A vibration test device connection structure and automobile controller test equipment

Abstract

The present invention proposes a vibration test device connection structure and an automobile controller test device using the connection structure, comprising a base plate, a test piece fixing frame mounted on the base plate, and a plurality of fixing components arranged on the periphery of the test piece fixing frame; a connection seat is provided on the test piece fixing frame, and a slope is provided on the top of the connection seat; a window is provided in the middle of the slope, and a first wire groove is provided on the side of the test piece fixing frame; a coolant pipe fixing component is provided on the periphery of one side of the bottom edge of the slope, a first wire harness fixing component is provided on the periphery of one side of the slope, and a second wire harness fixing component is provided on the periphery of the other side of the slope. The present invention can simultaneously tilt and fix two or more controllers for testing, thereby improving test efficiency and reducing test costs; the fixing component for fixing external pipes is optimized in design to prevent external high-voltage wire harnesses, low-voltage wire harnesses, coolant pipes, PDU wire harnesses, etc. from affecting the test or being damaged during the load endurance test.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile manufacturing, and in particular to a vibration testing device connection structure and automobile controller testing equipment. Background Art

[0002] With the continuous development of new energy vehicles, controllers and all-in-one controllers have become essential components for passenger cars, commercial vehicles, and construction machinery. Based on traditional controllers, all-in-one controllers have gradually developed, integrating OBCs (on-board chargers), DC-DC converters, MCUs, and PDUs (high-voltage and high-current distribution units).

[0003] Vibration testing is required to verify that the controller and its internal components meet the standard strength requirements for the automotive sector. A connection structure is required between the vibrator and the controller to secure the controller to the vibrator. To meet the actual placement of controllers in new energy vehicles and construction machinery, various test connection structures have emerged. The most common are horizontal and vertical plate connections. The horizontal plate connection connects the controller to the vibration device via a horizontal steel (aluminum) plate, while the vertical plate connection welds the horizontal (aluminum) plate to the vertical steel (aluminum) plate and uses reinforcing ribs to enhance the connection's strength.

[0004] To optimize the layout of controllers on hybrid vehicles, tilted placement has become a trend. However, traditional horizontal and vertical plate connection structures cannot accommodate vibration testing with controllers tilted at a specific angle, nor can they accommodate the tilted placement of two or more controllers on a single vibration device. Summary of the Invention

[0005] In view of the above, the present invention proposes a vibration testing device connection structure and an automobile controller testing device using the connection structure, which is used to solve the problem that the current horizontal plate type and vertical plate type connection structures cannot realize the controller tilting at a certain angle for vibration testing, and the problem that two or more controllers cannot be tested simultaneously on one vibration device.

[0006] The present invention provides a vibration test device connection structure, comprising a base plate, a test piece fixing frame mounted on the base plate, and a plurality of fixing components arranged on the periphery of the test piece fixing frame;

[0007] The test piece fixing frame is provided with a connecting seat, and the top of the connecting seat is provided with an inclined surface;

[0008] A window is provided in the middle of the inclined surface, and a first wire groove is provided on the side of the test piece fixing frame;

[0009] A coolant pipe fixing assembly is arranged on the periphery of one side of the bottom edge of the inclined surface, a first wire harness fixing assembly is arranged on the periphery of one side of the inclined surface, and a second wire harness fixing assembly is arranged on the periphery of the other side of the inclined surface.

[0010] Preferably, the main body of the first wire harness fixing assembly is a plate-like structure, which is fixedly mounted on the bottom plate, and has a first wire clamping arc hole on one side in the width direction and a second wire clamping arc hole on the other side;

[0011] The first wire harness fixing assembly further includes a side wire clamping plate, the side surface of the side wire clamping plate is provided with a third wire clamping arc hole that matches the first wire clamping arc hole;

[0012] The plate-like structure is also provided with a plurality of soft wire through holes, and the plurality of soft wire through holes are located on the periphery of the second wire clamping arc hole.

[0013] Preferably, the first wiring harness fixing assembly further includes a high voltage wiring harness, a PDU wiring harness and a low voltage wiring harness;

[0014] The first wire clamping arc hole and the third wire clamping arc hole are used to clamp and fix the high-voltage wire harness;

[0015] Two second wire clamping arc holes are provided on the plate-like structure, one of which is used to bind and fix the low-voltage wire harness, and the other is used to bind and fix the PDU wire harness.

[0016] Preferably, reinforcement plates are provided on both sides of the plate-like structure in the thickness direction, and the bottoms of the reinforcement plates are fixed to the base plate.

