A calibration test method utilizing a multi-cooling medium calibration test system for electric drive assemblies.

Abstract

This invention discloses a calibration test method using a multi-cooling medium calibration test system for electric drive assemblies. The calibration test system includes a multi-medium heat exchanger; it also includes a water-cooled circulation loop, an oil-cooled circulation loop, and a refrigerant circulation loop, wherein the water-cooled circulation loop, the oil-cooled circulation loop, and the refrigerant circulation loop exchange heat at the multi-medium heat exchanger. The multi-cooling medium calibration test system and method for electric drive assemblies described in this invention can test the performance of the electric drive system without refrigerant, as well as the performance of the electric drive system with different refrigerant capacities; it can also test the relationship between the rated, peak, and high-speed performance parameters of the electric drive system and the cooling environment, guiding the precise design of the vehicle's cooling circulation system.

Description

Technical Field

[0001] This invention relates to a calibration test method, and more particularly to a calibration test method utilizing a multi-cooling medium calibration test system for electric drive assemblies. Background Technology

[0002] With the rapid iteration and upgrading of technologies such as electric drive, battery, and electronic control in new energy vehicles, the market share of new energy vehicles is increasing, and they have become the main force in market consumption.

[0003] Among them, pure electric vehicles account for the largest proportion, and more and more pure electric vehicles are adopting "two-in-one" or "three-in-one" multi-in-one structures, which integrate mechanical / electrical components such as drive motor, reducer, motor controller, and vehicle controller into an electric drive system. This type of integrated electric drive system is beneficial for reducing size, weight, and cost, and also facilitates the front-wheel drive layout of the vehicle.

[0004] With decreasing space and materials, and increasing power density, the heat dissipation of electric drive systems faces challenges. More and more electric drive systems are opting for water-cooled drive motor controllers and oil-cooled motors and transmissions. Coolant carries away heat from the motor and transmission through oil coolers mounted on the assembly. Some systems even use refrigerants to cool the vehicle's air conditioning and battery. When so many cooling media are used in electric drive assemblies, it is necessary to measure in detail the relationship between the electric drive system's performance parameters and the cooling environment to more accurately guide the design of the vehicle's cooling circulation system. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a calibration test method utilizing a calibration test system for electric drive assemblies with multiple cooling media.

[0006] In the calibration test method of the present invention using a multi-cooling medium calibration test system for electric drive assemblies, the calibration test system includes a multi-medium heat exchanger;

[0007] It also includes a water-cooled circulation loop, an oil-cooled circulation loop, and a refrigerant circulation loop, wherein the water-cooled circulation loop, the oil-cooled circulation loop, and the refrigerant circulation loop exchange heat at the multi-medium heat exchanger;

[0008] The water-cooled circulation loop is equipped with a water chiller, an outlet water temperature sensor, a return water temperature sensor, and a water flow meter.

[0009] The oil cooling circulation loop is equipped with an oil outlet temperature sensor, an oil return temperature sensor, an oil flow meter, an oil pump, a motor, and a gearbox.

[0010] The refrigerant circulation loop is equipped with an air conditioning refrigeration unit, a refrigerant flow meter, a refrigerant outlet temperature sensor, a refrigerant circuit temperature sensor, a refrigerant outlet pressure gauge, and a refrigerant circuit pressure gauge;

[0011] The calibration test method includes:

[0012] With water cooling and oil cooling simultaneously engaged, at rated voltage, within the full speed range of the motor in the electric drive assembly;

[0013] At each predetermined speed difference interval, the continuous torque value of the electric drive assembly's motor is measured when it continues to operate under predetermined high temperature conditions.

[0014] In addition, at each predetermined speed difference interval, the peak torque value of the electric drive assembly motor is measured when it continues to operate for a predetermined time after rising from a predetermined low temperature condition to a predetermined high temperature condition.

[0015] When refrigerant is introduced, the refrigerant is introduced at each predetermined cooling capacity interval;

[0016] At each predetermined speed difference interval, the continuous torque value of the electric drive assembly's motor is measured when it continues to operate under predetermined high temperature conditions.

[0017] In addition, at each predetermined speed difference interval, the peak torque value of the electric drive assembly motor is measured when it continues to operate for a predetermined time after rising from a predetermined low temperature condition to a predetermined high temperature condition.

[0018] The impact of refrigerant cooling at different cooling capacities on the performance of the electric drive assembly was determined by comparing the continuous torque and peak torque values ​​at different cooling capacities.

[0019] The calibration test method can test the performance of the electric drive assembly without refrigerant, as well as the performance of the electric drive assembly with different refrigerant capacities.

[0020] In the calibration test method of the present invention, the predetermined high temperature condition is 150 degrees Celsius; the predetermined low temperature condition is 65 degrees Celsius.

[0021] In the calibration test method of the present invention, the predetermined time is 30 seconds or 1 minute.

