Motor controller performance detection device and system

Abstract

The invention discloses a motor controller performance detection device and system, comprising a tray, a track and an operating area, wherein a test fixture for testing a motor controller product is installed on the top surface of the tray, and photoelectric / ultrasonic tracking and obstacle avoidance modules are installed around the tray, a power supply line is installed on the upper end of the track, including a liftable physical track with a power supply mechanism, and also including a virtual track (the ground of the operating area) with a tracking guide line attached, a 4-wheel drive is installed on the bottom of the tray, and is designed as two sets of front and rear drive mechanisms, which can be driven in all directions in a time-sharing manner, the front drive motor is connected to the power driver of the tray, and the rear drive motor is connected to the motor controller to be tested as a test load motor, the test fixture of the tray is installed with a detection mechanism, and the tray is installed with a control module for autonomous on-track operation, testing products and communicating with a control center in real time. The invention conveniently and efficiently realizes the function of improving the detection efficiency of the motor controller.

Description

Technical Field

[0001] The present invention is applied to the technical field of motor controller performance detection, and is named as a motor controller performance detection device and system. Background Art

[0002] With the rapid development of electronic technology, the functions of motor controllers have become more and more diversified, and product assembly technology has become more and more sophisticated. Similarly, functional testing of finished motor controllers is becoming more and more important. Specific test items include port testing, communication testing, and aging testing. However, since motor controller models are usually diverse, the prior art requires different test equipment to perform different processes for different motor controller models. Manual matching tests require special production lines, which not only wastes manpower and material resources, but also wastes a lot of time. At the same time, technicians will inevitably make mistakes during the test, resulting in inaccurate test results. In addition, motor controllers usually require special high-current testing and aging. Traditional production lines often cannot be equipped with too many workstations, the test efficiency is very low, and large power consumption will be generated. The detection process of the present invention is simple and easy to operate. The motor controller test device can independently complete the large-current test items without manual plugging and unplugging of wiring and replacement of test equipment, realizing online dynamic detection, greatly saving manpower and material resources. The standard two-person system can realize the production process that originally required 8-10 people in the production process, improving the product testing efficiency and the accuracy of the test results. The design and manufacturing center can remotely observe the real-time data of the test process of each product and can control and intervene in each one. The greatest advantage of this invention is that it greatly simplifies the complex back-end process flow of the product. For ordinary SMT and wave crest processing factories that can only perform welding processing but do not have the technical ability to test products, they only need to focus on the front-end process they are good at to complete the production of product (finished product) orders, without having to find a factory with back-end production technical capabilities to cooperate. The back-end inspection and testing that cannot be completed by themselves will be automated, with professional testing equipment replacing manual labor. The product designer can directly monitor the entire testing process remotely. For the production of small and medium-power products, even a special production workshop is not needed, and only a piece of vacant land is needed to build a power supply line.

[0003] Therefore, it is necessary to provide a motor controller performance detection device and system to improve the detection efficiency. Summary of the invention

[0004] The object of the present invention is to provide a motor controller performance detection device and system to solve the problems raised in the above background technology.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions: a motor controller performance detection device and system, comprising a test device installed on the top surface of a tray, a test fixture installed on the upper surface of the test device, an anti-collision detection mechanism installed on the four sides of the tray, and a four-wheel drive and steering mechanism installed on the lower end of the tray;

[0006] The top surface of the pallet is also equipped with a display screen, warning lights, counterweight box and power distribution bracket.

[0007] In one embodiment, the test device includes a test module, a test fixture and a safety device;

[0008] The test fixture is designed to be quickly replaced and is used to test motor controllers with different shapes and structures. A safety device is installed under the test fixture, which includes a circuit breaker, an AC / DC arc extinguisher, a temperature sensor and a flame sensor, an aerosol fire extinguishing module, a fire extinguishing nozzle, an air cooling channel and a cooling fan. The air cooling channels are set on both sides of the test fixture, and the fire extinguishing nozzle is set inside the air cooling channel.