[0017] Preferably, the top of the second wiring harness fixing assembly is tilted, and its tilt angle is parallel to the inclined plane;

[0018] The second wiring harness fixing assembly includes a wiring block, a wiring fixing plate, a three-phase wiring harness and a copper busbar;

[0019] A second wire groove extending parallel to the inclined surface is provided on the side of the test piece fixing frame, and the terminal block is fixedly installed on the outer side of the test piece fixing frame along the second wire groove;

[0020] One end of the copper busbar is connected to the test piece, and the other end is connected to the three-phase wiring harness through the terminal block;

[0021] The cable fixing plate is fixedly installed on the bottom plate, and a slope is provided on the top of the plate, and the plane where the slope is located is parallel to the inclined surface.

[0022] Preferably, a straight knurled sleeve is embedded on the terminal block;

[0023] A cable arrangement clamp for clamping and fixing the three-phase wiring harness is installed on the slope. A row of upper semi-arc holes is provided at the bottom of the cable arrangement clamp, and lower semi-arc holes matching the upper semi-arc holes are provided on the slope.

[0024] Preferably, the coolant pipe fixing assembly includes a fixing plate, and a liquid inlet pipe and a liquid outlet pipe fixed on the top of the fixing plate;

[0025] The fixing plate is located at the periphery of the bottom edge of the inclined surface, and the bottom of the fixing plate is fixedly connected to the bottom plate;

[0026] The extending directions of the liquid inlet pipe and the liquid outlet pipe are parallel to the inclined plane.

[0027] Preferably, the test piece fixing frame is provided with two connecting seats;

[0028] The two connecting seats are symmetrically arranged on both sides of the test piece fixing frame.

[0029] Preferably, the test piece fixing frame is provided with a plurality of connecting seats;

[0030] The plurality of connection seats are evenly distributed in a ring shape around the periphery of the test piece fixing frame.

[0031] An automobile controller testing device is provided with a vibration testing device connection structure as described in any one of the above technical solutions. The vibrator of the automobile controller testing device is an XYZ three-directional vibrator.

[0032] The beneficial effects of the present invention are: it can simultaneously tilt and fix two or more controllers for testing, so as to improve test efficiency and reduce test costs; the fixing components for fixing external pipes are optimized in design to avoid external high-voltage wiring harnesses, low-voltage wiring harnesses, coolant pipes, PDU wiring harnesses, etc. from affecting the test or being damaged during the load endurance test. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The present invention is described in detail below with reference to the embodiments and accompanying drawings, in which:

[0034] Figure 1 It is a three-dimensional diagram of the connection structure of the vibration test device.

[0035] Figure 2 It is a top view of the connection structure of the vibration test device.

[0036] Figure 3 It is a structural explosion diagram of the connection structure of the vibration test device.

[0037] Figure 4 It is a side view of the connection structure of the vibration test device.

[0038] Figure 5 It is a front view of the connection structure of the vibration test device.

[0039] Figure 6 This is the structural exploded diagram of the controller.

[0040] Figure 7 It is a structural diagram of the test piece fixing frame.

[0041] Figure 8 It is a structural exploded diagram of the first wiring harness fixing component.

[0042] Figure 9 It is an exploded view of the structure of the second wiring harness fixing component.

[0043] Figure 10 It is an exploded view of the coolant pipe fixing assembly.

[0044] Description of reference numerals:

[0045] 1- bottom plate, 2- test piece fixing frame, 21- connecting seat, 211- inclined plane, 22- window, 23- first wire slot, 24- second wire slot, 3- coolant pipe fixing assembly, 31- fixing plate, 32- liquid inlet pipe, 33- liquid outlet pipe, 4- first wire harness fixing assembly, 41- first wire clamping arc hole, 42- second wire clamping arc hole, 43- third wire clamping arc hole, 44- side wire clamping plate, 45- soft wire through hole, 46- high voltage wire harness, 47- low voltage wire harness, 48- PD U wiring harness, 49-reinforcement plate, 5-second wiring harness fixing assembly, 51-terminal block, 511-straight knurled copper sleeve, 52-cable fixing plate, 521-slope, 5211-lower semi-arc hole, 522-cable clamping plate, 5221-upper semi-arc hole, 53-three-phase wiring harness, 54-copper busbar, 100-controller, 110-upper cover, 120-lower cover, 130-high-voltage two-pole plug-in, 140-PDU plug-in, 150-low-voltage plug-in, 160-resin terminal block. DETAILED DESCRIPTION

[0046] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0047] Thus, a feature indicated in this specification is intended to illustrate one of the features of one embodiment of the present invention, rather than to imply that every embodiment of the present invention must have the described feature. In addition, it should be noted that this specification describes many features. Although certain features can be combined together to illustrate possible system designs, these features can also be used in other, not explicitly described, combinations. Thus, unless otherwise noted, the described combinations are not intended to be limiting.

