Method and device for durability test of integrated two-in-one motor controller whole vehicle function

Abstract

The application discloses a durability test method and device for integrated two-in-one motor controller vehicle functions, and the durability test method for integrated two-in-one motor controller vehicle functions comprises the following steps: S1, an integrated two-in-one motor controller vehicle function durability test device is provided with a vehicle controller test module and a motor controller test module, so that subsequent tests on the vehicle controller and the motor controller can be simultaneously performed. The durability test method and device for integrated two-in-one motor controller vehicle functions can simultaneously test the functions of the motor controller and the vehicle controller, can save test costs compared with separate tests, and can simultaneously place multiple power electronic boxes in the environment chamber, so that multiple power electronic boxes can be simultaneously tested, and test efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the field of electronic test box technology, specifically relating to a durability test method for the vehicle functions of an integrated two-in-one motor controller and a durability test device for the vehicle functions of an integrated two-in-one motor controller. Background Technology

[0002] In new energy vehicles, the motor control unit (MCU) is one of the core components, playing a role in bidirectional conversion between direct current and alternating current. As electric vehicles become increasingly integrated, and in order to reduce hardware costs, the functions of the motor controller are gradually expanding. Thus, the Power Electronic Box (PEB), a two-in-one motor controller that combines the functions of both MCU and VCU (Vehicle Control Unit), has emerged (e.g., Figure 4 )

[0003] The main function of the MCU is to convert between DC and AC power. It can control the motor output torque to provide power to the whole vehicle, and it can also recover electrical energy. As the vehicle controller, the VCU is the brain of the vehicle. The controller needs to collect data such as the accelerator pedal, coolant temperature, slow charging temperature, and fast charging temperature to determine the driver's intentions and control the vehicle's power and the cooling devices required for power.

[0004] To ensure the reliability and stability of the PEB during user operation, it requires multiple reliability tests during the product development phase, with durability testing being particularly important. Since the PEB integrates the functions of both an MCU and a VCU controller, MCU durability testing typically includes temperature cycling durability testing and high-temperature durability testing. However, conducting durability tests on integrated two-in-one motor controllers presents several challenges:

[0005] 1. The MCU and VCU functions in PEB are relatively independent. If durability testing is performed separately, the durability test will take a long time and the test cost will double. How can we perform durability testing simultaneously to reduce test costs?

[0006] 2. The VCU in PEB has diverse functions and the road conditions of the whole vehicle are complex. VCU function durability test, VCU durability test conditions, and VCU load are defined.

[0007] 3. The VCU load includes various load types, requiring the design of an integrated load cell that can dynamically handle loads to meet the functional durability testing requirements of the VCU.

[0008] Therefore, further improvements will be made to address the aforementioned issues. Summary of the Invention

[0009] The main objective of this invention is to provide a durability testing method and apparatus for an integrated two-in-one motor controller for vehicle functions. It can simultaneously test the functions of the motor controller and the vehicle controller, saving testing costs compared to separate testing. At the same time, multiple power electronic boxes can be placed in the environmental chamber simultaneously, thereby allowing simultaneous testing of multiple power electronic boxes and improving testing efficiency.

[0010] To achieve the above objectives, this invention provides a durability testing method for an integrated two-in-one motor controller for vehicle functionality. This method utilizes an integrated two-in-one motor controller durability testing device to simultaneously perform durability tests on both the motor controller (MCU) and the vehicle controller (VCU), comprising the following steps:

[0011] Step S1: Set up a vehicle controller test module and a motor controller test module in the integrated two-in-one motor controller vehicle function durability test device to support subsequent simultaneous testing of the vehicle controller and the motor controller.

[0012] Step S2: The test piece (PEB integrating MCU and VCU) is placed in an environmental chamber to simulate parameter changes (including high temperature and temperature) during natural use. During the test, a high voltage power supply is output through a high voltage DC power supply cabinet. One high voltage power supply is connected to the MCU load, and the other is converted to low voltage through a low voltage power supply cabinet and then connected to the VCU load box. Then, the endurance tests of the vehicle controller and motor controller are carried out simultaneously through the vehicle controller test module and the motor controller test module, respectively.

[0013] As a further preferred technical solution to the above technical solution, in step S1, VCU operating condition settings and load settings are performed when setting the vehicle controller, specifically implemented as follows:

[0014] Step S1.1: Based on the target vehicle type, select the appropriate road spectrum to define the overall road condition ratio and the ratio of half-load to full-load of the vehicle, thereby defining the different road condition ratios and the vehicle speed and output torque values ​​under each road condition.

[0015] Step S1.2: Based on the vehicle speed and output torque value, the processing definition is performed to synchronously obtain the opening information of the vehicle controller under different operating conditions, thereby obtaining different VCU load values;

[0016] Step S1.3: Design and manufacture a VCU load cell with adjustable load function based on the VCU load value.

