Energy flow conversion architecture and test power supply system of automobile electric drive system test equipment

Abstract

This invention provides an energy flow architecture and test power supply system for automotive electric drive system testing equipment, belonging to the field of automotive technology. It includes: a three-phase rectified power supply; a dual-channel bidirectional DC / DC converter module, with its input connected to the output of the three-phase rectified power supply; a vehicle electric drive motor, connected to the first channel output of the dual-channel bidirectional DC / DC converter module via a second-stage high-voltage DC bus; a bidirectional inverter module, connected to the second channel output of the dual-channel bidirectional DC / DC converter module via a second-stage constant-voltage DC bus; a load motor module, connected to the bidirectional inverter module via a three-phase power cable; the load motor module includes at least two load motors, with the first load motor connected to a reducer, and the second load motor connected to the reducer or the first load motor via a mechanical stacking connection device. This invention solves the technical problems of resource waste and inefficient investment in existing electric drive system testing equipment.

Description

Technical Field

[0001] This invention relates to the field of automotive technology, and more specifically to an energy flow architecture and test power system for an automotive electric drive system testing equipment. Background Technology

[0002] In traditional electric drive system testing equipment, the configuration of the drive and load motors typically employs two separate rectifier power supplies—one high-voltage and one constant-voltage—to accommodate high-voltage power supply platforms. Both power supplies are connected to the AC busbar behind a three-phase distribution cabinet. The capacity of the high-voltage and constant-voltage power supplies is usually selected based on the power consumption of the test specimen. When the electric drive capacity of the test specimen varies significantly, or when the test specimen requires multiple drives, a completely new test bench must be purchased, leading to substantial resource waste and inefficient investment. Therefore, existing electric drive system testing equipment is prone to resource waste and inefficient investment. Summary of the Invention

[0003] In view of this, it is necessary to provide an energy flow architecture and test power system for automotive electric drive system testing equipment to solve the technical problem that existing electric drive system testing equipment requires investment in purchasing a brand new test bench when the electric drive capacity of the test piece changes significantly or the test piece has multiple drives, which easily leads to resource waste and inefficient investment.

[0004] To address the aforementioned problems, in a first aspect, the present invention provides an energy flow architecture for an automotive electric drive system testing device, comprising: The three-phase rectified power supply is connected to the three-phase distribution cabinet via a three-phase power cable at its input end. The dual-channel bidirectional DC / DC converter module has its input terminal connected to the output terminal of the three-phase rectifier power supply via a first-stage DC bus. The vehicle electric drive motor is connected to the first channel output terminal of the dual-channel bidirectional DC / DC converter module via the second-stage high-voltage DC bus. The bidirectional inverter module is connected to the second channel output terminal of the dual-channel bidirectional DC / DC converter module via the second-stage constant voltage DC bus. The load motor module is connected to the bidirectional inverter module via a three-phase power cable; The load motor module includes at least two load motors, and the first load motor is connected to the reducer through a mechanical main connection device, and the second load motor is connected to the reducer or the first load motor through a mechanical stacking connection device; the reducer is integrated with the vehicle electric drive motor.

[0005] In one possible implementation, the vehicle electric drive motor includes a single drive motor or multiple drive motors; the sum of the currents of the multiple drive motors is less than the rated current of the first channel output of the dual-channel bidirectional DC / DC converter module.

[0006] In one possible implementation, the sum of the rated currents of the at least two load motors is less than the rated current of the second channel output of the dual-channel bidirectional DC / DC converter module.

[0007] In one possible implementation, a motor for simulating a hybrid power engine is also included, which is connected to the bidirectional inverter module.

[0008] In one possible implementation, the motor for simulating a hybrid power engine includes a main drive motor and a secondary drive motor, the output shaft of the secondary drive motor being rigidly connected to the output shaft of the main drive motor via the mechanical stacking connection device; both the main drive motor and the secondary drive motor are connected to the second-stage atmospheric DC bus via the bidirectional inverter module.

[0009] In one possible implementation, the bidirectional inverter module includes: a first bidirectional inverter, a second bidirectional inverter, and a third bidirectional inverter; the first bidirectional inverter, the second bidirectional inverter, and the third bidirectional inverter are all standard commercial inverters. The third bidirectional inverter is connected to a motor used to simulate a hybrid power engine, the first bidirectional inverter is connected to the first load motor, and the second bidirectional inverter is connected to the second load motor.

[0010] In one possible implementation, the reducer is an axle reducer or an automotive reducer.

