A processing method and system for testing an electric drive system

Abstract

The application provides a processing method and system for electric drive system test, which comprises the following steps: inputting environmental temperature conditions according to the working temperature of an electric drive assembly; inputting DC bus voltage conditions according to the working voltage of the electric drive assembly; inputting the proportion conditions of the minimum working voltage, the maximum working voltage and the rated working voltage of a controller according to the working voltage of the controller; inputting oil seal high-temperature range control conditions according to the oil seal working temperature of a reducer; inputting the rotating number conditions of the matching shaft of the reducer according to the rotating number of the oil seal of the reducer; adjusting the purity of lubricating oil according to the replacement period of the lubricating oil of the reducer; and performing the endurance test of the electric drive assembly. The application can be used for performing comprehensive performance test of the electric drive system and ensuring the reliability of the electric drive system test.

Description

Technical Field

[0001] The present invention relates to the automotive field, and in particular to a processing method and system for testing an electric drive system. Background Art

[0002] As an essential means of transportation, cars are increasingly gaining market share in new energy electric vehicles (EVs) with technological advancements and growing environmental awareness. The electric drive system assembly, a key component of new energy electric vehicles, determines the vehicle's operational performance and safety.

[0003] The electric drive system assembly primarily consists of a motor, controller, and reducer, forming a three-in-one structure. Due to the complex structure and harsh operating environment of the electric drive system assembly, verification of electric drive systems often relies on separate verification methods. For example, independent durability tests of the motor and controller, life tests of the reducer gear shaft, or the assembly verification of only one gear shaft failure mode without examining the oil seal life. Summary of the Invention

[0004] The present invention provides a processing method and system for testing an electric drive system, which can be used to perform a comprehensive performance test of the electric drive system and ensure the reliability of the electric drive system test.

[0005] The present invention provides a method for processing an electric drive system test, comprising the steps of:

[0006] Enter the ambient temperature conditions based on the operating temperature of the electric drive assembly;

[0007] According to the operating voltage of the electric drive assembly, enter the DC bus voltage condition;

[0008] According to the operating voltage of the controller, enter the ratio of the minimum operating voltage, maximum operating voltage and rated operating voltage of the controller;

[0009] According to the reducer's oil seal operating temperature, enter the oil seal high temperature range control conditions;

[0010] According to the number of revolutions of the reducer's oil seal, enter the number of revolutions of the reducer's mating shaft.

[0011] Adjust the purity of the lubricating oil according to the replacement cycle of the reducer lubricating oil;

[0012] The durability test of the electric drive assembly is carried out according to the ambient temperature conditions, DC bus voltage conditions, the ratio of the minimum operating voltage, the maximum operating voltage and the rated operating voltage of the controller, the high temperature range control conditions of the oil seal, the number of rotations of the matching shaft of the reducer and the purity of the lubricating oil.

[0013] In one embodiment of the present invention, a durability test of the electric drive assembly is performed under durability test conditions based on ambient temperature conditions, DC bus voltage conditions, the ratio of the controller's minimum operating voltage, maximum operating voltage and rated operating voltage, oil seal high temperature range control conditions, the number of rotations of the reducer's mating shaft and the purity of the lubricating oil.

[0014] In one embodiment of the present invention, the endurance test operating conditions include low-speed and high-torque operating conditions, rapid acceleration and deceleration operating conditions, and high-speed operating conditions.

[0015] In one embodiment of the present invention, the temperature of the ambient temperature condition changes cyclically according to a cycle mileage, wherein the cycle mileage includes at least two sub-mileages, the cycle mileage cycles in the order of the sub-mileages, and the temperature of the ambient temperature condition cycles in the order of the sub-mileages.

[0016] In one embodiment of the present invention, the cycle mileage includes a first sub-mileage, a second sub-mileage, a third sub-mileage, and a fourth sub-mileage. The temperature of the ambient temperature condition is set to a first temperature in the first sub-mileage and the third sub-mileage, to a second temperature in the second sub-mileage, and to a third temperature in the fourth sub-mileage. The values ​​of the second temperature, the first temperature, and the third temperature decrease in sequence.

