Test method and device of electric drive system, electronic equipment and storage medium

Abstract

The application relates to the technical field of vehicles, in particular to a test method and device of an electric drive system, electronic equipment and a storage medium, wherein the method comprises the following steps: obtaining an electric drive test requirement of a to-be-tested electric drive system; controlling a load simulator, an environment simulator, a simulated charging pile and a battery simulator to provide at least one test state for the to-be-tested electric drive system according to the electric drive test requirement; obtaining test information output by the to-be-tested electric drive system in the corresponding test state, so as to generate a test result according to the test information. Thus, the problem of single test dimension and insufficient dynamic performance evaluation in the electric drive boost charging test method is solved, the real complex working condition is reproduced by synchronously applying electrical, thermal and control multi-dimensional stress, the dynamic response capability and control robustness of the system are quantitatively evaluated through step disturbance and transient mode switching, and the fault detection rate and the research and development efficiency are improved.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and in particular to a testing method, apparatus, electronic device, and storage medium for an electric drive system. Background Technology

[0002] In related technologies, the industry mainly relies on real vehicle road tests or laboratory bench tests to verify the electric drive boost charging function. Its core objective is to confirm whether the basic functions are achieved and whether the key parameters meet the standards.

[0003] However, the relevant technologies have the following drawbacks: First, the testing dimensions are isolated, typically examining only a single electrical parameter or fixed environmental conditions. They cannot simultaneously introduce multiple stresses such as grid voltage fluctuations, extreme temperatures, and changes in battery state of charge, making it difficult to reproduce the complex operating conditions of multiple factors in real-world use, and system-level potential faults are not easily triggered. Second, the testing process focuses on verifying the steady-state operating point, lacking effective stimulation and evaluation of dynamic processes. For example, the response characteristics and control stability under transient scenarios such as sudden input voltage changes, power jumps, or switching between charging and driving modes are not fully assessed. Third, the test outputs are mostly qualitative judgments, failing to systematically collect quantitative data such as efficiency, power loss, and temperature rise of key components. This makes it difficult to transform test results into design optimization basis and support front-end R&D activities such as control strategy improvement, thermal management design, or lifespan prediction. Summary of the Invention

[0004] This application provides a testing method, apparatus, electronic device, and storage medium for an electric drive system, addressing the problems of limited testing dimensions, insufficient dynamic performance evaluation, and inability of test data to support design optimization in traditional electric drive boost charging testing methods. This improves fault detection rates and R&D efficiency.

[0005] The first aspect of this application provides a testing method for an electric drive system, employing an electric drive testing system including: a load simulator, an environment simulator, and a simulated charging pile. The method includes the following steps: Obtain the electric drive test requirements of the electric drive system to be tested; According to the electric drive test requirements, control the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test; The test information output by the electric drive system under test in the corresponding test state is obtained, and the test results are generated based on the test information.

[0006] Optionally, in some embodiments, the electric drive testing requirements include at least one of frequency sweep testing, transient disturbance response testing, multi-stress coupling testing, and fault diagnosis testing.

[0007] Optionally, in some embodiments, when the electric drive test requirement is the frequency sweep test, the step of controlling the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirement includes: The output voltage of the simulated charging pile is controlled to increase from a first voltage to a second voltage in a first preset step size; At each output voltage of the simulated charging pile, the charging power of the battery simulator is controlled to increase from the first power to the second power in a second preset step size; Under each output voltage of the simulated charging pile and each charging power of the battery simulator, the battery simulator is controlled to simulate multiple states of charge to form multiple steady-state test points.

[0008] Optionally, in some embodiments, when the electric drive test requirement is a transient disturbance response test, the step of controlling the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirement includes: The charging power of the battery simulator is controlled to be the third power, the state of charge of the battery simulator is in the first state, the environmental simulator is adjusted to the first ambient temperature, and the output voltage of the simulated charging pile is controlled to drop from the third voltage to the fourth voltage within a first preset time period. When the maintenance time of the fourth voltage reaches the second preset time period, it is restored to the third voltage.

[0009] Optionally, in some embodiments, when the electric drive test requirement is the multi-stress coupling test, the step of controlling the load simulator, environmental simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirement includes: The charging power of the battery simulator is controlled to a fourth power, the environmental simulator is adjusted to a second ambient temperature, and the output voltage of the simulated charging pile is controlled to fluctuate sinusoidally around a first reference voltage with a first frequency and a first amplitude.

[0010] A second aspect of this application provides a testing apparatus for an electric drive system, comprising: The acquisition module is used to acquire the electric drive test requirements of the electric drive system to be tested. The testing module is used to control the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirements. The generation module is used to acquire the test information output by the electric drive system under test in the corresponding test state, so as to generate test results based on the test information.

[0011] Optionally, in some embodiments, the electric drive testing requirements include at least one of frequency sweep testing, transient disturbance response testing, multi-stress coupling testing, and fault diagnosis testing.

[0012] Optionally, in some embodiments, when the electric drive test requirement is the frequency sweep test, the test module includes: The first control unit is used to control the output voltage of the simulated charging pile to increase from the first voltage to the second voltage in a first preset step size; The second control unit is used to control the charging power of the battery simulator to increase from the first power to the second power in a second preset step size at each output voltage of the simulated charging pile. The third control unit is used to control the battery simulator to simulate multiple states of charge to form multiple steady-state test points under each combination of the output voltage of the simulated charging pile and each charging power of the battery simulator.