[0017] As a further preferred technical solution to the above technical solution, step S2 is specifically implemented as follows:

[0018] Step S2.1: Conduct a durability test on the vehicle controller using the vehicle controller test module;

[0019] Step S2.2: Conduct a durability test on the motor controller using the motor controller test module.

[0020] As a further preferred technical solution to the above technical solution, in step S2.1, the processor (CPU) built into the VCU load box receives load information at different times from the host computer, so that the VCU load box can dynamically adjust the load value to meet the load value requirements of the vehicle controller under different operating conditions.

[0021] As a further preferred technical solution of the above technical solution, in step S2, sensors are connected to the output terminals of the vehicle controller and the motor controller respectively, so that the sensors transmit the collected data to the host computer in real time, and then the host computer processes and analyzes the collected data to determine whether the current vehicle controller and motor controller meet the durability test.

[0022] To achieve the above objectives, the present invention also provides a durability device for an integrated two-in-one motor controller for vehicle functions, which is applied to the aforementioned durability test method for an integrated two-in-one motor controller for vehicle functions. The device includes a vehicle controller test module and a motor controller test module, thereby simultaneously testing the vehicle controller and the motor controller.

[0023] The beneficial effects of this invention are as follows:

[0024] 1. It can simultaneously verify the functions of the motor controller and the whole vehicle test function, which can save half of the test cost compared with separate tests. At the same time, multiple prototypes can be placed in the environmental chamber at the same time.

[0025] 2. The VCU functional durability conditions of the controller are obtained by converting the road conditions of the whole vehicle. The VCU load can be dynamically adjusted, which improves the comparability and equivalence of the VCU functional durability in the integrated two-in-one motor controller and the whole vehicle test.

[0026] 3. The integrated VCU load cell design is compact, reducing the space occupied by the test chamber. It also features built-in protection circuitry to protect against internal load overload. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the durability testing method and apparatus for the integrated two-in-one motor controller of the present invention for the whole vehicle function.

[0028] Figure 2A This is a left view of the VCU load cell of the integrated two-in-one motor controller vehicle function durability test method and device of the present invention.

[0029] Figure 2B This is a right view of the VCU load cell of the integrated two-in-one motor controller vehicle function durability test method and device of the present invention.

[0030] Figure 3 This is a flowchart of the vehicle controller setup process for the integrated two-in-one motor controller vehicle function durability test method and device of the present invention.

[0031] Figure 4 This is a schematic diagram of an existing power electronics box.

[0032] The attached reference numerals include: 10, environmental chamber; 11, water inlet; 12, water return; 21, low-voltage power supply cabinet; 22, VCU load box; 221, connector; 222, first connection terminal; 223, second connection terminal; 23, host computer; 31, wire harness adapter cabinet; 32, adapter tooling unit; 33, MCU load; 40, high-voltage DC power supply cabinet; 50, power electronics box. Detailed Implementation

[0033] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0034] In the preferred embodiments of the present invention, those skilled in the art should note that the MCU, VCU, and host computer involved in the present invention can be regarded as prior art.

[0035] Preferred embodiment.

[0036] This invention discloses a durability testing method for an integrated two-in-one motor controller for vehicle functionality. The method utilizes a durability testing device for the integrated two-in-one motor controller to simultaneously perform durability tests on both the motor controller (MCU) and the vehicle controller (VCU), and includes the following steps:

[0037] Step S1: Set up a vehicle controller test module and a motor controller test module in the integrated two-in-one motor controller vehicle function durability test device to support subsequent simultaneous testing of the vehicle controller and the motor controller.

[0038] Step S2: The test piece (PEB integrating MCU and VCU) is placed in an environmental chamber to simulate parameter changes (including high temperature and temperature) during natural use. During the test, a high voltage power supply is output through a high voltage DC power supply cabinet. One high voltage power supply is connected to the MCU load, and the other is converted to low voltage through a low voltage power supply cabinet and then connected to the VCU load box. Then, the endurance tests of the vehicle controller and motor controller are carried out simultaneously through the vehicle controller test module and the motor controller test module, respectively.

[0039] Specifically, in step S1, VCU operating conditions and load settings are performed when configuring the vehicle controller. The specific implementation steps are as follows:

[0040] Step S1.1: Based on the target vehicle type, select the appropriate road spectrum to define the overall road condition ratio and the ratio of half-load to full-load of the vehicle, thereby defining the different road condition ratios and the vehicle speed and output torque values ​​under each road condition.

[0041] Step S1.2: Based on the vehicle speed and output torque value, the processing definition is performed to synchronously obtain the opening information of the vehicle controller under different operating conditions, thereby obtaining different VCU load values;

[0042] Step S1.3: Design and manufacture a VCU load cell with adjustable load function based on the VCU load value.

