be detected using a current transformer to achieve online estimation of the insulation resistance.

[0077] The water cooling system is connected to the all-in-one motor controller under test to take away the heat generated by the operation of the all-in-one motor controller under test, control its temperature within a suitable range, and ensure stable operation of the equipment.

[0078] The performance test system for the commercial all-in-one motor controller in the embodiments of this application tests the temperature parameters, bus voltage parameters, motor speed parameters, three-phase voltage and current parameters, main drive output current parameters, and DCDC converter parameters of the all-in-one motor controller under test. Specifically, regarding the temperature parameters, the industrial control computer sends a query request to the all-in-one motor controller under test in the form of a CAN data frame, asking for the temperatures of the U, V, and W phase modules and the main drive motor temperature. After receiving the request, the all-in-one motor controller under test packs the corresponding temperature data into a CAN data frame according to the established communication protocol and then sends it back to the industrial control computer. After receiving the CAN data returned by the all-in-one motor controller under test, the industrial control computer analyzes the data according to the corresponding communication protocol of the all-in-one motor controller under test. After parsing out each temperature value, these temperature values are compared with the established temperature range index. This established temperature range is determined according to the design parameters, performance requirements, and safety standards of the all-in-one motor controller under test. If the temperatures of the U, V, and W phase modules and the main drive motor temperature are all within the index range, it indicates that the current temperature state of the all-in-one motor controller under test is normal and the subsequent tests can continue; if any one of the temperature values exceeds the established range, it indicates that the all-in-one motor controller under test may have abnormal conditions such as overheating. At this time, the test is stopped to avoid damage to the equipment caused by overheating or safety problems.

[0079] Regarding the bus voltage parameters, the CAN communication function is used to obtain relevant data from the all-in-one motor controller under test and analyze the data to obtain the bus voltage value of the all-in-one motor controller under test. The bus voltage value obtained by parsing through CAN communication is compared with the voltage value actually provided by the high-voltage DC source. The difference between the two is calculated as the error. An allowable error range is set, which is determined based on the design accuracy and performance requirements of the all-in-one motor controller under test. If the error is within the allowable range, it indicates that the bus voltage detection function of the all-in-one motor controller under test is normal and the subsequent tests can continue; if the error exceeds the allowable range, it indicates that there may be a deviation in the bus voltage detection, which may affect the normal operation of the all-in-one motor controller under test. At this time, the test is stopped to troubleshoot the problem.

[0080] In addition, it is also possible to test whether the main drive and auxiliary drive circuits can perform normal power-on and power-off operations. Power-on means connecting the power supply to the circuit to make it enter the working state; power-off means cutting off the power supply to stop the circuit from working. Normal power-on and power-off operations are the basis for the stable operation of the motor controller. If the power-on and power-off functions are abnormal, it may cause the equipment to fail to start or malfunction when shutting down.

[0081] Regarding the motor speed parameters, the main drive motor speed related data is read from the tested multi-motor controller through CAN communication. The dynamometer subsystem measures the main drive motor speed, and its measured value is used as a reference for the actual speed. The industrial computer sends a request command to the tested multi-motor controller through CAN communication to obtain a data frame containing the main drive motor speed information. After receiving the data frame, the data is parsed according to the communication protocol of the tested multi-motor controller, and the main drive motor speed value is extracted from it. The main drive motor speed value obtained through CAN communication parsing is compared with the speed value measured by the dynamometer subsystem, and the error is calculated. If the error is within the allowable range, it means that the resolver circuit (used to detect the rotor position and speed of the main drive motor) of the tested multi-motor controller is working normally, and the main drive motor speed measurement is accurate, and subsequent tests can continue; if the error exceeds the allowable range, it indicates that the resolver circuit may have a fault, such as sensor damage, abnormal signal transmission, etc. At this time, the test is stopped and the resolver circuit is inspected and checked.

[0082] Regarding the three-phase voltage and current parameters, three-phase electricity is crucial in the operation of the motor. The balance of the three-phase voltage and current directly affects the operating performance, efficiency and life of the motor. Under rated conditions, the measurement and control subsystem measures the three-phase voltage and current output by the multi-in-one motor controller under test. The collected three-phase voltage and current data are processed by the test bench software to calculate the voltage balance and current balance. The calculated voltage and current balance are compared with the pre-set allowable range. If the voltage and current balance are within the allowable range, it means that the three-phase electricity output by the motor controller is relatively balanced, and subsequent tests can continue; if it exceeds the allowable range, it indicates that the three-phase electricity is unbalanced, which may cause problems such as unstable motor operation and increased heating. At this time, the test needs to be stopped for troubleshooting and debugging.