[0013] Optionally, in some embodiments, when the electric drive test requirement is a transient disturbance response test, the test module includes: The fourth control unit is used to control the charging power of the battery simulator to the third power, the state of charge of the battery simulator to the first state, the environmental simulator to the first ambient temperature, and to control the output voltage of the simulated charging pile to drop from the third voltage to the fourth voltage within a first preset time period, and to restore to the third voltage when the maintenance time of the fourth voltage reaches a second preset time period.

[0014] Optionally, in some embodiments, when the electric drive test requirement is the multi-stress coupling test, the test module includes: The fifth control unit is used to control the charging power of the battery simulator to the fourth power, adjust the environmental simulator to the second ambient temperature, and control the output voltage of the simulated charging pile to fluctuate sinusoidally around the first reference voltage with a first frequency and a first amplitude.

[0015] A third aspect of this application provides an electronic device, including: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement a testing method for an electric drive system as described in the above embodiments.

[0016] A fourth aspect of this application provides a computer-readable storage medium having a computer program stored thereon, which is executed by a processor to implement a test method for an electric drive system as described in the above embodiments.

[0017] Therefore, by acquiring the electric drive testing requirements of the electric drive system under test, and based on these requirements, controlling a load simulator, environmental simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test, the test information output by the electric drive system under test in the corresponding test state is obtained, and test results are generated based on the test information. This solves the problems of single test dimensions and insufficient dynamic performance evaluation in electric drive boost charging test methods. By simultaneously applying multi-dimensional electrical, thermal, and control stresses, it achieves the reproduction of real complex operating conditions. Through step disturbances and transient mode switching, the dynamic response capability and control robustness of the system are quantitatively evaluated, improving the fault detection rate and R&D efficiency.

[0018] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0019] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a flowchart of a test method for an electric drive system provided according to an embodiment of this application; Figure 2 This is a block diagram of a test apparatus for an electric drive system provided according to an embodiment of this application; Figure 3 This is a schematic diagram of the structure of an electronic device provided according to an embodiment of this application. Detailed Implementation

[0020] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0021] The following description, with reference to the accompanying drawings, outlines a testing method, apparatus, electronic device, and storage medium for an electric drive system according to embodiments of this application. Addressing the issues of limited testing dimensions and insufficient dynamic performance evaluation in the electric drive boost charging testing methods mentioned in the background, this application provides a testing method for an electric drive system. In this method, the electric drive testing requirements of the electric drive system under test are obtained. Based on these requirements, a load simulator, an environmental simulator, a simulated charging pile, and a battery simulator are controlled to provide at least one test state for the electric drive system under test. Test information output by the electric drive system under test in the corresponding test state is obtained, and test results are generated based on this information. This solves the problems of limited testing dimensions and insufficient dynamic performance evaluation in electric drive boost charging testing methods. By simultaneously applying multi-dimensional electrical, thermal, and control stresses, the system can reproduce real-world complex operating conditions. Through step disturbances and transient mode switching, the system's dynamic response capability and control robustness are quantitatively evaluated, improving fault detection rate and R&D efficiency.

[0022] Before introducing the testing method of the electric drive system in the embodiments of this application, let me first introduce the electric drive testing system used in the embodiments of this application, which includes: a simulated charging pile, a battery simulator, an environmental simulator, a load simulator, and a control module.

[0023] Among them, the simulated charging pile: adopts a DC power supply device with high dynamic response capability and programmable function to accurately simulate the output characteristics of various DC charging piles. Its voltage and current output range needs to cover the rated operating range of the electric drive system under test.

[0024] Battery simulator: It adopts a bidirectional programmable DC power supply or a dedicated battery simulator, which must have the function of simulating battery voltage, internal resistance, charge and discharge characteristics and different states of charge (SOC) to simulate power battery packs.

[0025] An environmental simulator is used to adjust the ambient temperature of the electric drive system under test, such as a programmable temperature and humidity chamber. Its temperature control range needs to cover the operating limit temperature of the device under test and provide a certain rate of temperature change.

[0026] The load simulator can be connected to a dynamometer or load cell to apply simulated loads to the motor, depending on the testing requirements.

[0027] The control module includes an information processing unit, an acquisition unit, a communication unit, and a fault injection unit. The information processing unit is used to run the simulation model, manage the test sequence, and realize high-speed closed-loop control. The acquisition unit has multiple channels and a high sampling rate to synchronously acquire various analog and digital signals such as voltage, current, and temperature. The communication unit is used to realize bus communication (such as CAN, LIN, etc.) between the system and the controller under test and various devices. The fault injection unit is used to condition the sensor signals and can simulate various fault states such as open circuit, short circuit, and resistance drift of various sensor circuits.

[0028] In actual implementation, the embodiments of this application may also employ a preset software platform to coordinate the entire testing process. The preset software platform is used for test sequence management, model-in-the-loop simulation, and data management and analysis.

[0029] Among them, test sequence management involves writing automated test scripts in the integrated development environment to control all hardware devices to perform actions according to preset timing and logic, and to achieve automated batch execution of test cases.