[0022] The calibration test method described in this invention can test the performance of the electric drive system without refrigerant, as well as the performance of the electric drive system with different refrigerant capacities. It can also test the relationship between the rated, peak, and high-speed performance parameters of the electric drive system and the cooling environment, guiding the precise design of the vehicle's cooling cycle system. Attached Figure Description

[0023] Figure 1This is a schematic diagram of the multi-cooling medium calibration and testing system for electric drive assemblies described in this invention. Detailed Implementation

[0024] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0025] like Figure 1 As shown, the multi-cooling medium calibration test system for electric drive assemblies described in this invention is equipped with a multi-medium heat exchanger. This multi-medium heat exchanger can realize heat exchange of multiple media such as water, oil, and refrigerant (e.g., R134a). This allows the calibration test to not only test the impact of water and oil cooling media on the performance of the electric drive assembly, but also to achieve various cooling environments by increasing the refrigerant and adjusting the cooling capacity, and to test the impact of refrigerant circulation on the performance of the electric drive assembly.

[0026] The calibration and testing system for multiple cooling media in an electric drive assembly according to the present invention includes a water-cooled circulation loop, an oil-cooled circulation loop, and a refrigerant circulation loop, wherein the water-cooled circulation loop, the oil-cooled circulation loop, and the refrigerant circulation loop exchange heat at the multi-media heat exchanger.

[0027] Specifically, such as Figure 1 As shown, in the multi-cooling medium calibration and testing system for electric drive assemblies described in this invention, the water-cooled circulation loop is equipped with a water chiller, an outlet water temperature sensor, a return water temperature sensor, and a water flow meter. The coolant flows sequentially through the outlet water temperature sensor, the water chiller, the water flow meter, and the return water temperature sensor, then flows into the multi-medium heat exchanger and out again, thus circulating in this manner.

[0028] In the multi-cooling medium calibration and testing system for electric drive assemblies described in this invention, the oil cooling circulation loop is equipped with an oil outlet temperature sensor, an oil return temperature sensor, an oil flow meter, an oil pump, and a motor and gearbox. Cooling oil flows sequentially through the oil outlet temperature sensor, the motor and gearbox, the oil pump, the oil flow meter, and the oil return temperature sensor, before flowing into the multi-medium heat exchanger and then out again, thus circulating in this manner.

[0029] In the multi-cooling medium calibration and testing system for electric drive assemblies described in this invention, the refrigerant circulation loop is equipped with an air conditioning refrigeration unit, a refrigerant flow meter, a refrigerant outlet temperature sensor, a refrigerant circuit temperature sensor, a refrigerant outlet pressure gauge, and a refrigerant circuit pressure gauge. The refrigerant flows sequentially through the refrigerant outlet temperature sensor, the refrigerant outlet pressure gauge, the air conditioning refrigeration unit, the refrigerant flow meter, the refrigerant circuit pressure gauge, and the refrigerant circuit temperature sensor, before flowing into the multi-medium heat exchanger and then out again, thus completing the cycle.

[0030] The present invention also provides a calibration test method for an electric drive assembly using the above-mentioned calibration test system with multiple cooling media. Specifically, under the condition of water cooling and simultaneous oil cooling, at rated voltage, and within the full speed range of the motor, the continuous torque value of the motor continuously operating at a predetermined high temperature condition is measured at each speed point at a predetermined speed difference interval; and the peak torque value of the motor continuously operating for a predetermined time when it rises from a predetermined low temperature condition to a predetermined high temperature condition is measured at each speed point at a predetermined speed difference interval.

[0031] In other words, the performance calibration test of the electric drive system is conducted as follows when the refrigerant is not connected. Typically, the thermal performance test of the electric drive system is performed under the most severe cooling conditions. Therefore, the rated thermal characteristic test is set with a coolant temperature of 65℃, a flow rate of the rated flow (e.g., 8L / min), and an oil flow rate of the rated flow (e.g., 6L / min). The peak thermal characteristic test is set with a coolant temperature of 65℃, a flow rate of the peak flow (e.g., 12L / min), and an oil flow rate of the peak flow (e.g., 10L / min). Thus, under the rated voltage platform, within the full speed range of the motor, a speed point is selected every 1000 rpm. At each speed point, the continuous torque at which the motor can operate continuously at 150℃ (temperature change within 8 minutes not exceeding 1℃ is considered balanced, and the motor controller and transmission are not overheated) is measured and recorded in Table 1. At each speed point, the maximum torque at which the motor temperature rises from 65℃ to 150℃ and can be sustained for 30 seconds (or 1 minute) is measured and recorded in Table 1.

[0032] Table 1:

[0033]

[0034] Table 1 above shows the rated and peak performance of the electric drive system without refrigerant cooling.