[0083] When testing the main drive output current, the tested multi-in-one motor controller is set to work in the rated peak cycle state. By setting the parameters such as the speed of the accompanying motor and the torque of the tested multi-in-one motor controller, the working conditions close to the limit in the actual operation of the main drive motor are simulated, so that the tested multi-in-one motor controller works in a cycle at the rated output current and peak output current respectively, so as to fully demonstrate its performance under different load currents. The main drive output current parameters are detected by monitoring the temperature rise changes and fault points of the tested multi-in-one motor controller. Excessive temperature rise will cause the performance of the tested multi-in-one motor controller to decline, shorten its life or even damage; the detection of fault points can timely detect abnormal conditions during operation and avoid more serious faults. With the help of CAN communication, the internal relevant data of the tested multi-in-one motor controller is read, such as the temperature information collected by the temperature sensor, the fault code generated by the fault diagnosis module, etc., and then these data are transmitted to the test bench software, which parses and calculates the data to obtain specific temperature rise values and fault codes. The obtained temperature rise value and fault code are compared with the established range. If the temperature rise value is within the allowable range and no serious fault code appears, it means that the tested all-in-one motor controller operates normally under the current test conditions and subsequent tests can continue; if the temperature rise value exceeds the range or a serious fault code appears, it indicates that the tested all-in-one motor controller has poor heat dissipation or other fault problems. At this time, the test needs to be stopped and the tested all-in-one motor controller needs to be repaired and checked.

[0084] Regarding the parameters of the DCDC converter, the rated and peak cycle conditions are used to test the parameters of the DCDC converter. In actual applications, the load of the DCDC converter will change. Through this cycle condition simulation, its performance under different load conditions can be more comprehensively examined. The rated condition simulates the normal working load, and the peak condition simulates the extreme load condition. By setting the current value of the programmable bidirectional analog electronic load, the output load current of the DCDC converter is determined. The programmable bidirectional analog electronic load can accurately simulate different load requirements and provide accurate load conditions for the test. Use CAN communication to send instructions to the DCDC converter to put it into working state. The industrial computer reads the voltage, current and other parameters of the electronic load. These parameters reflect the output of the DCDC converter. The industrial computer can process and analyze the collected data. Focus on monitoring the voltage, current and other parameters output by the DCDC converter. These parameters are key indicators for evaluating its performance. The stability of the voltage affects the normal operation of the back-end electrical equipment, and the current parameters reflect the load capacity of the DCDC converter. Compare the read and calculated output voltage, current and other parameters with the established indicator range. If the parameters are within the range, it means that the DCDC converter is working normally under the current working conditions and the test can continue. If they are out of the range, it indicates that the DCDC converter may have performance problems and it is necessary to stop the test and troubleshoot, such as checking whether the circuit is abnormal or whether the control algorithm is wrong.

[0085] In this embodiment, intelligent fault detection can also be performed based on machine learning. By collecting parameters such as the temperature, current, and voltage of the multi-in-one motor controller under test during the test process, and combining historical test data, a prediction model is trained to predict possible faults that may be encountered in future operations. By identifying potential problems in advance, the test sequence can be optimized, and in-depth tests can be carried out specifically, thereby improving the test efficiency and the accuracy of fault identification. In the specific implementation process, machine learning algorithms such as support vector machines, neural networks, or random forests can be used to train the model based on a large amount of test data. After each test, the model will update its prediction algorithm to adapt to the performance changes of the multi-in-one motor controller under test and newly emerging fault modes.