[0030] Model-in-the-loop simulation: Deploying a high-fidelity simulation model of the controlled object (such as a motor model or vehicle model) in a real-time processing device, which together with the controller under test constitutes a hardware-in-the-loop test environment.

[0031] Data Management and Analysis: All test data is stored synchronously in a central database with time stamps, and is processed, visualized (such as generating curves and maps), and generated reports using data analysis tools.

[0032] Specifically, Figure 1 This is a flowchart illustrating a testing method for an electric drive system provided in an embodiment of this application.

[0033] like Figure 1 As shown, the test method for this electric drive system includes the following steps: In step S101, the electric drive test requirements of the electric drive system to be tested are obtained.

[0034] Optionally, in some embodiments, the electric drive testing requirements include at least one of frequency sweep testing, transient disturbance response testing, multi-stress coupling testing, and fault diagnosis testing.

[0035] Among them, the electric drive system under test refers to an integrated electric drive assembly including a motor controller and a motor, with boost charging function; electric drive test requirements refer to the types of test tasks set to verify the performance and reliability of the system under different operating conditions; frequency sweep test refers to traversing the steady-state operating point under multi-dimensional parameter combinations to obtain the system performance baseline; transient disturbance response test refers to applying voltage or power step disturbances on the basis of steady-state operation to evaluate the system's dynamic recovery capability; multi-stress coupling test refers to simultaneously applying electrical, thermal and control extreme conditions to simulate complex and harsh operating conditions; fault diagnosis test refers to verifying the effectiveness of the system's fault identification and safety protection mechanisms by injecting sensor or communication faults.

[0036] Specifically, at the beginning of the testing process, the electric drive testing requirements of the electric drive system under test are first obtained to determine the subsequent test content and resource configuration. These requirements are determined by the test objectives and may include one or more combinations of frequency sweep testing, transient disturbance response testing, multi-stress coupling testing, and fault diagnosis testing. For example, if the objective is to build an efficiency map, frequency sweep testing is selected; if the objective is to verify control robustness, transient disturbance response testing or multi-stress coupling testing is enabled; if the objective is to evaluate functional safety, fault diagnosis testing is performed. By clearly defining the test requirements, the system can automatically configure the operating modes of the simulated charging pile, battery simulator, environmental simulation box, and central control unit to ensure that the testing process is consistent with the verification objectives.

[0037] In step S102, according to the electric drive test requirements, the load simulator, environment simulator, simulated charging pile, and battery simulator are controlled to provide at least one test state for the electric drive system under test.

[0038] Among them, the load simulator refers to a device used to apply a controllable mechanical load to the output shaft of the motor of the electric drive system under test, usually a dynamometer; the environmental simulator refers to an environmental test chamber with adjustable internal temperature to simulate different climatic conditions; the simulated charging pile refers to a programmable DC power supply used to simulate the output characteristics of external DC charging facilities; the battery simulator refers to a bidirectional programmable DC power supply used to simulate the voltage, state of charge and charging and discharging behavior of power batteries; the test state refers to specific operating conditions established by the above devices in collaboration, including steady-state operating points, dynamic disturbance conditions, multi-stress coupling environments or fault injection scenarios.

[0039] Specifically, after obtaining the electric drive test requirements, the controller analyzes the required test type based on these requirements and coordinates the operating parameters of the load simulator, environmental simulator, simulated charging pile, and battery simulator to jointly construct the corresponding test state. For example, if the requirements include frequency sweep testing, the output voltage of the simulated charging pile, the charging power and state of charge of the battery simulator are set, and the environmental simulator is stabilized at the reference temperature; if the requirements include multi-stress coupling testing, the environmental simulator is simultaneously adjusted to a high temperature, the simulated charging pile is subjected to fluctuating voltage, the battery simulator is set to a high-power absorption state, and the load simulator supports subsequent mode switching; if the requirements include fault diagnosis testing, after the system is running stably, the fault injection unit is triggered to simulate sensor abnormalities, and each device acts in concert according to preset timing and parameters to ensure that the test state accurately reproduces the target operating condition.

[0040] In step S103, the test information output by the electric drive system under test in the corresponding test state is obtained, so as to generate test results based on the test information.

[0041] Among them, test information refers to the raw or processed data output by the electric drive system under test through sensors, controllers or communication interfaces under specific test conditions, including but not limited to DC bus voltage, input / output current, system efficiency, IGBT heatsink temperature, motor winding temperature, phase current waveform, switching frequency, fault codes (DTC) and mode status signals; test results refer to the evaluable indicators or conclusions formed based on the test information after synchronous acquisition, time-stamp alignment and analysis, such as dynamic overshoot, recovery time, temperature rise trend, efficiency value, fault identification timeliness or performance map.

[0042] Specifically, the control module synchronously acquires multi-source test information from the electric drive controller, power unit, and environmental monitoring points through a high-speed data acquisition card, CAN / LIN communication interface, and signal conditioning module. All data is tagged with a unified clock to ensure time alignment. Subsequently, the test information is processed according to preset evaluation logic: in frequency sweep testing, the system efficiency at each operating point is calculated and an efficiency map is generated; in transient disturbance testing, the overshoot and stable recovery time of the bus voltage are extracted; in multi-stress coupling testing, the temperature peaks and fluctuation trends of key components are recorded; and in fault diagnosis testing, the accuracy and timeliness of fault code reporting are verified. Finally, the processed results are integrated into structured test results for performance evaluation or design feedback.