[0009] In one embodiment, a four-wheel drive is installed under the tray, which is divided into front and rear drive mechanisms. The front drive mechanism includes a dual-hub motor and a dual driver, which cooperate with each other to synchronously move forward / backward, and can support steering functions in a differential and reverse manner. The two rear drive mechanisms include a load motor, a multi-stage speed change structure and a clutch. The load motor is a quick-release design, which can quickly replace the permanent magnet synchronous motor and the AC asynchronous motor to adapt to the testing of different types of motor drivers;

[0010] The load motor is electrically connected to the test fixture, and the tray is equipped with a lithium battery compartment and a lithium battery charging management module.

[0011] Compared with the prior art, the beneficial effect achieved by the present invention is that the controller of the motor under test can be cooled by providing a cooling fan. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The technical solution and other beneficial effects of the present application will be made apparent by describing in detail the specific implementation methods of the present application in conjunction with the accompanying drawings.

[0013] In the attached picture:

[0014] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0015] Figure 2 It is a side schematic diagram of the overall structure of the present invention;

[0016] In the figure: 1. tray; 2. test device; 3. test fixture; 4. anti-collision detection mechanism; 5. display screen; 6. warning light; 7. movable counterweight box; 8. power distribution bracket; 9. test module; 10. power lithium battery; 11. safety device; 12. air cooling channel; 13. cooling fan; 14. ventilation and cooling port; 15. dual-hub motor; 16. dual drive; 17. load motor; 18. multi-speed transmission mechanism; 19. clutch; 20. turntable; 21. obstacle avoidance module; 22. photoelectric tracking module; 23. visual recognition module; 24. main control device; 25. motor controller; 26. lithium battery charger; DETAILED DESCRIPTION

[0017] The disclosure below provides many different embodiments or examples to realize the different structures of the present application. In order to simplify the disclosure of the present application, the parts and settings of specific examples are described below. Of course, they are only examples, and the purpose is not to limit the present application. In addition, the present application can repeat reference numbers and / or reference letters in different examples, and this repetition is for the purpose of simplification and clarity, which itself does not indicate the relationship between the various embodiments and / or settings discussed. In addition, the various specific processes and material examples provided by the present application, but those of ordinary skill in the art can appreciate the application of other processes and / or the use of other materials.

[0018] See also Figure 1-2 The present invention provides a technical solution: a motor controller performance detection device and system, comprising a tray 1, a track, and an operation area. A test device 2 is installed on the top surface of the tray 1 for placing the motor controller to be tested. A test fixture 3 is installed on the upper surface of the test device 2. Anti-collision detection mechanisms 4 are installed on the four sides of the tray. A four-wheel drive and steering mechanism is installed on the lower end of the tray 1. The tray runs on the upper side of the track, a power supply line is installed on the inner side of the track, and a power receiving slider is installed on the front side of the tray.

[0019] The top surface of the tray 1 is also equipped with a display screen 5, a warning light 6, a counterweight box 7 and a power distribution bracket 8. The counterweight box 7 can hold a counterweight steel ingot within 100 kg to increase the load current of the motor controller under test;

[0020] The testing device includes a testing module 9, a testing fixture 3 and a safety device 11;

[0021] The test device is installed on the top surface of the tray 1, and a test module is installed inside to connect with the test fixture. The test fixture is designed to be quickly replaced and is used to test motor controllers with different appearance structures. A safety device is installed under the test fixture 3, and the safety device includes a circuit breaker, an AC / DC arc extinguisher, a temperature sensor and a flame sensor, an aerosol fire extinguishing module, a fire extinguishing nozzle, and a cooling fan 13. Air cooling channels 12 are arranged on both sides of the test fixture 3. The cooling fan 13 is arranged behind the air cooling channel 12 to cool the motor controller under test. The fire extinguishing nozzle and the flame sensor are arranged inside the air cooling channel 12. Whether there is an open flame is detected by the flame sensor. If there is an open flame, the signal is transmitted to the fire extinguishing nozzle, and the open flame can be extinguished. The tray 1 is equipped with an aerosol fire extinguishing agent to prevent contamination of the tested product and facilitate fault analysis.