[0048] The following is combined with Figure 1-10 The principles of the present invention are described in detail with reference to the accompanying drawings and embodiments.

[0049] The present invention proposes a vibration test device connection structure, comprising a base plate 1, a test piece fixing frame 2 mounted on the base plate 1, and a plurality of fixing components arranged on the periphery of the test piece fixing frame 2;

[0050] The test piece fixing frame 2 is provided with a connecting seat 21, and the top of the connecting seat 21 is provided with an inclined surface 211;

[0051] A window 22 is provided in the middle of the inclined surface 211, and mounting holes for fixing the controller are provided on the side strips around the window 22;

[0052] Two first wire grooves 23 are provided on the side of the test piece fixing frame 2;

[0053] A coolant pipe fixing assembly 3 is provided on the periphery of one side of the bottom edge of the inclined surface 211 , a first wire harness fixing assembly 4 is provided on the periphery of one inclined side, and a second wire harness fixing assembly 5 is provided on the periphery of the other inclined side.

[0054] This connection structure can simultaneously tilt and fix two or more controllers for testing, so as to improve test efficiency and reduce test costs; the fixing components for fixing external pipes are optimized to prevent external high-voltage wiring harnesses, low-voltage wiring harnesses, coolant pipes, PDU wiring harnesses, three-phase wiring harnesses, etc. from affecting the test or being damaged during the load endurance test.

[0055] The test piece fixture 2, coolant pipe fixture assembly 3, first wiring harness fixture assembly 4, and second wiring harness fixture assembly 5 are connected to the base plate 1 by welding and screwing. Welding is more effective for vibration testing, while screwing is less effective. However, screwing allows for disassembly, facilitating installation and repair. A combination of screwing and welding can also be used, where the above components are first screwed to the base plate 1 and then welded. This method is more convenient to install and has higher connection strength.

[0056] The controller 100 tested in this embodiment has a shell composed of an upper cover 110 and a lower cover 120 fixed by screws. The outside of the upper cover 110 is installed with a high-voltage two-pole plug-in 130, a PDU plug-in 140 and a low-voltage plug-in 150, and the outside of the lower cover 120 is installed with a resin terminal block 160, as well as the water inlet and outlet of the circulating cooling system.

[0057] During vehicle installation, the high-voltage bipolar connector 130 connects to the vehicle's charging port via a high-voltage wiring harness. The low-voltage connector 150 connects to the vehicle's low-voltage electrical equipment via a low-voltage wiring harness. The PDU connector 140 connects to the vehicle's electric air-conditioning compressor's wiring port via a PUD wiring harness. The resin terminal block 160 is a plastic-coated assembly containing six copper busbars. Three of these are connected to the generator's three-phase output terminal via a three-phase wiring harness, and the remaining three are connected to the motor's three-phase output terminal via a three-phase wiring harness. The high-voltage wiring harness is 50mm², while the entire low-voltage wiring harness consists of 40-50 thin wires with a diameter of 1.5mm. The PUD wiring harness consists of two wires with a diameter of 10mm, and the three-phase wiring harness is 50mm². The connecting wiring harnesses of various components are large in diameter and high in rigidity. During vibration testing, the swing of the wiring harnesses of each component significantly affects the test results, so the wiring harnesses of each component need to be fixed to the vibration device.

[0058] When testing the controller, first fix the controller 100 on the inclined surface 211, then fix the external wires and tubes of the controller 100 on the fixed components, and then perform a base frequency sweep test and a power-on and load endurance test.

[0059] The sensor signal line for testing can pass through the two first wire grooves 23 into the test piece fixing frame 2 and then be connected to the controller at the window 22 .

[0060] In this embodiment, the first harness fixing assembly 4 is used to fix the high-voltage harness 46, the low-voltage harness 47, and the PDU harness 48. The main body of the first harness fixing assembly 4 is a plate-like structure fixedly mounted on the base plate 1. One side of the plate-like structure is provided with a first wire clamping arc hole 41, and the other side is provided with a second wire clamping arc hole 42.

