A test method and test tool for a new energy vehicle motor driver

Abstract

This invention discloses a testing fixture for a new energy vehicle motor driver, including a motor under test, a power battery, a motor driver, a driver testing device, a sensor group, a PLC metering device, and an ECU signal receiving testing device. The driver testing device is used to fix the motor driver and measure its input and output signals. The driver testing device includes a base, an automatic telescopic pressurizing mechanism, and contact heads. Each contact head includes at least several contact pieces, and each contact piece has at least one arc surface that can mate with a contact hole. This testing fixture achieves multi-stage pressurization through the automatic telescopic pressurizing mechanism and provides stability for the controller test through clamping devices and vibration damping plates. It enables rapid installation of the motor driver, greatly improving the testing efficiency. The tester does not need frequent movement and adjustment; simply installing the motor driver on the base of the driver testing device allows the motor driver to automatically complete positioning and contact connection, reducing labor intensity.

Description

Technical Field

[0001] This invention relates to the field of motor control for new energy vehicles, and in particular to a testing method and testing fixture for a new energy vehicle motor driver. Background Technology

[0002] The motor driver issues corresponding control commands based on the input signals from the brake pedal and accelerator pedal to control the speed and direction of the drive motor, thereby driving the electric vehicle.

[0003] As the most crucial controller component in a vehicle, the quality of the motor driver is paramount. Current technology typically involves directly powering on the controller and then connecting it to the test motor, a cumbersome process, particularly time-consuming disassembly and assembly, resulting in low testing efficiency. Furthermore, the direct connection to the motor driver exposes it to vibrations during operation, leading to unstable connection at the test sampling signal points. Additionally, the entire functional testing process is labor-intensive and inefficient, particularly hindering the batch testing of motor drivers.

[0004] Therefore, how to improve the automation level and accuracy of the entire functional testing process has become an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0005] This invention overcomes the shortcomings of the prior art and provides a testing method and testing fixture for a new energy vehicle motor driver.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a testing fixture for a new energy vehicle motor driver, characterized in that it includes: a motor under test, a power battery, a motor driver, a driver testing device, a sensor group, a PLC metering device, and an ECU signal receiving testing device; the power battery is electrically connected to the motor under test and supplies power to the motor under test; the motor driver is connected to the motor under test, and the surface of the motor driver is provided with a plurality of contact holes; the sensor group tests the direction and speed of the motor under test; the metering device collects the PLC encoding conversion values; and the ECU signal receiving testing device collects ECU signal output commands.

[0007] The driver testing device is used to fix the motor driver and measure the input and output signals of the motor driver. The driver testing device includes a base, an automatic telescopic pressurization mechanism, and a contact head. The contact head includes at least a plurality of contact pieces, and each contact piece has at least one arc surface that can mate with the contact hole.

[0008] The bottom of the groove in the base is provided with a vibration damping plate; the automatic telescopic pressurization mechanism includes a support rod, a rotating telescopic rod, a pressure plate, a connecting groove opened on the pressure plate and a plate provided on the top of the connecting groove. The support rod is fixed on the base, and the rotating telescopic rod can realize vertical and circumferential movement to drive the rotation and vertical movement of the pressure plate.

[0009] In a preferred embodiment of the present invention, the contact piece has the ability to elastically deform.

[0010] In a preferred embodiment of the present invention, the contact piece is further provided with a through hole to buffer deformation.

[0011] In a preferred embodiment of the present invention, the contact piece is formed with a waist-shaped transition.

[0012] In a preferred embodiment of the present invention, the test fixture further includes an oscilloscope connected to the motor under test, used to acquire and output the operating current waveform of the motor under test.

[0013] In a preferred embodiment of the present invention, the end of the contact piece away from the contact hole extends 1-2 mm beyond the communicating groove.

[0014] In a preferred embodiment of the present invention, a clamping device is provided on the inner wall of the groove, wherein the clamping device is a spring or a self-expanding clamp.

[0015] In a preferred embodiment of the present invention, the contact piece and the contact hole are connected by crimping or contact.

[0016] This invention also provides a testing method for a new energy vehicle motor driver, comprising:

[0017] When the accelerator pedal and brake pedal output signals, the ECU responds to the acceleration or braking signal, and the ECU signal receiving device samples the ECU input and output signals.

[0018] PLC metering devices measure the encoded signals of PLC inputs and outputs;

[0019] The motor driver is installed in the base groove of the driver test device. After being positioned and pressed, the external tester is connected to the connecting groove and pressed by the plate to collect the input and output signals of the motor driver.

[0020] The motor under test is connected to the power battery. The control commands of the motor driver control the speed and direction of the motor under test. The speed and direction signals are sampled by the sensor group.

[0021] In a preferred embodiment of the present invention, a big data comparison and analysis is performed on the sampling signals of the ECU signal receiving test device, the encoded signals measured by the PLC metering device, the sampling signals of the driver test device, and the signals of the motor speed and direction of the motor under test sampled by the sensor group to determine whether these four types of collected signals fall within the standard threshold, and then determine whether the function of the motor driver meets the design requirements.