[0017] In one embodiment of the present invention, the temperature simulation of the electric drive assembly is performed by using the cooling water temperature according to the operating temperature of the electric drive assembly, and the ambient temperature condition is input.

[0018] In one embodiment of the present invention, the electric drive assembly is placed in a supporting environmental warehouse according to the operating temperature of the electric drive assembly, and the temperature in the supporting environmental warehouse is used to perform temperature simulation of the electric drive assembly, and the ambient temperature conditions are input.

[0019] The present invention further provides a processing system for testing an electric drive system, characterized by comprising:

[0020] A temperature cycling unit for inputting ambient temperature conditions based on the operating temperature of the electric drive assembly;

[0021] The battery simulator high voltage power supply unit is used to input the DC bus voltage conditions according to the operating voltage of the electric drive assembly.

[0022] and for inputting a ratio condition of the minimum operating voltage, the maximum operating voltage and the rated operating voltage of the controller according to the operating voltage of the controller;

[0023] A lubricating oil supply unit, used to adjust the purity of the lubricating oil according to the replacement cycle of the reducer lubricating oil; and

[0024] The test unit is used to input the oil seal high temperature range control conditions according to the reducer oil seal operating temperature.

[0025] Used to input the number of revolutions of the reducer's mating shaft according to the number of revolutions of the reducer's oil seal.

[0026] It is also used to conduct durability tests on the electric drive assembly based on ambient temperature conditions, DC bus voltage conditions, the ratio of the controller's minimum operating voltage, maximum operating voltage and rated operating voltage, oil seal high temperature range control conditions, the number of rotations of the reducer's mating shaft and the purity of the lubricating oil.

[0027] In one embodiment of the present invention, the processing system for the electric drive system test further includes:

[0028] a bench control unit, configured to control the cooling circulation unit, the battery simulator high-voltage power supply unit, the tester unit, and the lubricating oil supply unit; and

[0029] An automatic control unit is connected to the gantry control unit, and the automatic control unit is used to control the gantry control unit.

[0030] In one embodiment of the present invention, the processing system for the electric drive system test further includes:

[0031] Fan unit, used to simulate the air intake function of the electric drive system.

[0032] This invention proposes a method and system for testing electric drive systems, enabling durability testing of electric drive assemblies. This method verifies the reliability of not only the reducer gear shaft but also key components such as the oil seal, motor, and controller. Furthermore, it implements automated durability testing equipment for electric drive systems, enabling comprehensive durability testing that simulates the actual operating environment of a real vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 A schematic flow chart of a method for processing an electric drive system test according to the present invention;

[0034] Figure 2 A schematic diagram of temperature cycle mileage in a processing method for testing an electric drive system according to the present invention;

[0035] Figure 3 A schematic diagram of torque and vehicle speed under different working conditions in a processing method for testing an electric drive system according to the present invention;

[0036] Figure 4This is a schematic diagram of the module connection structure in a processing system for testing an electric drive system according to the present invention;

[0037] Figure 5 This is a schematic diagram of the control module connection structure in a processing system for testing an electric drive system according to the present invention. DETAILED DESCRIPTION

[0038] The following describes the embodiments of the present invention through specific examples. Those skilled in the art will readily understand the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the details in this specification may be modified or altered based on different viewpoints and applications without departing from the spirit of the present invention.

[0039] It should be noted that the illustrations provided in this embodiment are only used to schematically illustrate the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component can be changed at will, and the component layout type may also be more complicated.

[0040] The present invention proposes a processing method for testing an electric drive system, which can be applied to the comprehensive performance test of the electric drive system of a new energy electric vehicle, and can be used to verify the reliability of the electric drive system assembly and ensure the safety of the electric drive system.