[0043] Optionally, in some embodiments, when the electric drive test requirement is a frequency sweep test, according to the electric drive test requirement, the load simulator, environment simulator, simulated charging pile, and battery simulator are controlled to provide at least one test state for the electric drive system under test, including: controlling the output voltage of the simulated charging pile to increase from a first voltage to a second voltage in a first preset step; controlling the charging power of the battery simulator to increase from a first power to a second power in a second preset step under each output voltage of the simulated charging pile; and controlling the battery simulator to simulate multiple states of charge to form multiple steady-state test points under each output voltage of the simulated charging pile and each charging power of the battery simulator.

[0044] Among them, the first preset step size, first voltage, second voltage, second preset step size, first power, and second power can be preset by the user, obtained through a limited number of experiments, or obtained through a limited number of computer simulations, and are not specifically limited here; the frequency sweep test refers to traversing multiple electrical operating points in a systematic stepping manner within the preset parameter range to obtain the performance baseline data of the electric drive system under steady-state conditions; the first voltage and the second voltage represent the starting and ending values ​​of the simulated charging pile output voltage, respectively; the first preset step size is a fixed increment of voltage increase; the first power and the second power represent the starting and ending values ​​of the battery simulator charging power, respectively; the second preset step size is a fixed increment of power increase; the state of charge (SOC) represents the remaining charge level of the power battery simulated by the battery simulator, expressed as a percentage; the steady-state test point refers to the stable working state after the system reaches thermal and electrical balance under a specific combination of output voltage, charging power, and state of charge.

[0045] Specifically, firstly, the output voltage of the simulated charging pile is controlled to gradually increase from a first preset step size to a second voltage, starting from a first voltage. Secondly, under each set output voltage, the battery simulator is controlled to operate in constant power mode, so that its charging power gradually increases from a first power to a second preset step size. Finally, under each combination of output voltage and charging power, the battery simulator is sequentially set to simulate multiple states of charge (such as 10%, 30%, 50%, and 80%), and the system is maintained for a sufficient duration under each combination of conditions until key parameters (such as bus voltage and temperature) tend to stabilize, forming a steady-state test point. All test points constitute a parameter space grid covering the entire operating range for systematically collecting performance data.

[0046] In actual implementation, the testing requirement of this application embodiment is frequency sweep test, and the purpose of the test is to obtain the performance baseline data of the system under all operating conditions.

[0047] The specific steps are as follows: (1) Set initial conditions: Set the ambient temperature to the reference temperature (e.g., 25°C).

[0048] (2) Parameter Scan: The main control computer automatically executes a three-layer loop test: First layer (voltage loop): Controls the output voltage (V_in) of the simulated charging pile to increase from the lowest value (e.g., 350V) to the highest value (e.g., 600V) in fixed steps (e.g., 50V). Second layer (power loop): Under each V_in, controls the power (P_req) received by the battery simulator according to the instruction to increase from the minimum power (e.g., 10kW) in steps (e.g., 20kW) to the maximum allowable power of the system (e.g., 150kW). Third layer (SOC loop): Under each (V_in, P_req) combination, sets the battery simulator to simulate different battery SOC values ​​(e.g., 10%, 30%, 50%, 80%).

[0049] (3) Data recording: At each steady-state test point (each (V_in, P_req, SOC) combination), after running continuously for at least 60 seconds, record the following parameters through the data acquisition system: System efficiency (η): η=(U_bat*I_bat) / (U_in*I_in)*100%; DC bus voltage (U_dc) and its ripple (U_ripple, required ≤±5V); Key point temperatures: IGBT heat sink temperature (T_igbt), motor winding temperature (T_winding, estimated by model or pre-embedded sensors); Control frequency: Actual switching frequency of inverter (F_sw) (4) Output: Generate a series of performance maps (such as efficiency map, temperature rise map) Optionally, in some embodiments, when the electric drive test requirement is a transient disturbance response test, according to the electric drive test requirement, the load simulator, environmental simulator, simulated charging pile, and battery simulator are controlled to provide at least one test state for the electric drive system under test, including: controlling the charging power of the battery simulator to a third power, the state of charge of the battery simulator to a first state, adjusting the environmental simulator to a first ambient temperature, and controlling the output voltage of the simulated charging pile to drop from a third voltage to a fourth voltage within a first preset duration, and restoring to the third voltage when the maintenance duration of the fourth voltage reaches a second preset duration.

[0050] The third power, first state, first ambient temperature, first preset duration, third voltage, fourth voltage, and second preset duration can be obtained through a limited number of experiments or computer simulations, without specific limitations. The third power is the constant charging power value set by the battery simulator during the test. The first state is the specific state of charge (SOC) simulated by the battery simulator. The first ambient temperature is the constant test temperature set by the environmental simulator. The third voltage is the initial output voltage of the simulated charging pile before the disturbance. The fourth voltage is the target output voltage during the disturbance, which is lower than the third voltage. The first preset duration is the time required for the voltage to drop from the third voltage to the fourth voltage, used to characterize the drop rate. The second preset duration is the duration for which the fourth voltage is maintained. A step drop refers to a voltage drop that is approximately vertical in a short period of time, forming a sudden excitation.