[0061] The first wire harness fixing assembly 4 further includes a side clamping plate 44, and a third clamping arc hole 43 is formed on the side of the side clamping plate 44 to match the first clamping arc hole 41;

[0062] The plate-like structure is further provided with a plurality of flexible wire through holes 45 , which are located around the second wire clamping arc hole 42 .

[0063] The first wire clamping arc hole 41 and the third wire clamping arc hole 43 are used to clamp the high-voltage wire harness 46 connected to the test piece. One end of the high-voltage wire harness 46 is connected to the high-voltage two-pole plug-in 130, and the other end is clamped and fixed to one side of the first wire harness fixing assembly 4 through the side wire clamping plate 44;

[0064] Two second wire clamping arc holes 42 are provided on the plate-like structure, one of which is used to bind and fix the low-voltage wire harness 47 connected to the test piece, and the other is used to bind and fix the PDU wire harness 48 connected to the test piece; one end of the low-voltage wire harness 47 is connected to the low-voltage plug-in 150, and the other end is fixed to the other side of the first wire harness fixing component 4 with a soft rope through the soft wire through-hole 45; one end of the PDU wire harness 48 is connected to the PDU plug-in 140, and the other end is fixed to the same side as the low-voltage wire harness 47 with a soft rope through the soft wire through-hole 45.

[0065] In order to improve the strength of the first wire harness fixing assembly 4 , reinforcement plates 49 are welded on both sides of the plate-like structure in the thickness direction, and the bottom of the reinforcement plate 49 is fixed on the bottom plate 1 .

[0066] In this embodiment, the second harness fixing assembly 5 is used to fix the three-phase harness. When the vehicle is assembled, one end of the three-phase harness is connected to the resin terminal block 160 of the controller, and the other end is connected to the vehicle drive motor and generator.

[0067] The three-phase wiring harness 53 is pre-installed on the second wiring harness fixing assembly 5. Since the controller 100 is fixed at an angle on the inclined surface 211, in order to facilitate the docking of the three-phase wiring harness with the resin terminal block 160 and avoid interference of the wiring harness with the test during the vibration test, the top of the second wiring harness fixing assembly 5 is tilted, and its inclination angle is parallel to the inclined surface 211.

[0068] The second wiring harness fixing assembly 5 includes a wiring strip seat 51, a wiring fixing plate 52, a three-phase wiring harness 53 and a copper busbar 54;

[0069] A second wire groove 24 extending parallel to the inclined surface 211 is formed on the side of the test piece holder 2. The terminal block 51 is fixedly mounted on the outside of the test piece holder 2 along the second wire groove 24.

[0070] The cable fixing plate 52 is fixedly mounted on the base plate 1 and has a slope 521 on its top that is parallel to the inclined surface 211. A cable clamping plate 522 is mounted on the slope 521 to clamp and secure the three-phase wiring harness 53. The bottom of the cable clamping plate 522 has a row of upper semi-arc holes 5221, and the slope 521 has lower semi-arc holes 5211 that match the upper semi-arc holes 5221.

[0071] One end of the three-phase wiring harness 53 is clamped and secured by a cable retaining plate 52 to prevent swinging during vibration testing and potentially affecting the test results. The other end of the three-phase wiring harness 53 is secured to the terminal block 51 via screws. The terminal block 51 is inlaid with a straight knurled copper sleeve 511 or a straight knurled steel sleeve to enhance contact strength and facilitate the securing of the copper busbar 54. One end of the copper busbar 54 passes through the second wire channel 24 and connects to the resin terminal block 160. The other end is connected to the three-phase wiring harness 53 via a straight knurled copper sleeve 511. The straight knurling facilitates machining and prevents rotation when the screws are tightened.

[0072] In this embodiment, the coolant pipe fixing assembly 3 includes a fixing plate 31, and a liquid inlet pipe 32 and a liquid outlet pipe 33 fixed on the top of the fixing plate 31;

[0073] The fixing plate 31 is located at the periphery of the bottom edge of the inclined surface 211, and its bottom is fixedly connected to the bottom plate 1;

[0074] The extension direction of the liquid inlet pipe 32 and the liquid outlet pipe 33 is parallel to the inclined surface 211. The liquid inlet pipe 32 is connected to the water inlet of the controller 100, and the liquid outlet pipe 33 is connected to the water outlet of the controller 100. During the load test, coolant is pumped to the controller through the liquid inlet pipe 32 to simulate the real working conditions and help the controller cool down.