[0041] See also Figure 1 The present invention provides a method for processing an electric drive system test. In some embodiments, the method may include the following steps:

[0042] S10. Input an ambient temperature condition based on the operating temperature of the electric drive assembly. In some embodiments, the ambient temperature condition can simulate temperature values ​​of spring, summer, autumn, and winter. Based on the ambient temperature condition, different temperature values ​​can be used to reflect the comprehensive test of the vehicle's electric drive system during driving. In some embodiments, temperature values ​​for each season can be calculated using computer fitting, and the calculated temperature values ​​for each season can be set as the ambient temperature condition. Durability testing of the electric drive system during driving can be performed under different ambient temperatures.

[0043] S20. Input the DC bus voltage condition based on the operating voltage of the electric drive assembly. In some embodiments, the DC bus voltage can serve as an energy source for the electric drive system. In some embodiments, a battery provides the power source. During the driving process of an actual vehicle, the battery charge causes the DC voltage to not remain constant within the rated voltage operating range, resulting in voltage being too high or too low. Therefore, during the durability test of the entire electric drive assembly, the DC bus voltage can be tested at the highest operating voltage and the lowest operating voltage to perform the durability test of the electric drive system.

[0044] S30. Input the proportion of the minimum operating voltage, maximum operating voltage and rated operating voltage of the controller according to the operating voltage of the controller. In some embodiments, the controller is set with a minimum operating voltage, a maximum operating voltage and a rated operating voltage. The power supply voltage of the real vehicle is not stable at a fixed voltage value, and the power supply voltage will fluctuate. When it is lower than the minimum operating voltage, the controller will not work, and when it is higher than the maximum operating voltage, the controller will be damaged. In order to simulate the working conditions of a real vehicle in the durability test, the durability test of the electric drive system is carried out under different proportions of the minimum operating voltage, the maximum operating voltage and the rated operating voltage of the controller.

[0045] S40. Input the oil seal high temperature range control condition according to the oil seal operating temperature of the reducer. In some embodiments, the oil seal temperature is an assessment of the durability of the oil seal of the reducer. The key factor in the life of the oil seal is temperature, which will affect the service life of the oil seal. In the durability test, the influencing factors of the oil seal temperature need to be considered. The effect of high temperature on the oil temperature is more obvious. The oil temperature of 90°C to 120°C belongs to the high temperature range of the reducer. In some embodiments, a continuous operation condition with high speed and high torque can be provided to ensure that the oil seal temperature operates within the high temperature range. The oil seal temperature is kept within the high temperature range to fully verify the life of the oil seal. The proportion of the oil seal high temperature can be determined based on the combination of the oil seal design and the actual working conditions.

[0046] S50. Input the number of rotations of the reducer's mating shaft based on the number of rotations of the reducer's oil seal. In some embodiments, the wear resistance of the oil seal is determined by the number of rotations of the mating shaft, which is a key factor affecting the service life. The wear resistance of the oil seal is verified during the durability test, and the number of oil seal rotations depends on the design requirements of the oil seal. In some embodiments, the proportion of high speeds can be increased in the operating conditions to shorten the durability test time.

[0047] S60. Adjust the purity of the reducer lubricant according to the lubricant replacement cycle. In some embodiments, the reducer lubricant in a real vehicle is regularly replaced to ensure the purity of the lubricant within the reducer. The purity of the reducer lubricant needs to be considered during the endurance test. The reducer lubricant can be replaced after the vehicle has traveled a certain distance to maintain the purity of the lubricant.

[0048] S70. The electric drive assembly may be subjected to a durability test based on ambient temperature conditions, DC bus voltage conditions, the ratio of the controller's minimum operating voltage, maximum operating voltage, and rated operating voltage, oil seal high temperature range control conditions, the number of rotations of the reducer's mating shaft, and the purity of the lubricating oil.