[0051] Specifically, when the electric drive test requires transient disturbance response testing, the system first establishes a stable initial operating condition: the battery simulator is controlled to absorb energy at the third power level, its state of charge is set to the first state, and the environmental simulator is adjusted to the first ambient temperature, so that the electric drive system under test enters a thermal-electrical equilibrium state. Subsequently, the central control unit instructs the simulated charging pile to rapidly step down its output voltage from the third voltage to the fourth voltage within a first preset time period, simulating a sudden drop in grid voltage. After this low voltage state lasts for a second preset time period, the simulated charging pile immediately restores the output voltage to the third voltage. Throughout the process, the high-speed data acquisition system synchronously records key parameters such as DC bus voltage, input current, control signals, and fault status to analyze the system's response characteristics to voltage surges, including overshoot, recovery time, and whether oscillation or protection shutdown occurs.

[0052] In actual implementation, the testing requirement of this application embodiment is transient disturbance response testing. The purpose of the test is to test the stability of the system under dynamic disturbances.

[0053] Operating steps: Set the system to enter steady-state boost charging state (e.g., V_in=500V, P_req=80kW, SOC=50%, T_env=25°C).

[0054] Execution of step disturbances: Case A (Input step): Using software commands, the output voltage of the simulated charging pile is caused to drop from 500V to 450V within 1ms, remain at that level for 100ms, and then recover. Case B (Load step): The power demand of the battery simulator is commanded to increase from 80kW to 120kW within 5ms.

[0055] Monitoring and Recording: A high-frequency data acquisition card (sampling rate ≥ 1MHz) records the overshoot of U_dc and the time to recover to the stable range (e.g., ±2%) within 500ms after the step jump. The waveform of the motor phase current (I_phase) is also recorded.

[0056] Evaluation criteria: Overshoot should be <5%, recovery time should be <50ms, and there should be no continuous oscillation during the process.

[0057] Optionally, in some embodiments, when the electric drive test requirement is a multi-stress coupling test, according to the electric drive test requirement, the load simulator, environmental simulator, simulated charging pile, and battery simulator are controlled to provide at least one test state for the electric drive system under test, including: controlling the charging power of the battery simulator to a fourth power, adjusting the environmental simulator to a second ambient temperature, and controlling the output voltage of the simulated charging pile to fluctuate sinusoidally around a first reference voltage with a first frequency and a first amplitude.

[0058] Among them, the fourth power is the high charging power value set by the battery simulator during the test, representing the heavy load operation state of the system; the second ambient temperature is the high temperature test condition set by the environmental simulator to introduce thermal stress; the first reference voltage is the DC center value of the simulated charging pile output voltage; the first frequency represents the number of cycles completed per second of the sinusoidal fluctuation, in Hertz (Hz); the first amplitude represents the peak offset of the output voltage fluctuating around the first reference voltage, in Volts (V); sinusoidal fluctuation refers to the AC disturbance in which the voltage changes continuously with time according to a sinusoidal function.

[0059] Specifically, when the electric drive test requires multi-stress coupling testing, the control module regulates each device to establish a composite stress test state: First, the charging power of the battery simulator is set to the fourth power, placing it in a high-load absorption state; second, the environmental simulator is adjusted to a second ambient temperature (e.g., 85°C) to apply thermal stress to the electric drive system under test; simultaneously, the output voltage of the simulated charging pile is controlled to superimpose a sinusoidal disturbance on its first reference voltage. This disturbance has a first frequency and a first amplitude, for example, fluctuating around the reference voltage (e.g., 500V) at a frequency of 5Hz and an amplitude of ±20V, to simulate grid voltage instability. The aforementioned electrical stress, thermal stress, and high-power load act synchronously on the electric drive system under test, forming a multi-dimensional coupled extreme condition. Under this state, the system runs continuously for a preset duration, and can further superimpose operations such as mode switching or fault injection to comprehensively assess its overall robustness and reliability boundaries.

[0060] In actual implementation, when the test requirement is multi-stress coupling test, the test objective is to assess the system limits under extreme combined stress.

[0061] The specific steps are as follows: Set coupling stress; set the ambient simulation chamber temperature to 85°C; set the simulated charging pile output voltage to the minimum value of 400V; set the battery simulator to the maximum required power of 150kW.

[0062] Injecting dynamic disturbances: Based on the above steady state, the command simulates the output voltage of the charging pile fluctuating sinusoidally at a frequency of 5Hz and an amplitude of ±20V.

[0063] Execution mode switching: After running for 300 seconds, a drive mode enable signal is sent via the CAN bus to simulate the driver pressing the accelerator while charging.

[0064] Full-process monitoring: Records data such as T_igbt, T_winding, U_dc, and I_phase from start to finish, with a focus on voltage and current surges during mode switching.

[0065] Final output: Obtain the overall performance and potential failure modes of the system under the worst operating conditions.

[0066] In addition, during actual implementation, when the test requirement is fault diagnosis testing, the purpose is to verify the accuracy and timeliness of fault detection and protection logic.