[0022] Two groups of nozzles are located in the ventilation and cooling ports 14 on both sides of the test fixture, facing the power line, motor phase line and power module respectively, and are used to extinguish abnormal explosions caused by faulty motor controllers during the test;

[0023] A four-wheel drive is installed under the tray 1, which is divided into two groups of front and rear drive mechanisms and can be driven in time. The front drive mechanism includes a dual-hub motor 15 and a dual driver 16. The two cooperate with each other to synchronously move forward / backward, and can support the steering function in a differential and reverse manner. The two rear drive mechanisms include a load motor 17, a multi-stage speed change structure 18 and a clutch 19. The load motor 17 is connected to the motor controller to be tested. The load motor 17 is a quick-release design, which can be used to quickly replace permanent magnet synchronous and AC asynchronous motors to adapt to testing of different types of motor drivers. The power receiving slider is slidably connected to the power supply circuit on the track;

[0024] The clutch 19 of the rear drive can select the motor power to be transmitted to the rear wheel or output torque to the external loading device through the turntable 20 for the limit output test. The load motor 17 is electrically connected to the test fixture 3, and the electrical part of the rear drive motor is connected to the test fixture. The tray 1 is equipped with a lithium battery compartment and a lithium battery charging management module;

[0025] The anti-collision detection mechanism includes an anti-collision column 4 and an obstacle avoidance module 21. The anti-collision column 4 is made of rubber. A rubber anti-collision surround 4 is designed around the pallet 1. There are obstacle avoidance modules 21 on the four sides. Photoelectric tracking modules 22 are set on the front and rear sides of the bottom of the pallet 1. Photoelectric tracking modules 22 are designed in the front and rear directions and under the chassis. A visual recognition module 23 is installed in front of the pallet 1 for work area identification. A main control device 24 is set under the pallet 1. The pallet main control module 24 is located under the pallet and is responsible for overall control of the pallet's travel, testing, communication, human-computer interaction, etc. A load box 7 is also designed on the pallet 1, which can be placed with a counterweight iron ingot for simulated loading tests on motor controllers at different powers;

[0026] The inspection system also includes tracks and work areas: There are two types of tracks: one is a physical test track, which consists of a steel double track and a power supply line, and can be raised and lowered to adjust the angle to simulate uphill and downhill operation;

[0027] The other is a virtual track, which consists of a ground with tracking reflective strips and power supply lines installed only in the test loading area. It is used for the autonomous tracking of the pallet and driving it to the operation area. The operation area includes the code scanning and test parameter binding area, the defective product processing area, the packaging and warehousing area, the parking and charging area, the extreme aging area and the control center. Each area uses a visual recognition module to identify the signboard at the entrance of the area. In actual operation, if the output power of the tested products is not much different, the physical steel track can be completely cancelled and replaced by a ground virtual track with a slope to increase the load simulation loading;

[0028] The front end of the tray 1 is fixed with a tracking sensor and a visual recognition module for autonomous driving.

[0029] The main control device 24 is electrically connected to the display control screen 5 and the warning light 6;

[0030] The main control device 24 includes a main control processor, a wireless communication module, a power distribution box, and a cable interface. The main control device 24 is also electrically connected to the front drive mechanism, the main drive and the motor of the front wheel are connected. The test device 2 has a cable interface, and the main control processor is connected to the cable interface.