[0043] More specifically, step S2 is implemented as follows:

[0044] Step S2.1: Conduct a durability test on the vehicle controller using the vehicle controller test module;

[0045] Step S2.2: Conduct a durability test on the motor controller using the motor controller test module.

[0046] Furthermore, in step S2.1, the processor (CPU) built into the VCU load cell receives load information from the host computer at different times, so that the VCU load cell can dynamically adjust the load value to meet the load value requirements of the vehicle controller under different operating conditions.

[0047] Furthermore, in step S2.1, the processor (CPU) built into the VCU load cell receives load information from the host computer at different times, so that the VCU load cell can dynamically adjust the load value to meet the load value requirements of the vehicle controller under different operating conditions.

[0048] The present invention also discloses a durability device for an integrated two-in-one motor controller for vehicle functions, which is applied to the aforementioned durability test method for an integrated two-in-one motor controller for vehicle functions. The device includes a vehicle controller test module and a motor controller test module, thereby simultaneously testing the vehicle controller and the motor controller.

[0049] The environmental compartment 10 contains (several) power electronics boxes 50 (PEBs) for integrated motor controllers and vehicle controllers, and the power electronics boxes are mounted on a tooling bracket.

[0050] The vehicle controller test module includes a low-voltage power supply cabinet 21 (integrated with a host computer) and a VCU load cell 22. The input terminal of the low-voltage power supply cabinet 21 is electrically connected to the first output terminal of the high-voltage DC power supply cabinet 40 (equipped with U / V / W high-voltage input), and the output terminal of the low-voltage power supply cabinet 21 is electrically connected to the input terminal of the vehicle controller. The output terminal of the vehicle controller is electrically connected to the power input terminal of the VCU load cell 22 (the VCU load cell integrates the load values ​​under various operating conditions, and it is powered by low voltage through the vehicle controller).

[0051] The motor controller test module includes a wiring harness adapter cabinet 31 (used to distribute circuits and has insulation functions), an adapter fixture unit 32 (preferably a copper busbar, a high-voltage connector, used for fixed connection, etc.), and an MCU load 33. The input terminal of the wiring harness adapter cabinet 31 is electrically connected to the second output terminal of the high-voltage DC power supply cabinet 10, and the output terminal of the wiring harness adapter cabinet 31 is electrically connected to the DC bus of the motor controller through a high-voltage wiring harness. The input terminal of the adapter fixture unit 32 is electrically connected to the three-phase line of the motor controller, and the output terminal of the adapter fixture unit 32 is electrically connected to the MCU load 33 through the wiring harness adapter cabinet 31 (the MCU load is preferably a three-phase motor, which is powered by high voltage through the motor controller).

[0052] Specifically, the VCU load box 22 is equipped with a 48-pin connector 221 (power input terminal), and the first connection terminal is electrically connected to the power output terminal of the vehicle controller.

[0053] More specifically, the VCU load cell 22 is provided with a first connection terminal 222 (preferably a DP9 serial port) and a second connection terminal 223 (preferably a network cable port). The first connection terminal or the second connection terminal is electrically connected to the host computer 23 (the connection to the host computer can be either a DP9 serial port or a network cable port; on the one hand, the host computer's instructions are transmitted to adjust the load of the VCU load cell, and on the other hand, the parameters obtained by the sensor are transmitted to the host computer to determine whether the VCU is qualified).

[0054] Furthermore, the wiring harness adapter 31 includes a first high-voltage wiring harness and a second high-voltage wiring harness. The first high-voltage wiring harness is electrically connected to the positive DC bus of the motor controller, and the second high-voltage wiring harness is electrically connected to the negative DC bus of the motor controller.

[0055] Furthermore, the environmental chamber 10 is equipped with a water inlet 11 and a water outlet 12 (the environmental chamber is used to simulate parameter changes (including high temperature and temperature) during natural use, and then condensation and heat dissipation are achieved through the water inlet and water outlet).

[0056] Preferably, the VCU load cell 22 is equipped with a power indicator light, which is used to indicate the power supply of the entire vehicle.

[0057] Preferably, the VCU load cell 22 is equipped with an overload protection circuit.

[0058] Preferably, the configuration of the vehicle controller test module is as follows:

[0059] First, appropriate road patterns need to be selected based on the target vehicle type. For example, according to the road condition definitions in "GBT 38146.1 China Automotive Driving Conditions Part 1: Light Vehicles CLTC-P", several typical road conditions are selected to obtain the vehicle's torque and speed information, and simultaneously, the throttle, coolant temperature, and fan opening information under different VCU operating conditions are obtained. Based on this opening information, the VCU load value is calculated. The percentage of test time for different load values ​​corresponds to the percentage of different road conditions, as shown in Table 1.