[0086] The commercial multi-in-one motor controller test system in this solution has comprehensive test capabilities, covering multiple subsystems such as a bidirectional high-voltage DC power supply, a measurement and control subsystem, a dynamometer subsystem, and a simulated load. It can conduct a full range of tests on the commercial multi-in-one motor controller, from electrical parameter measurement to load condition simulation, and then to temperature control, comprehensively evaluating its performance. Through the cooperation of a power analyzer, a multimeter, various sensors, etc., data such as power, electrical parameters, torque, and temperature are accurately collected, providing a reliable basis for performance evaluation. The industrial control computer serves as the control center to achieve automated control and data processing of each subsystem, flexibly adjusting test parameters and processes according to test requirements, improving test efficiency and accuracy. Through the dynamometer subsystem and simulated load settings, various actual operating conditions can be simulated, making the test results closer to actual applications, helping to discover potential problems, and optimizing the design of the motor controller. In particular, this solution introduces a programmable bidirectional analog electronic load into the multi-in-one motor controller test, absorbs and converts the energy output by the DCDC converter, and returns the stored energy to the commercial multi-in-one motor controller test system. The programmable bidirectional analog electronic load supports bidirectional energy flow. It can not only act as a load to absorb the energy of the DCDC converter but also return the energy to the performance test system when needed, realizing the recycling of energy, improving energy utilization efficiency, and thus solving the problem of low energy utilization efficiency of the existing commercial multi-in-one motor controller test system.

[0087] Obviously, those skilled in the art should understand that the various modules or steps of the present invention described above can be implemented by a general-purpose computing device. They can be centralized on a single computing device or distributed over a network composed of multiple computing devices. They can be implemented by program codes executable by the computing device. Thus, they can be stored in a storage device and executed by the computing device. And in some cases, the steps shown or described can be executed in a different order than here, or they can be separately fabricated into individual integrated circuit modules, or multiple modules or steps among them can be fabricated into a single integrated circuit module for implementation. In this way, the present invention is not limited to any specific combination of hardware and software.

[0088] Those skilled in the art should understand that the embodiments of the present application can be provided as a method, a system, or a computer program product. Therefore, the present application can take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program codes.

[0089] The present application is described with reference to the flowcharts and / or block diagrams of methods, apparatuses (systems), and computer program products according to the embodiments of the present application. It should be understood that each flow and / or block in the flowcharts and / or block diagrams, as well as the combination of flows and / or blocks in the flowcharts and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, such that the instructions executed by the processor of the computer or other programmable data processing devices generate means for implementing the functions specified in Figure 1 one or more of the flows Figure 1 or blocks or the combination of multiple flows and / or blocks.

[0090] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, such that the instructions stored in the computer-readable memory generate a manufactured article including instruction means, and the instruction means implements the functions specified in Figure 1 one or more of the flows Figure 1 or blocks or the combination of multiple flows and / or blocks.

[0091] These computer program instructions can also be loaded onto a computer or other programmable data processing device, such that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process. Thus, the instructions executed on the computer or other programmable device provide means for implementing the functions in the flowFigure 1 one or more processes and / or blocks Figure 1 steps of functions specified in one or more blocks

[0092] In a typical configuration, a computing device includes one or more processors (CPUs), an input / output interface, a network interface, and memory.

[0093] The memory may include non-permanent memory in the form of computer-readable media, random access memory (RAM) and / or non-volatile memory such as read-only memory (ROM) or flash memory (flash RAM). Memory is an example of computer-readable media.

[0094] Computer-readable media includes permanent and non-permanent, removable and non-removable media that can store information by any method or technology. The information can be computer-readable instructions, data structures, program modules, or other data. Examples of computer storage media include, but are not limited to, phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, compact disc read-only memory (CD-ROM), digital versatile disc (DVD) or other optical storage, magnetic cassette tapes or other magnetic storage devices, or any other non-transmission media that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transitory media such as modulated data signals and carrier waves.

[0095] It should also be noted that the term "comprising", "including" or any other variation thereof is intended to cover non-exclusive inclusion, so that a process, method, commodity or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or elements inherent to such process, method, commodity or device. Without further limitation, an element defined by the statement "comprising an..." does not exclude the presence of additional identical elements in the process, method, commodity or device comprising the element.

[0096] The above are only the preferred embodiments of the present application and are not intended to limit the present application. For those skilled in the art, the present application can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A performance test system for a commercial all-in-one motor controller, characterized in that, It includes a measurement and control subsystem, a simulated load and a main drive motor. The measurement and control subsystem includes an industrial computer. The simulated load includes a programmable bidirectional simulated electronic load. The programmable bidirectional simulated electronic load includes a power conversion circuit, an energy storage unit and a control circuit. The industrial computer communicates with the simulated load, and the simulated load is used to simulate the mechanical load and electromagnetic load of the main drive motor under real working conditions according to the first control instruction issued by the industrial computer, so as to provide the required load environment for the main drive motor; The programmable bidirectional simulated electronic load is connected to the DCDC converter of the all-in-one motor controller under test. The power conversion circuit is used to convert the electric energy output by the DCDC converter into different forms of energy for consumption during the test, and to feed the electric energy back to the commercial all-in-one motor controller performance test system when the electric energy in the energy storage unit reaches a preset threshold. The control circuit is used to control the working state of the power conversion circuit.