[0049] See also Figure 2 The present invention provides a method for testing an electric drive system. In some embodiments, the temperature of the ambient temperature condition changes cyclically according to a cycle mileage. The cycle mileage may include at least two sub-mileages, and the cycle mileage may be cycled in the order of the sub-mileages. The temperature of the ambient temperature condition may vary in different sub-mileages, and may be the same within the same sub-mileage. In some embodiments, the cycle mileage S may include a first sub-mileage S1, a second sub-mileage S2, a third sub-mileage S3, and a fourth sub-mileage S4. The length of the cycle mileage S may be equal to the sum of the lengths of the sub-mileages: L = S1 + S2 + S3 + S4. The temperature of the ambient temperature condition is set to a first temperature in the first sub-mileage S1 and the third sub-mileage S3, a second temperature in the second sub-mileage S2, and a third temperature in the fourth sub-mileage S4. The values ​​of the second, first, and third temperatures decrease in sequence. The ambient temperature conditions at sub-mileages S1 and S3 can be set to the same temperature, and can range from 10°C to 25°C. The ambient temperature conditions at sub-mileage S2 can range from 25°C to 40°C. The ambient temperature conditions at sub-mileage S3 can range from -10°C to 10°C. The ambient temperature conditions corresponding to sub-mileages S1, S2, S3, and S4 can be used to simulate the four different solar terms of spring, summer, autumn, and winter. Durability testing of the electric drive assembly can be performed under the different temperatures of spring, summer, autumn, and winter.

[0050] See also Figure 3The present application provides a processing method for testing an electric drive system. The durability test of the electric drive assembly can be tested under different working conditions. After the test conditions in steps S10-S70 are specified, the test working conditions should meet the durability verification of the electric drive assembly, and the working conditions in the working conditions should meet the requirements of the test conditions. In some embodiments, the durability test of the electric drive assembly can be tested under low-speed high-torque working condition, rapid acceleration and deceleration working condition, and high-speed running working condition. The low-speed high-torque working condition is mainly used to verify the fatigue life of the tooth shaft. The rapid acceleration and deceleration working condition is mainly used to examine the overall performance of the electric drive assembly system and to verify the high temperature characteristics of the oil seal. The high-speed running working condition is mainly used to examine the durability of the electric drive assembly under high-speed working condition, and the number of revolutions of the oil seal fitting shaft can be increased in a short time to verify the wear resistance of the oil seal.

[0051] Please refer to Figure 4 、 Figure 5 The present application provides a processing system for testing an electric drive system. In some embodiments, the processing system for testing the electric drive system can include an automatic control unit 100, a test bench control unit 200, a cooling circulation unit 300, a battery simulator high-voltage power supply unit 400, a test machine unit 600, a fan unit 700, and a lubricating oil supply unit 800. The cooling circulation unit 300, the battery simulator high-voltage power supply unit 400, the test machine unit 600, the fan unit 700, and the lubricating oil supply unit 800 can be electrically connected to the electric drive assembly 500, and can be used to provide the electric drive assembly 500 with the conditions for durability test. The automatic control unit 100 can be electrically connected to the test bench control unit 200, and the test bench control unit 200 can be electrically connected to the cooling circulation unit 300, the battery simulator high-voltage power supply unit 400, the test machine unit 600, the fan unit 700, and the lubricating oil supply unit 800. The test bench control unit 200 can be used to control the cooling circulation unit 300, the battery simulator high-voltage power supply unit 400, the test machine unit 600, the fan unit 700, and the lubricating oil supply unit 800.

[0052] The test bench control unit 200 conducts human-computer interaction with the test personnel through the automatic control unit 100. The test personnel can program through the dedicated upper computer software provided by the automatic control unit 100, and convert the experimental conditions and test working conditions into machine language code and write it into the test bench control unit 200. The test bench control unit 200, as a lower computer control system, can perform automatic control according to the program code. If the automatic control unit 100 fails, the test bench control unit 200 can also continue to complete the test independently according to the written code. At the same time, the test bench control unit 200 will also transmit the experimental data and monitoring system failures to the automatic control unit 100 to achieve interaction. The automatic control unit 100 can transmit the test bench failure to the test personnel through application software such as python, so that the test personnel will know the test bench operation status at any time. The automatic control unit 100 can also transmit the failure data to the test personnel, and the test personnel can analyze the test data remotely, and unmanned monitoring operation can be achieved.