[0075] In this embodiment, the test piece holder 2 can simultaneously hold two controllers. It has two connecting sockets 21, symmetrically arranged on either side of the holder. Each connecting socket 21 is equipped with a coolant pipe fixing assembly 3, a first wiring harness fixing assembly 4, and a second wiring harness fixing assembly 5.

[0076] In this embodiment, the test piece holder 2 can hold more than two controllers, enabling simultaneous testing of multiple controllers. The test piece holder 2 is equipped with multiple connectors 21, which are evenly distributed in a circular pattern around the periphery of the test piece holder 2. Each connector 21 is equipped with a coolant pipe fixing assembly 3, a first wiring harness fixing assembly 4, and a second wiring harness fixing assembly 5.

[0077] The present invention also proposes an automobile controller testing device, which is provided with a vibration testing device connection structure described in any of the above embodiments. The automobile controller testing device is provided with an XYZ three-directional vibrator, and the base plate 1 is installed on the vibrator.

[0078] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A vibration test device connection structure, characterized in that: It includes a bottom plate, a test piece fixing frame mounted on the bottom plate, and a plurality of fixing components arranged on the periphery of the test piece fixing frame; The test piece fixing frame is provided with at least two connecting seats, and the top of each connecting seat is provided with an inclined surface; A window is provided in the middle of the inclined surface, and mounting holes for fixing the controller are provided on the side strips around the window; A first wire groove is provided on the side of the test piece fixing frame; A coolant pipe fixing assembly is provided on the periphery of one side of the bottom edge of the inclined surface, a first wire harness fixing assembly is provided on the periphery of one side of the inclined surface, and a second wire harness fixing assembly is provided on the periphery of the other side of the inclined surface; The coolant pipe fixing assembly includes a fixing plate, and a liquid inlet pipe and a liquid outlet pipe fixed on the top of the fixing plate; the fixing plate is located outside the bottom edge of the inclined surface, and its bottom is fixedly connected to the bottom plate; the extension direction of the liquid inlet pipe and the liquid outlet pipe is parallel to the inclined surface; The first wiring harness fixing assembly includes a main body, a side wire clamping plate, a high-voltage wire harness, a PDU wire harness and a low-voltage wire harness; the main body is a plate-shaped structure, which is fixedly mounted on the base plate, and has a first wire clamping arc hole on one side in the width direction, and two second wire clamping arc holes on the other side for binding and fixing the low-voltage wire harness and the PDU wire harness, and a third wire clamping arc hole is formed on the side of the side wire clamping plate to cooperate with the first wire clamping arc hole for clamping and fixing the high-voltage wire harness; The top of the second wiring harness fixing assembly is tilted, and its inclination angle is parallel to the inclined surface; the second wiring harness fixing assembly includes a terminal block, a wiring fixing plate, a three-phase wiring harness and a copper busbar; a second wire passing groove extending parallel to the inclined surface is provided on the side of the test piece fixing frame, and the terminal block is fixedly installed on the outside of the test piece fixing frame along the second wire passing groove; one end of the copper busbar is connected to the test piece, and the other end is connected to the three-phase wiring harness through the terminal block; the wiring fixing plate is fixedly installed on the bottom plate, and a slope parallel to the inclined surface is provided on the top of the copper busbar.

2. The vibration test device connection structure according to claim 1, wherein: The plate-like structure is further provided with a plurality of soft wire through holes, and the plurality of soft wire through holes are located on the periphery of the second wire clamping arc hole.

3. The vibration test device connection structure according to claim 2, wherein: Reinforcement plates are respectively provided on both sides of the plate-like structure in the thickness direction, and the bottoms of the reinforcement plates are fixed to the bottom plate.

4. The vibration test device connection structure according to claim 1, wherein: A straight knurled sleeve is embedded on the terminal block; A cable arrangement clamp for clamping and fixing the three-phase wiring harness is installed on the slope. A row of upper semi-arc holes is provided on the bottom of the cable arrangement clamp, and lower semi-arc holes cooperating with the upper semi-arc holes are provided on the slope.

5. The vibration test device connection structure according to claim 1, wherein: The test piece fixing frame is provided with two connecting seats; The two connecting seats are symmetrically arranged on both sides of the test piece fixing frame.

6. The vibration test device connection structure according to claim 1, wherein: The test piece fixing frame is provided with a plurality of connecting seats; The plurality of connection seats are evenly distributed in a ring shape around the periphery of the test piece fixing frame.

7. An automobile controller testing device, characterized in that: A vibration test device connection structure according to any one of claims 1 to 6 is provided, wherein the vibrator of the automobile controller test equipment is an XYZ three-directional vibrator.

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