[0011] In one possible implementation, when the reducer is an axle reducer, the second load motor is connected to the axle reducer via a mechanical stacking connection device, and the axle reducer is also connected to a motor for simulating a hybrid power engine via the mechanical stacking connection device. When the reducer is an automotive reducer, the second load motor is connected to the first load motor via a mechanical stacking connection device.

[0012] In one possible implementation, the three-phase rectified power supply is an SVPWM three-phase rectified power supply.

[0013] In one possible implementation, the power capacity of the SVPWM three-phase rectified power supply is less than the rated capacity of the bidirectional inverter module.

[0014] Secondly, the present invention also provides a test power supply system, including the above-described energy transfer architecture.

[0015] The beneficial effects of adopting the above implementation method are as follows: The energy flow architecture and test power system of the automotive electric drive system test equipment provided by the present invention are equipped with an integrated three-phase rectifier power supply and a dual-channel bidirectional DC / DC converter. The bidirectional DC / DC converter has two independent pairs of DC buses; one pair is a high-voltage DC bus and the other pair is a normal-voltage DC bus. The high-voltage DC bus is usually connected to the high-voltage vehicle electric drive motor and allows multiple drive motors to be stacked to meet the needs of distributed drive electric drive testing of new energy vehicles. The normal-voltage DC bus is usually connected to a single or stacked bidirectional inverter operating at normal voltage, and thus multiple load motors can be connected one-to-one.

[0016] This invention requires only one integrated three-phase rectified power supply and dual-channel bidirectional DC / DC converter to connect a vehicle electric drive and at least two load motors. The first load motor is connected to the reducer via a mechanical main connection device, and the second load motor is connected to the reducer or the first load motor via a mechanical stacking connection device. The reducer is integrated with the vehicle electric drive motor. Even when the electric drive capacity of the test piece varies greatly or the test piece has multiple drives, the structure provided by this invention is still applicable, eliminating the need to purchase a completely new test bench and avoiding resource waste. This solves the problem of resource waste and inefficient investment that existing electric drive system testing equipment easily causes. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A structural diagram of an embodiment of the energy flow architecture of the automotive electric drive system testing equipment provided by the present invention; Figure 2 This is a structural diagram of another embodiment of the energy flow architecture of the automotive electric drive system testing equipment provided by the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] In the description of the embodiments of this application, unless otherwise stated, "a plurality of" means two or more.

[0021] In this embodiment of the invention, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion, for example, a process, method, apparatus, product or device that includes a series of steps or modules is not necessarily limited to those steps or modules that are explicitly listed, but may include other steps or modules that are not explicitly listed or that are inherent to such process, method, product or device.

[0022] The naming or numbering of steps in the embodiments of the present invention does not mean that the steps in the method flow must be executed in the time / logical order indicated by the naming or numbering. The execution order of the named or numbered process steps can be changed according to the technical purpose to be achieved, as long as the same or similar technical effect can be achieved.

[0023] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0024] This invention provides an energy flow architecture for an automotive electric drive system testing device and an automotive electric drive system, which will be described below.

[0025] like Figure 1 As shown, the present invention provides an energy flow architecture for a test device for an automotive electric drive system, comprising: The three-phase rectified power supply is connected to the three-phase distribution cabinet via a three-phase power cable at its input end; the three-phase rectified power supply is connected to the three-phase distribution cabinet 101. The dual-channel bidirectional DC / DC converter module has its input terminal connected to the output terminal of the three-phase rectifier power supply via a first-stage DC bus; the dual-channel bidirectional DC / DC converter module and the three-phase rectifier power supply can be integrated into a single module 103; The vehicle electric drive motor 106 is connected to the first channel output terminal of the dual-channel bidirectional DC / DC converter module via the second-stage high-voltage DC bus. Bidirectional inverter modules 108, 109, and 110 are connected to the second channel output of the dual-channel bidirectional DC / DC converter module via the second-stage constant voltage DC bus. The load motor module is connected to the bidirectional inverter module via a three-phase power cable.

[0026] The load motor module includes at least two load motors 111 and 112. The first load motor 111 is connected to the reducer 113 through a mechanical main connection device 114, and the second load motor 112 is connected to the reducer 113 or the first load motor 111 through a mechanical stacking connection device 115. The reducer 113 is integrated with the vehicle electric drive motor 106.