[0067] The specific steps are as follows: control the electric drive test system to operate normally under steady-state conditions.

[0068] Fault injection: The current sensor signal output value is artificially and slowly shifted by +8% through the fault injection unit (simulating sensor failure).

[0069] Monitoring and Recording: Monitor whether the motor controller detects a fault within 100ms, and record whether the reported fault codes (DTCs) are accurate (they should report "unreasonable current sensor signal" rather than a general fault); record the degradation strategy executed by the system (e.g., whether the power gradually decreases to 0 or the high voltage is immediately cut off).

[0070] Evaluation criteria: The fault should be accurately identified within the specified time and trigger safe and reasonable protective actions.

[0071] Therefore, this application embodiment can quantitatively scan the entire parameter space through frequency sweep testing, leaving no gaps and fundamentally avoiding test blind spots; through multi-stress coupling testing, multiple extreme stresses (high temperature, low pressure, high power, grid fluctuations) are actively combined and applied synchronously, creating complex scenarios that cannot be reproduced by a single test, thereby discovering coupled faults; through precise step disturbances in dynamic stress injection testing, it is like conducting a "stress test" on the control system, directly exposing its defects such as slow response, large overshoot, and susceptibility to oscillation. Engineers can optimize the PID parameters of the control algorithm based on the recorded precise waveform data, thereby directly improving dynamic performance. In addition, this application embodiment can generate test results based on test information. For example, the efficiency map can clearly show which operating range of the system is most efficient, thereby guiding the formulation of the vehicle's energy management strategy; the temperature rise map can identify the system's thermal bottleneck, providing a direct basis for the design and selection of radiators; and the peak values ​​and fluctuations of T_igbt and T_winding are continuously monitored. If the temperature continues to approach the material's limit value (such as 150°C), it indicates that the current design margin is insufficient. These quantified temperature data provide a direct basis for decision-making regarding whether to select a higher-level IGBT module or enhance heat dissipation capabilities, thereby improving reliability during the design phase.

[0072] To enable those skilled in the art to further understand the testing method of the electric drive system according to the embodiments of this application, a detailed description is provided below in conjunction with specific embodiments.

[0073] Example 1: System performance boundary test under multiple stress coupling conditions. Test objective: To investigate the comprehensive performance of the electric drive boost system under complex operating conditions and to identify performance boundaries and potential failure modes.

[0074] Implementation Procedure: Initial Condition Setup: The device under test is placed in a constant temperature environment (not at room temperature) using an environmental simulation device. The simulated DC power supply is set to a relatively low output voltage value, while the power requirement of the battery simulation device is set to a relatively high level.

[0075] Applying composite stress: Based on the above steady-state condition, the output voltage of the simulated DC power supply is subjected to a periodic fluctuation with a specific frequency and amplitude. After the system has been running stably for a period of time, a mode switching command is sent to the controller under test via the communication bus.

[0076] Data monitoring and acquisition: Throughout the testing process, the high-speed data acquisition system continuously monitors and records key data, such as DC bus voltage, current, power device temperature, and motor phase current.

[0077] Results Analysis: The analysis focuses on the voltage and current stability during mode switching transients, as well as the system's temperature rise trend and maximum temperature value throughout the multi-stress coupling phase. The reliability margin of the system under this extreme condition is evaluated by comparing it with design specifications.

[0078] In summary, Example 1, by actively constructing an extreme composite operating condition with high temperature, low voltage input, high power output, superimposed grid fluctuations and mode switching, can effectively expose system-level problems (such as control timing conflicts and insufficient heat dissipation) that are difficult to detect under single-factor testing, providing extremely valuable input for design improvement.

[0079] Example 2: Full-condition performance characteristic scanning test.

[0080] Test objective: To systematically obtain the performance of the boost charging function at different operating points and establish a comprehensive performance database.

[0081] Implementation Process: Under ambient temperature conditions, the control system automatically traverses a series of different input voltage, output power, and battery SOC combinations. At each combination point, after the system stabilizes, it automatically records performance parameters such as system efficiency and critical node temperature. Finally, all data points are integrated and analyzed to generate a system efficiency map and a temperature rise distribution map with input voltage and output power as coordinates.

[0082] In summary, the performance map produced in Example 2 is not a simple pass / fail verification. It can clearly indicate the system's high-efficiency operating range and thermal management pressure points, and can be directly used to guide the optimization of the vehicle's energy management strategy and the design and selection of the cooling system, realizing the direct empowerment of front-end design by test data.

[0083] Therefore, this application's embodiments solve the problem of "single-dimensional testing and lack of real-world operating condition simulation": most related technologies conduct isolated single-factor tests, which cannot simulate the complex scenarios where multiple stress conditions act simultaneously in real-world use. This application's embodiments, through a multi-stress coupling testing method, achieve simultaneous application of electrical, thermal, and mechanical stresses, solving the problem that single-factor testing cannot reveal systemic faults. In addition, it solves the problem of "insufficient dynamic performance and control robustness evaluation": addressing the shortcomings of related technologies that focus on steady-state verification, this application's embodiments, through dynamic step tests and mode-switching transient tests, can comprehensively assess the dynamic response characteristics of the system and the adaptability of the control algorithm under drastically changing operating conditions, filling the gap in in-depth dynamic performance evaluation. Finally, it solves the problem of "disconnect between testing and design optimization": this application's embodiments, through full-condition performance scanning tests and refined tests, generate a quantitative database that can be used for design optimization, directly solving the problem of test data not effectively serving product improvement.