2. The commercial all-in-one motor controller performance testing system according to claim 1, characterized in that The simulated load also includes a distributed electric field sensor, which is deployed and installed on the housing of the all-in-one motor controller under test and is used to monitor the insulation performance of the insulation material in the all-in-one motor controller under test in real time.

3. The commercial all-in-one motor controller performance testing system according to claim 1, characterized in that The commercial all-in-one motor controller performance testing system also includes a dynamometer subsystem, which includes a companion test motor and a companion test motor controller. The companion test motor controller is electrically connected to the companion test motor and is used to control the speed and torque of the companion test motor. The companion test motor is used to simulate the torque load and speed load of the main drive motor under actual operating conditions.

4. The commercial all-in-one motor controller performance testing system according to claim 3, wherein The dynamometer subsystem also includes a torsion sensor, a first coupling and a second coupling, wherein the input shaft end of the torsion sensor is connected to the main drive motor through the first coupling, and the output shaft end of the torsion sensor is connected to the accompanying measurement motor through the second coupling, and is used to measure the torque output by the main drive motor and the torque borne by the accompanying measurement motor, as well as the torsion angle of the shaft between the main drive motor and the accompanying measurement motor.

5. The commercial all-in-one motor controller performance testing system according to claim 3, characterized in that, The dynamometer subsystem communicates with the industrial computer, the dynamometer subsystem transmits measured data to the industrial computer for analysis, and the industrial computer sends a second control instruction to the dynamometer subsystem to control the dynamometer subsystem.

6. The commercial all-in-one motor controller performance testing system according to claim 1, wherein The tested all-in-one motor controller also includes an oil pump controller and an air pump controller, and the simulated load also includes a first asynchronous motor, a second asynchronous motor, a first excitation motor and a second excitation motor, wherein the power output shaft of the first asynchronous motor is connected to the oil pump controller, the connection terminal of the rotor winding of the first asynchronous motor is connected to the first excitation motor, the power output shaft of the second asynchronous motor is connected to the air pump controller, and the connection terminal of the rotor winding of the second asynchronous motor is connected to the second excitation motor.

7. The commercial all-in-one motor controller performance testing system according to claim 1, characterized in that The industrial computer is installed with host computer software, and the host computer software is used to write test sequence program files suitable for different tested machine models. The industrial computer communicates with the tested all-in-one motor controller through a CAN bus, and is used to receive and analyze at least one of the following parameters of the tested all-in-one motor controller: temperature parameters, bus voltage parameters, motor speed parameters, three-phase voltage and current parameters, main drive output current parameters, and DCDC converter parameters.

8. The commercial all-in-one motor controller performance testing system according to claim 1, characterized in that The commercial all-in-one motor controller performance testing system also includes a bidirectional high-voltage DC power supply, the AC input end of the bidirectional high-voltage DC power supply is connected to the input end of the mains power, and is used to convert the mains power into high-voltage DC power, and the DC output end of the bidirectional high-voltage DC power supply is connected to the all-in-one motor controller under test, and is used to provide DC power for the all-in-one motor controller under test.

9. The commercial all-in-one motor controller performance testing system according to claim 1, characterized in that, The commercial all-in-one motor controller performance testing system also includes a water cooling subsystem, which is connected to the all-in-one motor controller under test and is used to control the temperature of the all-in-one motor controller under test within a preset range during the test.

10. The commercial all-in-one motor controller performance test system according to claim 1, wherein The measurement and control subsystem also includes a power analyzer and a multimeter. The power analyzer is used to measure the relevant power parameters of the electrical equipment in the commercial all-in-one motor controller performance test system, and the multimeter is used to measure the relevant electrical parameters of the electrical equipment. Among them, the power analyzer and the multimeter are respectively connected to the industrial computer, and the industrial computer is used to send a third control instruction to the power analyzer and the multimeter to control the measurement of the power analyzer and the multimeter, and the power analyzer and the multimeter are used to transmit the measured relevant power parameters and the relevant electrical parameters to the industrial computer for analysis.

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