[0027] It is understood that the energy flow architecture in this embodiment is the energy flow control architecture of the electric drive motor testing equipment. The energy flow architecture provided in this embodiment is configured with two levels of DC buses: a first-level DC bus, a second-level high-voltage DC bus, and a second-level normal-voltage DC bus. A dual-channel bidirectional DC / DC converter, i.e., a DC-DC converter, is connected after the first-level DC bus.

[0028] The energy flow architecture and automotive electric drive system of the automotive electric drive system testing equipment provided by this invention are equipped with an integrated three-phase rectifier power supply and a dual-channel bidirectional DC / DC converter. The bidirectional DC / DC converter has two independent pairs of DC buses: one pair is a high-voltage DC bus and the other pair is a normal-voltage DC bus. The high-voltage DC bus is usually connected to the high-voltage vehicle electric drive motor and allows multiple drive motors to be stacked to meet the needs of distributed drive electric drive testing of new energy vehicles. The normal-voltage DC bus is usually connected to a single or stacked bidirectional inverter operating at normal voltage, and can then be connected to multiple load motors one by one.

[0029] This invention requires only one integrated three-phase rectified power supply and dual-channel bidirectional DC / DC converter to connect a vehicle electric drive and at least two load motors. The first load motor is connected to the reducer via a mechanical main connection device, and the second load motor is connected to the reducer or the first load motor via a mechanical stacking connection device. The reducer is integrated with the vehicle electric drive motor. Even when the electric drive capacity of the test piece varies greatly or the test piece has multiple drives, the structure provided by this invention is still applicable, eliminating the need to purchase a completely new test bench and avoiding resource waste. This solves the problem of resource waste and inefficient investment that existing electric drive system testing equipment easily causes.

[0030] In some embodiments, the vehicle electric drive motor includes a single drive motor or multiple drive motors; the sum of the currents of the multiple drive motors is less than the rated current of the first channel output terminal of the dual-channel bidirectional DC / DC converter module.

[0031] It is understandable that the sum of the currents of the multiple motors is less than the rated current of the first channel output of the dual-channel bidirectional DC / DC converter module, which ensures that each motor in the vehicle's electric drive motor can reach its rated operating current.

[0032] In some embodiments, the sum of the rated currents of the at least two load motors is less than the rated current of the second channel output of the dual-channel bidirectional DC / DC converter module.

[0033] It is understood that the sum of the rated currents of the multiple load motors is less than the rated current of the second channel output of the dual-channel bidirectional DC / DC converter module, which ensures that each load motor can reach its rated current.

[0034] In some embodiments, the energy transfer architecture further includes a motor for simulating a hybrid power engine, the motor being connected to the bidirectional inverter module.

[0035] It is understood that the bidirectional inverter module may include multiple commercial bidirectional inverters, with the motor of the simulated hybrid engine connected to one of the commercial bidirectional inverters, and the two connected by a three-phase power cable.

[0036] Furthermore, the motor used to simulate a hybrid power engine includes a main drive motor and a secondary drive motor. The output shaft of the secondary drive motor is rigidly connected to the output shaft of the main drive motor through the mechanical stacking connection device. Both the main drive motor and the secondary drive motor are connected to the second-stage atmospheric DC bus through the bidirectional inverter module.

[0037] In some embodiments, the bidirectional inverter module includes: a first bidirectional inverter, a second bidirectional inverter, and a third bidirectional inverter; the load motor module includes: a first load motor and a second load motor; the first bidirectional inverter, the second bidirectional inverter, and the third bidirectional inverter are all standard commercial inverters; The third bidirectional inverter is connected to a motor used to simulate a hybrid power engine, the first bidirectional inverter is connected to the first load motor, and the second bidirectional inverter is connected to the second load motor.

[0038] It is understood that the first, second, and third bidirectional inverters are all bidirectional transducer inverters. It should be noted that although two load motors are listed in this embodiment, the number of load motors is not limited to two.

[0039] In some embodiments, the reducer is an axle reducer or an automotive reducer.

[0040] When the reducer is an axle reducer, the second load motor is connected to the axle reducer through a mechanical stacking connection device, and the axle reducer is also connected to a motor used to simulate a hybrid power engine through the mechanical stacking connection device. When the reducer is an automotive reducer, the second load motor is connected to the first load motor via a mechanical stacking connection device.

[0041] Understandably, mechanical stacking connection devices can achieve functions such as dual-shaft series stacking and hollow shaft series stacking.

[0042] In some embodiments, the three-phase rectified power supply is an SVPWM three-phase rectified power supply.