[0022] This invention addresses the shortcomings of the prior art and has the following beneficial effects:

[0023] (1) The present invention provides a test fixture for a new energy vehicle motor driver. The test fixture achieves multi-stage pressurization through an automatic telescopic pressurization mechanism, and provides stability for the test of the controller through a clamping device and a damping plate. It can realize the rapid installation of the motor driver and greatly improve the test efficiency of the motor driver.

[0024] (2) The present invention uses a contact head to make contact or press-fit connection with the contact hole on the motor driver, which improves the reliability of the connection.

[0025] (3) During the testing of this invention, the tester does not need to move and adjust frequently. He only needs to install the motor driver on the base of the driver testing device. The motor driver automatically completes the positioning and contact connection, which reduces the labor intensity.

[0026] (4) The present invention analyzes and compares the sampling signals of the ECU signal receiving test device, the encoded signals measured by the PLC metering device, the sampling signals of the driver test device, and the signals of the speed and direction of the motor under test sampled by the sensor group, and samples the control signals of the entire system, which can improve the accuracy during testing. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the test fixture according to a preferred embodiment of the present invention;

[0029] Figure 2 This is a perspective structural diagram of the driver testing device and motor driver assembly according to a preferred embodiment of the present invention;

[0030] Figure 3 This is a perspective structural diagram of a driver testing device according to a preferred embodiment of the present invention;

[0031] Figure 4 This is a preferred embodiment of the present invention. Figure 2 A magnified view of position A in the middle;

[0032] In the diagram: 1. Driver testing device; 11. Base; 111. Groove; 112. Vibration damping plate; 113. Clamping device; 12. Automatic telescopic pressurization mechanism; 121. Support rod; 122. Rotary telescopic rod; 123. Pressure plate; 124. Connecting groove; 125. Plate; 13. Contact head; 131. Contact piece; 2. Motor driver; 21. Contact hole. Detailed Implementation

[0033] 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 some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein. Therefore, the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0035] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this application. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0036] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0037] like Figure 1 The diagram shows a structural schematic of a test fixture for a new energy vehicle motor driver 2. The test fixture includes: a motor under test (DUT), a power battery, a motor driver 2, a driver testing device 1, a sensor group, a PLC metering device, and an ECU signal receiving testing device. The power battery is electrically connected to the DUT and supplies power to it; the motor driver 2 is connected to the DUT, and its surface has several contact holes 21; the sensor group tests the direction and speed of the DUT; the metering device collects PLC encoding conversion values; and the ECU signal receiving testing device collects ECU signal output commands. The test fixture also includes an oscilloscope connected to the DUT for collecting and outputting the operating current waveform of the DUT. This test fixture achieves multi-stage pressurization through an automatic telescopic pressurization mechanism 12, and provides stability for the controller test through a clamping device 113 and vibration damping plates 112, enabling rapid installation of the motor driver 2 and greatly improving the testing efficiency of the motor driver 2.

[0038] like Figure 2 and Figure 3 As shown, the driver testing device 1 is used to fix the motor driver 2 and measure the input and output signals of the motor driver 2. The driver testing device 1 includes a base 11, an automatic telescopic pressurizing mechanism 12, and a contact head 13. A groove 111 is provided in the base 11 for mounting the motor driver 2. Slots are provided on both sides of the groove 111 to accommodate the wiring harness connected to the motor driver 2. A damping plate 112 is provided at the bottom of the groove 111 in the base 11, and a clamping device 113 is provided on the inner wall of the groove 111. The clamping device 113 includes, but is not limited to, springs or self-retracting clamps, the purpose of which is to enable the motor driver 2 to be automatically positioned and installed.

[0039] like Figure 4 As shown, the automatic telescopic pressurizing mechanism 12 of this invention includes a support rod 121, a rotating telescopic rod 122, a pressure plate 123, a connecting groove 124 formed on the pressure plate 123, and a mounting plate 125 disposed on the top of the connecting groove 124. The support rod 121 is fixed to the base 11 and can be fixed to the base 11 by bolts. The rotating telescopic rod 122 can realize vertical and circumferential movement to drive the rotation and vertical movement of the pressure plate 123.

[0040] The contact head 13 of the present invention includes at least a plurality of contact pieces 131, each contact piece 131 having at least one arc surface that can mate with the contact hole 21. The contact pieces 131 are formed with an oblong transition.

[0041] The end of contact piece 131 furthest from contact hole 21 extends 2mm beyond the connecting groove 1241, allowing the plate 125 to press against the external tester and contact piece 131 as it moves downwards, ensuring reliable contact. The rotating telescopic rod 122 acts as the first stage of vertical pressurization for the contact head 13, providing coarse control over the vertical pressurization stroke; the plate 125 acts as the second stage of vertical pressurization for the contact head 13, providing precise control over the vertical pressurization stroke. This multi-stage pressurization increases the contact stability between contact piece 131 and contact hole 21.