[0035] With refrigerant connected, the performance calibration test of the electric drive system shall be conducted as follows.

[0036] That is, under the condition of water cooling and simultaneous oil cooling, at rated voltage, within the full speed range of the motor, at each refrigerant point that is introduced at a predetermined cooling capacity interval;

[0037] At each predetermined speed difference interval, the continuous torque value of the motor when it continues to operate under a predetermined high temperature condition is measured; and at each predetermined speed difference interval, the peak torque value of the motor when it continues to operate for a predetermined time after rising from a predetermined low temperature condition to a predetermined high temperature condition is measured.

[0038] Considering that the refrigerant in the vehicle is mainly used to cool the air conditioner and battery, and the electric drive system is mainly cooled by the coolant when it is working normally, the refrigerant will only be connected to the cooling assembly when the coolant has reached its maximum heat dissipation capacity (the coolant and oil flow rates are at their maximum values). Therefore, the coolant temperature is set to 65℃, the flow rate is set to the peak flow rate (e.g., 12L / min), the oil flow rate is set to the peak flow rate (e.g., 10L / min), and the refrigerant (e.g., R134a) cooling capacity is set to different levels such as 500W, 1000W, 1500W, and 2000W.

[0039] Specifically, under the rated voltage platform and different refrigerant cooling capacities, within the full speed range of the motor, a speed point is selected every 1000 rpm. At each speed point, the continuous torque at which the motor can operate continuously at 150℃ is measured and recorded in Table 2. At each speed point, the maximum torque at which the motor temperature rises from 65℃ to 150℃ for 30 seconds (or 1 minute) is measured and recorded in Table 2.

[0040] Table 2:

[0041]

[0042] Table 2 above shows the rated and peak performance of the electric drive system when refrigerant is connected for cooling.

[0043] The above is a comparison of the performance of the electric drive assembly under different cooling environments. By comparing the continuous and peak output characteristics at different cooling capacities, the impact of different cooling capacities on the performance of the electric drive assembly can be calibrated and tested, which can then accurately guide the design of the vehicle cooling system.

[0044] The calibration and testing system and method for electric drive assemblies described in this invention can test the performance of electric drive systems without refrigerant, as well as the performance of electric drive systems with different refrigerant capacities. It can also test the relationship between the rated, peak, and high-speed performance parameters of the electric drive system and the cooling environment, guiding the precise design of the vehicle's cooling circulation system.

[0045] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A calibration test method using a multi-cooling medium calibration test system for electric drive assemblies, characterized in that, The calibration test system includes a multi-media heat exchanger; It also includes a water-cooled circulation loop, an oil-cooled circulation loop, and a refrigerant circulation loop, wherein the water-cooled circulation loop, the oil-cooled circulation loop, and the refrigerant circulation loop exchange heat at the multi-medium heat exchanger; The water-cooled circulation loop is equipped with a water chiller, an outlet water temperature sensor, a return water temperature sensor, and a water flow meter. The oil cooling circulation loop is equipped with an oil outlet temperature sensor, an oil return temperature sensor, an oil flow meter, an oil pump, and a motor and gearbox for the electric drive assembly. The refrigerant circulation loop is equipped with an air conditioning refrigeration unit, a refrigerant flow meter, a refrigerant outlet temperature sensor, a refrigerant circuit temperature sensor, a refrigerant outlet pressure gauge, and a refrigerant circuit pressure gauge; The calibration test method includes: With water cooling and oil cooling simultaneously engaged, at rated voltage, within the full speed range of the motor in the electric drive assembly; At each predetermined speed difference interval, the continuous torque value of the electric drive assembly's motor is measured when it continues to operate under predetermined high temperature conditions. In addition, at each predetermined speed difference interval, the peak torque value of the electric drive assembly motor is measured when it continues to operate for a predetermined time after rising from a predetermined low temperature condition to a predetermined high temperature condition. When refrigerant is introduced, the refrigerant is introduced at each predetermined cooling capacity interval; At each predetermined speed difference interval, the continuous torque value of the electric drive assembly's motor is measured when it continues to operate under predetermined high temperature conditions. In addition, at each predetermined speed difference interval, the peak torque value of the electric drive assembly motor is measured when it continues to operate for a predetermined time after rising from a predetermined low temperature condition to a predetermined high temperature condition. The impact of refrigerant cooling at different cooling capacities on the performance of the electric drive assembly was determined by comparing the continuous torque and peak torque values ​​at different cooling capacities. The calibration test method can test the performance of the electric drive assembly without refrigerant, as well as the performance of the electric drive assembly with different refrigerant capacities.

2. The calibration test method as described in claim 1, characterized in that, The predetermined high temperature condition is 150 degrees Celsius; the predetermined low temperature condition is 65 degrees Celsius.

3. The calibration test method as described in claim 1, characterized in that, The predetermined time is 30 seconds or 1 minute.

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