[0084] The embodiments of this application have the following beneficial effects: (1) Comprehensive improvement of test coverage and fault detection capability: The use of multi-dimensional coupling test can simulate a more severe composite stress environment than the actual working conditions, and can detect systemic and coupled faults that are difficult to be exposed in conventional tests at an early stage, which greatly improves the reliability of product quality. This effect is directly brought about by the feature of "multi-dimensional coupling test".

[0085] (2) Significantly enhances the dynamic performance and reliability of the product: Through dynamic stress injection and transient testing, the performance indicators of the control system in the dynamic process can be accurately quantified, providing accurate experimental data support for the optimization of control parameters, and directly improving the dynamic performance and robustness of the product.

[0086] (3) Generate a high-value design optimization database: By adopting full-parameter spatial performance scanning test, it is possible to establish quantitative design basis such as system efficiency map and heat distribution database. These data can be directly used to guide the selection of power components, optimization of thermal management strategies and improvement of system efficiency, significantly shorten the R&D cycle and improve design accuracy.

[0087] (4) Achieve quantitative assessment of product reliability: Through refined thermal testing and stress analysis, the thermal behavior and stress state of key components can be monitored in real time during the testing process, thereby achieving quantitative assessment of product reliability. This provides experimental basis for product improvement and quality assurance, and improves product reliability from the source.

[0088] The testing method for an electric drive system proposed in this application obtains the electric drive test requirements of the electric drive system under test. Based on these requirements, a load simulator, an environmental simulator, a simulated charging pile, and a battery simulator are controlled to provide at least one test state for the electric drive system under test. The test information output by the electric drive system under test in the corresponding test state is obtained, and test results are generated based on the test information. This solves the problems of single test dimensions and insufficient dynamic performance evaluation in electric drive boost charging test methods. By simultaneously applying multi-dimensional electrical, thermal, and control stresses, the method achieves the reproduction of real complex operating conditions. Through step disturbances and transient mode switching, the system's dynamic response capability and control robustness are quantitatively evaluated, improving the fault detection rate and R&D efficiency.

[0089] Next, the test apparatus for the electric drive system proposed according to the embodiments of this application is described with reference to the accompanying drawings.

[0090] Figure 2 This is a block diagram of a test apparatus for an electric drive system according to an embodiment of this application.

[0091] like Figure 2 As shown, the test device 10 for the electric drive system includes: an acquisition module 100, a test module 200, and a generation module 300.

[0092] The acquisition module 100 is used to acquire the electric drive test requirements of the electric drive system to be tested.

[0093] The test module 200 is used to control the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirements. The generation module 300 is used to acquire the test information output by the electric drive system under test in the corresponding test state, so as to generate test results based on the test information.

[0094] Optionally, in some embodiments, the electric drive testing requirements include at least one of frequency sweep testing, transient disturbance response testing, multi-stress coupling testing, and fault diagnosis testing.

[0095] Optionally, in some embodiments, when the electric drive test requirement is a frequency sweep test, the test module 200 includes: a first control unit to a third control unit.

[0096] The first control unit is used to control the output voltage of the simulated charging pile to increase from the first voltage to the second voltage in a first preset step.

[0097] The second control unit is used to control the charging power of the battery simulator to increase from the first power to the second power in a second preset step size at each output voltage of the simulated charging pile.

[0098] The third control unit is used to control the battery simulator to simulate multiple states of charge and form multiple steady-state test points under each output voltage of the simulated charging pile and each charging power of the battery simulator.

[0099] Optionally, in some embodiments, when the electric drive test requirement is a transient disturbance response test, the test module 200 includes: a fourth control unit.

[0100] The fourth control unit is used to control the charging power of the battery simulator to the third power, the state of charge of the battery simulator to the first state, the environmental simulator to the first ambient temperature, and to control the output voltage of the simulated charging pile to drop from the third voltage to the fourth voltage within a first preset time period. When the maintenance time of the fourth voltage reaches the second preset time period, it is restored to the third voltage.

[0101] Optionally, in some embodiments, when the electric drive test requirement is a multi-stress coupling test, the test module 200 includes: a fifth control unit.

[0102] The fifth control unit is used to control the charging power of the battery simulator to the fourth power, adjust the environmental simulator to the second ambient temperature, and control the output voltage of the simulated charging pile to fluctuate sinusoidally around the first reference voltage with a first frequency and a first amplitude.

[0103] It should be noted that the foregoing explanation of the test method embodiment for the electric drive system also applies to the test device for the electric drive system in this embodiment, and will not be repeated here.

[0104] The testing apparatus for an electric drive system proposed in this application obtains the electric drive test requirements of the electric drive system under test, and controls a load simulator, an environmental simulator, a simulated charging pile, and a battery simulator to provide at least one test state for the electric drive system under test based on the electric drive test requirements. It then obtains the test information output by the electric drive system under test in the corresponding test state, and generates test results based on the test information. This solves the problems of single test dimensions and insufficient dynamic performance evaluation in electric drive boost charging test methods. By simultaneously applying multi-dimensional electrical, thermal, and control stresses, it achieves the reproduction of real complex working conditions. Through step disturbances and transient mode switching, it quantitatively evaluates the system's dynamic response capability and control robustness, improving the fault detection rate and R&D efficiency.