[0043] The power capacity of the SVPWM three-phase rectified power supply is less than the rated capacity of the bidirectional inverter module.

[0044] It is understandable that SVPWM technology three-phase rectifier power supply refers to a three-phase PWM rectifier controlled by Space Vector Pulse Width Modulation (SVPWM) technology, which is used to efficiently and with low harmonics convert three-phase AC power into DC power, and has advantages such as high power factor and bidirectional energy flow.

[0045] The present invention also provides a test power supply system, comprising: the energy transfer architecture described in any of the preceding claims.

[0046] This invention relates to a stacked structure of drive and load motors for a test equipment of an electric drive system for new energy vehicles (but not limited to new energy vehicles). The total power supply of the stacked structure is a three-phase distribution cabinet, equipped with an integrated rectified DC power supply and a dual-channel bidirectional DC / DC converter. The bidirectional DC / DC converter has two independent pairs of DC buses: one pair is a high-voltage DC bus, and the other pair is a normal-voltage DC bus. The high-voltage DC bus is typically connected to the high-voltage vehicle electric drive and allows multiple drive motors to be stacked to meet the needs of distributed drive electric drive testing for new energy vehicles. The normal-voltage DC bus is typically connected to a single or stacked commercial bidirectional transducer inverter operating at normal voltage. Multiple commercial bidirectional transducer inverters can be connected one-to-one to multiple load motors. If necessary, the normal-voltage DC bus can also be connected to drive motors used to simulate hybrid engines via a commercial normal-voltage bidirectional transducer inverter.

[0047] In some embodiments, a drive and load motor stacking structure for a new energy vehicle (but not limited to) electric drive motor testing equipment includes: a three-phase power distribution cabinet 101 with a power output much smaller than the rated power of the testing system; an integrated rectifier power supply and a dual-channel bidirectional DC / DC converter 103; a pair of high-voltage DC buses 104 and a vehicle electric drive motor 106; a reducer 113 integrated with the vehicle electric drive motor 106; a pair of normal-voltage DC buses 105 and their commercial bidirectional converter inverter combinations 108, 109, and 110; the three-phase power distribution cabinet 101 is connected to an integrated rectifier DC power supply and a dual-channel bidirectional DC / DC converter 103 via a three-phase power cable 102; the high-voltage channel and the low-voltage channel of the integrated rectifier DC power supply and the dual-channel bidirectional DC / DC converter 103 are respectively connected to the high-voltage DC bus 104 and the low-voltage DC bus 105; the high-voltage DC bus 104 is dedicated to connecting the vehicle electric drive motor 106 under test.

[0048] Figure 1 The vehicle electric drive motor shown is a single unit. When the bidirectional DC / DC capacity is sufficient, the electric drive motor in this invention will not be limited to a single unit. For example, when meeting the test requirements of the electric drive motor of a four-wheel drive vehicle, up to four or more electric drive motors can be selected and connected in parallel to the high-voltage DC bus 104. The atmospheric DC bus 105 is dedicated to connecting commercial bidirectional transducer inverters 108, 109, and 110. The commercial bidirectional transducer inverters 108 and 109 are used to connect load motor combinations 111 and 112.

[0049] Figure 1The load motor combination shown is two units. When the bidirectional DC / DC capacity is sufficient, the load motor stacking combination in this invention is not limited to one or two units. As long as the total electric drive capacity of the test vehicle matches the total capacity of the load motors, multiple load motors can be selected and connected in parallel to the atmospheric DC bus 105. The atmospheric DC bus 105 can connect not only the load motors but also the drive motors, such as the simulated hybrid vehicle engine motor 107 connected through a commercial bidirectional converter inverter 110. Finally, through the mechanical main connection device 114 and the mechanical stacking connection device 115, the mechanical connection of the test vehicle electric drive motor 106, the simulated hybrid engine motor 107, and the integrated assembly reducer 113 with the load motor combinations 111 and 112 is completed, thereby completing the energy closed loop of the entire test system. In this invention, the constant-voltage DC bus 105 can be connected to both the load motor and the drive motor, meaning that the constant-voltage DC bus 105 can operate in a complementary energy exchange state. However, regarding the constant-voltage channel of the integrated rectified DC power supply and bidirectional DC / DC converter 103, it generally operates in a load state, but this reduces the load on the constant-voltage channel of the integrated rectified DC power supply and bidirectional DC / DC converter 103. Meanwhile, the high-voltage channel of the integrated rectified DC power supply and bidirectional DC / DC converter 103 mostly operates in a drive state. Thus, the output node of the rectifier section of the integrated rectified power supply and dual-channel bidirectional DC / DC converter 103 also operates in a complementary energy exchange state.