[0042] To improve the contact stability between the contact piece 131 and the contact hole 21, the material of the contact piece 131 is designed to have elastic deformation capability. The waist-shaped transition portion of the contact piece 131 is slightly larger than the contact hole 21, therefore the contact piece 131 and the contact hole 21 are press-fitted. The contact piece 131 also has through holes to buffer deformation and prevent excessive deformation of the contact piece 131 during press-fitting, which could lead to damage due to the material of the contact piece 131 itself or external environmental factors such as temperature.

[0043] The outer surface of each contact piece 131 can be, but is not limited to, U-shaped or concave, which will not be described in detail here. The purpose is to allow the arc-shaped portion of the contact piece 131 to make contact or be pressed with the contact hole 21 through the concave structure, thereby increasing the contact area and increasing the reliability of the connection.

[0044] This invention also provides a test method for a new energy vehicle motor driver 2, comprising:

[0045] When the accelerator pedal and brake pedal output signals, the ECU responds to the acceleration or braking signal, and the ECU signal receiving device samples the ECU input and output signals.

[0046] PLC metering devices measure the encoded signals of PLC inputs and outputs;

[0047] The motor driver 2 is installed in the groove 111 of the base 11 of the driver test device 1. After being positioned and pressed, the external tester is connected to the connecting groove 124 and pressed by the plate 125 to collect the input and output signals of the motor driver 2.

[0048] The motor under test is connected to the power battery. The control commands of the motor driver 2 are used to control the speed and direction of the motor under test. The speed and direction signals are sampled by the sensor group.

[0049] By conducting big data comparison and analysis on the sampling signals of the ECU signal receiving test device, the encoded signals measured by the PLC metering device, the sampling signals of the driver test device 1, and the signals of the motor speed and direction of the motor under test sampled by the sensor group, it is determined whether these four types of collected signals fall within the standard threshold, and then it is determined whether the function of the motor driver 2 meets the design requirements. Sampling the control signals of the entire system can improve the accuracy during testing.

[0050] During testing, the tester does not need to move and adjust frequently. He only needs to install the motor driver 2 on the base 11 of the driver testing device 1. The motor driver 2 automatically completes the positioning and contact connection, which reduces the labor intensity.

[0051] Based on the preferred embodiments of the present invention described above, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A testing fixture for a new energy vehicle motor driver, characterized in that, include: Test devices include: motor under test, power battery, motor driver, driver testing device, sensor group, PLC metering device, and ECU signal receiving testing device. The power battery is electrically connected to the motor under test and supplies power to the motor under test; the motor driver is connected to the motor under test, and the surface of the motor driver is provided with several contact holes; the sensor group tests the direction and speed of the motor under test; the PLC metering device collects the PLC encoding conversion values; the ECU signal receiving test device collects the ECU signal output instructions; The driver testing device is used to fix the motor driver and measure the input and output signals of the motor driver. The driver testing device includes a base, an automatic telescopic pressurization mechanism, and a contact head. The contact head includes at least a plurality of contact pieces, and each contact piece has at least one arc surface that can mate with the contact hole. The bottom of the groove in the base is provided with a damping plate; the automatic telescopic pressurization mechanism includes a support rod, a rotating telescopic rod, a pressure plate, a connecting groove opened on the pressure plate and a plate provided on the top of the connecting groove. The support rod is fixed on the base, and the rotating telescopic rod can realize vertical and circumferential movement to drive the rotation and vertical movement of the pressure plate. The contact piece has the ability to elastically deform; The contact piece is also provided with through holes to buffer deformation; The contact piece has a waist-shaped transition; The test fixture also includes an oscilloscope connected to the motor under test, used to acquire and output the operating current waveform of the motor under test.

2. The test tool of a new energy vehicle motor driver according to claim 1, characterized in that: The end of the contact piece furthest from the contact hole extends 1-2 mm beyond the communicating groove.

3. The test tool of a new energy vehicle motor driver according to claim 1, characterized in that: The inner wall of the groove is provided with a clamping device, which is a spring or a self-expanding clamp.

4. The test tool of a new energy vehicle motor driver according to claim 1, characterized in that: The contact piece and the contact hole are connected by crimping or by contact.

5. A testing method of a new energy vehicle motor driver, using the testing tool of the new energy vehicle motor driver according to any one of claims 1-4, characterized in that, include: When the accelerator pedal and brake pedal output signals, the ECU responds to the acceleration or braking signal, and the ECU signal receiving device samples the ECU input and output signals. PLC metering devices measure the encoded signals of PLC inputs and outputs; The motor driver is installed in the base groove of the driver test device. After being positioned and pressed, the external tester is connected to the connecting groove and pressed by the plate to collect the input and output signals of the motor driver. The motor under test is connected to the power battery. The control commands of the motor driver control the speed and direction of the motor under test. The speed and direction signals are sampled by the sensor group. Big data comparison and analysis are performed on the sampling signals of the ECU signal receiving test device, the encoded signals measured by the PLC metering device, the sampling signals of the driver test device, and the signals of the motor speed and direction of the motor under test sampled by the sensor group to determine whether these four types of collected signals fall within the standard threshold, and then determine whether the function of the motor driver meets the design requirements.

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