[0053] See also Figure 4 、 Figure 5 In some embodiments, the cooling circulation unit 300 can provide ambient temperature conditions for the electric drive assembly 500, so that the ambient temperature of the electric drive assembly 500 can be switched to meet the temperature changes of the four seasons of spring, summer, autumn and winter in real life, and the durability test of the electric drive system can be carried out. In some embodiments, the cooling circulation unit 300 can simulate the ambient temperature conditions of a real vehicle through the temperature of the cooling water. It is also possible to set up a supporting environmental warehouse, set the electric drive assembly 500 in the supporting environmental warehouse, and use the temperature in the supporting environmental warehouse to simulate the ambient temperature conditions of a real vehicle. The supporting environmental warehouse can control the ambient temperature, realize simulated operation at different ambient temperatures, and carry out the durability test of the electric drive system. In addition, the supporting environmental warehouse can also realize the verification of low-temperature startup and operation of the electric drive assembly 500, and has good sealing, which can ensure that the ambient temperature conditions are within a stable numerical range.

[0054] The battery simulator high-voltage power supply unit 400 can provide the maximum and minimum operating voltages of the DC bus voltage for the electric drive assembly 500, allowing the electric drive system to be tested for durability at these voltages. The power simulator high-voltage power supply unit 400 can also provide the minimum, maximum, and rated operating voltages for the controller of the electric drive assembly 500, simulating the controller's battery voltage and enabling durability testing of the electric drive system.

[0055] The tester unit 600 is used to simulate vehicle loads. The electric drive assembly 500 is connected to the tester unit 600 via axles. The tester unit 600 acts like a wheel on a real vehicle, providing torque to the electric drive assembly 500. The tester unit 600 can simulate low-speed, high-torque operating conditions, rapid acceleration and deceleration, and high-speed operation.

[0056] The fan unit 700 simulates the air intake function of a real vehicle. It determines fan activation and fan opening levels based on low-speed, high-torque operating conditions, rapid acceleration and deceleration, and high-speed operating conditions to simulate air volume. The fan unit 700 fully simulates the air intake at various vehicle speeds, cooling the electric drive assembly 500 and mimicking the operating environment of a real vehicle.

[0057] In summary, the present invention proposes a method and system for testing electric drive systems, enabling durability testing of electric drive assemblies. This method verifies the reliability of not only the reducer gear shaft but also key components such as the oil seal, motor, and controller. Furthermore, it implements automated durability testing equipment for electric drive systems, enabling comprehensive durability testing that simulates the actual operating environment of a real vehicle.

[0058] The above description is only a preferred embodiment of the present application and an explanation of the technical principles used. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to the technical solutions formed by the specific combination of the above-mentioned technical features, but should also cover other technical solutions formed by any combination of the above-mentioned technical features or their equivalent features without departing from the inventive concept, such as the technical solutions formed by the mutual replacement of the above-mentioned features with (but not limited to) technical features with similar functions disclosed in this application.

[0059] Except for the technical features described in the specification, the remaining technical features are known technologies to those skilled in the art. In order to highlight the innovative features of the present invention, the remaining technical features will not be described here in detail.

Claims

1. A processing method for testing an electric drive system, characterized in that: Including steps: Enter the ambient temperature conditions based on the operating temperature of the electric drive assembly; According to the operating voltage of the electric drive assembly, enter the DC bus voltage condition; According to the operating voltage of the controller, enter the ratio of the minimum operating voltage, maximum operating voltage and rated operating voltage of the controller; According to the reducer's oil seal operating temperature, enter the oil seal high temperature range control conditions; According to the number of revolutions of the reducer's oil seal, enter the number of revolutions of the reducer's mating shaft. Adjust the purity of the lubricating oil according to the replacement cycle of the reducer lubricating oil; The durability test of the electric drive assembly is carried out according to the ambient temperature conditions, DC bus voltage conditions, the ratio of the minimum operating voltage, the maximum operating voltage and the rated operating voltage of the controller, the high temperature range control conditions of the oil seal, the number of rotations of the matching shaft of the reducer and the purity of the lubricating oil.