[0050] Therefore, in this invention, high-power electrical energy enables energy exchange and complementarity within the equipment, and the rated capacity of the three-phase distribution cabinet 102 can be much smaller than the rated capacity of the test system. Furthermore, both the vehicle drive motor and the load motor can be flexibly matched and stacked via the stacking connection device 115 to adapt to the different requirements of various test specimens of different specifications and capacities, reducing the problem of redundant construction of similar testing equipment in general laboratories. For simplicity, the stacking refers to the parallel or series connection of the drive and load motors in a mechanical sense. Figure 1 The dashed section represents components that can be stacked flexibly.

[0051] In another embodiment, the energy transfer architecture is as follows: Figure 2 As shown, the difference between this embodiment and the previous one is that the second load motor 112 is connected to the first load motor 111 through a mechanical stacking connection device 115, and the reducer 113 is a car reducer, and there is no connection between the motor 107 simulating a hybrid engine and the car reducer.

[0052] The energy flow architecture and test power system of the automotive electric drive system test equipment provided by the present invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An energy flow architecture for a testing device for an automotive electric drive system, characterized in that, include: The three-phase rectified power supply is connected to the three-phase distribution cabinet via a three-phase power cable at its input end. The dual-channel bidirectional DC / DC converter module has its input terminal connected to the output terminal of the three-phase rectifier power supply via a first-stage DC bus. The vehicle electric drive motor is connected to the first channel output terminal of the dual-channel bidirectional DC / DC converter module via the second-stage high-voltage DC bus. The bidirectional inverter module is connected to the second channel output terminal of the dual-channel bidirectional DC / DC converter module via the second-stage constant voltage DC bus. The load motor module is connected to the bidirectional inverter module via a three-phase power cable, and is also connected to the vehicle electric drive motor via a mechanical connection device. The load motor module includes at least two load motors, and the first load motor is connected to the reducer through a mechanical main connection device, and the second load motor is connected to the reducer or the first load motor through a mechanical stacking connection device; the reducer is integrated with the vehicle electric drive motor.

2. The energy flow architecture of the automotive electric drive system testing equipment according to claim 1, characterized in that, The vehicle electric drive motor includes a single drive motor or multiple drive motors; the sum of the currents of the multiple drive motors is less than the rated current of the first channel output terminal of the dual-channel bidirectional DC / DC converter module.

3. The energy flow architecture of the automotive electric drive system testing equipment according to claim 1, characterized in that, The sum of the rated currents of the at least two load motors is less than the rated current of the second channel output of the dual-channel bidirectional DC / DC converter module.

4. The energy flow architecture of the automotive electric drive system testing equipment according to claim 1, characterized in that, It also includes a motor for simulating a hybrid power engine, which is connected to the bidirectional inverter module.

5. The energy flow architecture of the automotive electric drive system testing equipment according to claim 4, characterized in that, The bidirectional inverter module includes: a first bidirectional inverter, a second bidirectional inverter, and a third bidirectional inverter; the first bidirectional inverter, the second bidirectional inverter, and the third bidirectional inverter are all standard commercial inverters; The third bidirectional inverter is connected to a motor used to simulate a hybrid power engine, the first bidirectional inverter is connected to the first load motor, and the second bidirectional inverter is connected to the second load motor.

6. The energy flow architecture of the automotive electric drive system testing equipment according to claim 4, characterized in that, The reducer is an axle reducer or a vehicle reducer.

7. The energy flow architecture of the automotive electric drive system testing equipment according to claim 6, characterized in that, When the reducer is an axle reducer, the second load motor is connected to the axle reducer through a mechanical stacking connection device, and the axle reducer is also connected to a motor used to simulate a hybrid power engine through the mechanical stacking connection device. When the reducer is an automotive reducer, the second load motor is connected to the first load motor via a mechanical stacking connection device.

8. The energy flow architecture of the automotive electric drive system testing equipment according to claim 1, characterized in that, The three-phase rectified power supply is an SVPWM three-phase rectified power supply.

9. The energy flow architecture of the automotive electric drive system testing equipment according to claim 8, characterized in that, The power capacity of the SVPWM three-phase rectified power supply is less than the rated capacity of the bidirectional inverter module.

10. A test power supply system, characterized in that, include: The energy transfer architecture according to any one of claims 1-9.

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