[0060] Table 1

[0061] Road conditions percentage Low-speed operating conditions 37.4％ Medium-speed operating conditions 38.5％ High-speed operating conditions 24.1％

[0062] The following example is based on a calculated total endurance test duration of 2000 hours for a two-in-one motor controller. According to the definition, the vehicle's half-load and full-load account for 60% and 40% respectively. The total test duration is defined under different loads for three road conditions as shown in Table 2 below.

[0063] Table 2

[0064]

[0065]

[0066] After obtaining the load values ​​of different load types in the VCU, an integrated VCU load cell is designed. This load cell integrates all load types in the VCU. The load values ​​are obtained according to the above experimental method definition. At the same time, the VCU load cell also integrates a CPU. The load information at different times can be sent to the load cell by the MCU bench via CAN communication. The load cell can be dynamically adjusted.

[0067] like Figure 1 As shown, during the durability test, the test piece was placed in an environmental chamber, which simulated the high temperature and temperature changes during natural use. During the durability test of the two-in-one controller, the high voltage was connected to the MCU load to perform MCU function testing, while the low voltage was connected to the VCU load to perform VCU durability testing simultaneously.

[0068] The VCU load cell has a front-mounted power indicator light to show whether the vehicle is receiving power. It connects to the test device (DDT) via a 48-pin connector, and communicates with the host computer via a DP9 serial port and a network cable port to receive commands from the host computer. Internally, it features circuit breaker protection and different DC power supplies. The CPU acts as the control center of the load cell, receiving and processing commands to dynamically adjust the VCU load.

[0069] Preferably, the power electronics box is provided with a second water inlet and a second water outlet. The second water inlet and the second water outlet are used to control the operating temperature of the power electronics box itself through condensation, thereby conducting a durability test. The water inlet 11 and the water outlet 12 are used to simulate the ambient temperature, and the dual temperature control is used for the durability test.

[0070] It is worth mentioning that the technical features of MCU, VCU and host computer involved in this patent application should be regarded as prior art. The specific structure, working principle and possible control method and spatial arrangement of these technical features can be adopted by conventional choices in the field and should not be regarded as the inventive point of this patent. This patent will not be further elaborated in detail.

[0071] For those skilled in the art, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the protection scope of this invention.

Claims

1. A durability testing method for an integrated two-in-one motor controller for vehicle functions, comprising simultaneously performing durability tests on the motor controller and the vehicle controller using an integrated two-in-one motor controller for vehicle functions durability testing device, characterized in that, Includes the following steps: Step S1: Set up a vehicle controller test module and a motor controller test module in the integrated two-in-one motor controller vehicle function durability test device to support subsequent simultaneous testing of the vehicle controller and the motor controller. Step S2: Place the test specimen in the environmental chamber to simulate the parameter changes during natural use. During the test, output high voltage power through the high voltage DC power supply cabinet. One high voltage power supply is connected to the MCU load, and the other is converted to low voltage power through the low voltage power supply cabinet and then connected to the VCU load box. Then, the durability test of the vehicle controller and the motor controller is carried out simultaneously through the vehicle controller test module and the motor controller test module respectively. In step S1, VCU operating conditions and load settings are performed when configuring the vehicle controller. The specific implementation steps are as follows: Step S1.1: Based on the target vehicle type, select the appropriate road spectrum to define the overall road condition ratio and the ratio of half-load to full-load of the vehicle, thereby defining the different road condition ratios and the vehicle speed and output torque values ​​under each road condition. Step S1.2: Based on the vehicle speed and output torque value, the processing definition is performed to synchronously obtain the opening information of the vehicle controller under different operating conditions, thereby obtaining different VCU load values; Step S1.3: Design and manufacture a VCU load cell with load regulation function based on the VCU load value; Step S2 is specifically implemented as follows: Step S2.1: Conduct a durability test on the vehicle controller using the vehicle controller test module; Step S2.2: Conduct a durability test on the motor controller using the motor controller test module; In step S2.1, the processor built into the VCU load cell receives load information from the host computer at different times, so that the VCU load cell can dynamically adjust the load value to meet the load value requirements of the vehicle controller under different operating conditions. In step S2, sensors are connected to the output terminals of the vehicle controller and the motor controller respectively, so that the sensors transmit the collected data to the host computer in real time. The host computer then processes and analyzes the collected data to determine whether the current vehicle controller and motor controller meet the durability test requirements.

2. A durable device for integrating a two-in-one motor controller with vehicle-wide functionality, characterized in that, The durability test method for the integrated two-in-one motor controller of claim 1 for vehicle functions includes a vehicle controller test module and a motor controller test module, thereby simultaneously testing the vehicle controller and the motor controller.

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