2. The processing method for electric drive system testing according to claim 1, characterized in that: The durability test of the electric drive assembly is carried out under the durability test conditions according to the ambient temperature conditions, DC bus voltage conditions, the ratio of the minimum operating voltage, the maximum operating voltage and the rated operating voltage of the controller, the high temperature range control conditions of the oil seal, the number of rotations of the matching shaft of the reducer and the purity of the lubricating oil.

3. The processing method for testing an electric drive system according to claim 2, characterized in that: The durability test operating conditions include low-speed and high-torque conditions, rapid acceleration and deceleration conditions, and high-speed operation conditions.

4. The processing method for testing an electric drive system according to claim 1, characterized in that: The temperature of the ambient temperature condition changes cyclically according to a cycle mileage, wherein the cycle mileage includes at least two sub-mileages, the cycle mileage circulates according to the order of the sub-mileages, and the temperature of the ambient temperature condition circulates according to the order of the sub-mileages.

5. The processing method for electric drive system testing according to claim 4, characterized in that: The cycle mileage includes a first sub-mileage, a second sub-mileage, a third sub-mileage, and a fourth sub-mileage. The temperature of the ambient temperature condition is set to a first temperature in the first sub-mileage and the third sub-mileage, to a second temperature in the second sub-mileage, and to a third temperature in the fourth sub-mileage. The values ​​of the second temperature, the first temperature, and the third temperature decrease in sequence.

6. The processing method for testing an electric drive system according to claim 1, characterized in that: According to the operating temperature of the electric drive assembly, the temperature simulation of the electric drive assembly is performed by using the cooling water temperature, and the ambient temperature condition is input.

7. The processing method for electric drive system testing according to claim 1, characterized in that: According to the operating temperature of the electric drive assembly, the electric drive assembly is placed in a supporting environmental warehouse, the temperature in the supporting environmental warehouse is used to perform temperature simulation of the electric drive assembly, and the environmental temperature conditions are input.

8. A processing system for testing an electric drive system, characterized in that: include: A temperature cycling unit for inputting ambient temperature conditions based on the operating temperature of the electric drive assembly; The battery simulator high voltage power supply unit is used to input the DC bus voltage conditions according to the operating voltage of the electric drive assembly. and for inputting a ratio condition of the minimum operating voltage, the maximum operating voltage and the rated operating voltage of the controller according to the operating voltage of the controller; The lubricating oil supply unit is used to adjust the purity of the lubricating oil according to the replacement cycle of the reducer lubricating oil; as well as The testing machine unit is used to input the oil seal high temperature range control conditions according to the oil seal working temperature of the reducer, and is used to input the number of rotations of the reducer's mating shaft according to the number of rotations of the reducer's oil seal. It is also used to conduct durability tests on the electric drive assembly based on ambient temperature conditions, DC bus voltage conditions, the ratio of the controller's minimum operating voltage, maximum operating voltage and rated operating voltage, oil seal high temperature range control conditions, the number of rotations of the reducer's mating shaft and the purity of the lubricating oil.

9. The processing system for testing an electric drive system according to claim 8, characterized in that: The processing system for the electric drive system test further includes: a bench control unit, configured to control a cooling circulation unit, the battery simulator high voltage power supply unit, the test machine unit, and the lubricating oil supply unit; and An automatic control unit is connected to the gantry control unit, and the automatic control unit is used to control the gantry control unit.

10. The processing system for testing an electric drive system according to claim 8 or 9, characterized in that: The processing system for the electric drive system test further includes: Fan unit, used to simulate the air intake function of the electric drive system.

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