[0105] Figure 3 A schematic diagram of the structure of an electronic device provided in an embodiment of this application. The electronic device may include: The memory 301, the processor 302, and the computer program stored on the memory 301 and capable of running on the processor 302.

[0106] When the processor 302 executes the program, it implements the test method for the electric drive system provided in the above embodiments.

[0107] Furthermore, electronic devices also include: Communication interface 303 is used for communication between memory 301 and processor 302.

[0108] The memory 301 is used to store computer programs that can run on the processor 302.

[0109] The memory 301 may include high-speed RAM (Random Access Memory) memory, and may also include non-volatile memory, such as at least one disk storage.

[0110] If the memory 301, processor 302, and communication interface 303 are implemented independently, then the communication interface 303, memory 301, and processor 302 can be interconnected via a bus to complete communication between them. The bus can be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, or an EISA (Extended Industry Standard Architecture) bus, etc. The bus can be divided into address bus, data bus, control bus, etc. For ease of representation, Figure 3 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0111] Optionally, in a specific implementation, if the memory 301, processor 302, and communication interface 303 are integrated on a single chip, then the memory 301, processor 302, and communication interface 303 can communicate with each other through an internal interface.

[0112] Processor 302 may be a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), or one or more integrated circuits configured to implement the embodiments of this application.

[0113] This application also provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the above-described test method for the electric drive system.

[0114] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0115] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0116] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0117] It should be understood that the various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (FPGAs), field-programmable gate arrays (FPGAs), etc.

[0118] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0119] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A test method for an electric drive system, characterized in that, An electric drive testing system is employed, comprising: a load simulator, an environment simulator, and a simulated charging pile. The method includes the following steps: Obtain the electric drive test requirements of the electric drive system to be tested; According to the electric drive test requirements, control the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test; The test information output by the electric drive system under test in the corresponding test state is obtained, and the test results are generated based on the test information.

2. The method according to claim 1, characterized in that, The electric drive testing requirements include at least one of the following: frequency sweep test, transient disturbance response test, multi-stress coupling test, and fault diagnosis test.

3. The method according to claim 2, characterized in that, When the electric drive test requirement is the frequency sweep test, the step of controlling the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirement includes: The output voltage of the simulated charging pile is controlled to increase from a first voltage to a second voltage in a first preset step size; At each output voltage of the simulated charging pile, the charging power of the battery simulator is controlled to increase from the first power to the second power in a second preset step size; Under each output voltage of the simulated charging pile and each charging power of the battery simulator, the battery simulator is controlled to simulate multiple states of charge to form multiple steady-state test points.

4. The method according to claim 2, characterized in that, When the electric drive test requirement is a transient disturbance response test, the step of controlling the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirement includes: The charging power of the battery simulator is controlled to be the third power, the state of charge of the battery simulator is in the first state, the environmental simulator is adjusted to the first ambient temperature, and the output voltage of the simulated charging pile is controlled to drop from the third voltage to the fourth voltage within a first preset time period. When the maintenance time of the fourth voltage reaches the second preset time period, it is restored to the third voltage.

5. The method according to claim 2, characterized in that, When the electric drive test requirement is the multi-stress coupling test, the step of controlling the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirement includes: The charging power of the battery simulator is controlled to a fourth power, the environmental simulator is adjusted to a second ambient temperature, and the output voltage of the simulated charging pile is controlled to fluctuate sinusoidally around a first reference voltage with a first frequency and a first amplitude.

6. A testing device for an electric drive system, characterized in that, include: The acquisition module is used to acquire the electric drive test requirements of the electric drive system to be tested. The testing module is used to control the load simulator, environment simulator, simulated charging pile, and battery simulator to provide at least one test state for the electric drive system under test according to the electric drive test requirements. The generation module is used to acquire the test information output by the electric drive system under test in the corresponding test state, so as to generate test results based on the test information.

7. The apparatus according to claim 6, characterized in that, The electric drive testing requirements include at least one of the following: frequency sweep test, transient disturbance response test, multi-stress coupling test, and fault diagnosis test.

8. The apparatus according to claim 7, characterized in that, When the electric drive test requirement is the frequency sweep test, the test module includes: The first control unit is used to control the output voltage of the simulated charging pile to increase from the first voltage to the second voltage in a first preset step size; The second control unit is used to control the charging power of the battery simulator to increase from the first power to the second power in a second preset step size at each output voltage of the simulated charging pile. The third control unit is used to control the battery simulator to simulate multiple states of charge to form multiple steady-state test points under each combination of the output voltage of the simulated charging pile and each charging power of the battery simulator.

9. An electronic device, characterized in that, include: A memory, a processor, and a computer program stored in the memory and executable on the processor, the processor executing the program to implement a test method for an electric drive system as described in any one of claims 1-5.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, The program is executed by the processor to implement the test method for the electric drive system as described in any one of claims 1-5.

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