[0031] A power receiving device 8 is provided in front of the tray 1, and a lithium battery charger 26 is provided at the bottom of the tray 1. The power distribution box is used to distribute the external input power of the power receiving device 8 in front of the tray 1 to the test device 2 and the lithium battery charger 26 at the bottom of the tray, including the recognition and conversion of AC 3-phase 4-wire, AC 2-phase 3-wire and DC input;

[0032] The test device 2 is provided with a motor controller 25 inside, and the cable interface is used for the test device 2 to perform an interface test on the motor controller 25 under test, and to electrically connect the test load motor 17 with the motor controller 25 under test;

[0033] The main control processor is used to control the entire operation state of the tray 1, including but not limited to autonomous driving, track identification, power distribution and loading, motor controller parameter binding, autonomous testing and result reporting, exception handling, human-computer interaction, visual identification of working areas, charging management, etc.;

[0034] The wireless communication module is used to exchange data with the control center and display relevant information on the display control screen 5;

[0035] The detection device 2 is internally provided with a motor controller 25, and the motor controller 25 includes a motor controller input / output port detection module, a data transmission module, a test processor, and a current detection module;

[0036] The motor controller input / output port detection module simulates the various signal lines and control harnesses connected to the periphery when the motor controller is actually working, and detects the response of each port.

[0037] The test processor is the main controller, which is used to test the various electrical properties of the motor controller and to monitor the safety of the test process. It is controlled by the main control device 24 of the tray 1 and exchanges data with it.

[0038] The data transmission module is used to transfer the detection data parameters and instructions from the main control device 24 to the test processor, and to exchange data with the motor controller under test, control the motor controller under test to make corresponding test responses, and transmit the instruction results back to the main control device;

[0039] The test fixture 3 is connected to the motor controller 25 by a cable. The test fixture 3 uses a pin and a high-current chuck to reliably connect to the motor controller under test, transmits the power and control signals required for the normal operation of the motor controller under test, and connects the output of the motor controller under test to the test load motor 17; in conventional and heavy-load tests, the load motor is responsible for driving the rear wheel. In the limit test, the test processor will control the clutch to disengage the rear wheel, so that the motor torque is output by the turntable located at the rear of the tray 20, and the turntable is equipped with a coupling that can be connected to a loader, a magnetic powder machine or a dynamometer.

[0040] The test device is provided with a safety device 11 inside. The safety device 11 detects the temperature and current changes of the motor controller under test in real time during the test. When abnormal temperature rise, sparking, arcing, or open flame combustion occurs, the device will promptly cut off the power, extinguish the arc, or start the aerosol fire extinguishing module to extinguish the fire. At the same time, the abnormal data is transmitted back to the main control device through the data transmission module.

[0041] How it works

[0042] The control center activates a standby tray in the parking and charging area through a remote connection, downloads the model of the product under test - the motor controller and the test process program to the module 24 of the tray 1 and activates it. The tray autonomously drives along the virtual track on the ground to the code scanning and test parameter binding area at the set speed. According to the model of the motor controller 25 to be tested on the screen of tray 1, the staff scans the code of the motor controller 25 to be tested and puts it into the test fixture 3 to lock it, and places or removes the counterweight in the counterweight box 7 according to the test requirements. After tray 1 detects that the motor controller 25 to be tested is in place, tray 1 connects to the low-voltage power supply according to the test process, binds the test parameters to the memory of the motor controller to be tested, and starts the static electrical parameter test. The pallet autonomously leaves the code scanning and test parameter binding area and drives into the track entrance, lowers the pantograph and connects to the track power supply mechanism, applies high-voltage power to the motor controller 25 under test, starts the high-voltage power supply static test of the motor controller 25 under test, and initializes the motor controller 25 at the same time, and injects the parameters of the bottom main drive motor into the motor controller under test, starts the motor controller 25 under test according to the set parameters, and the test processor distributes the power and drives the test load motor 17 to start. When the pallet 1 moves to the middle section of the workbench 3, the power drive of the pallet 1 is switched to the rear drive motor driven by the motor driver under test, enters the track, and runs at the set speed on the track. Different track angles and running speeds can be configured according to the technical requirements of different motor drivers, and the distance (number of repetitions back and forth) is used to test the performance of the motor driver.

[0043] After the test is completed, the pallet stays at the track exit, and the laser marking machine directly prints a nameplate on the controller shell. Then the staff removes the motor driver under test for packaging. The pallet switches back to its own power drive and drives along the ground with track lines (virtual track) back to the track starting point to start the next test;

[0044] When the motor driver 8 under test fails, the tray 1 will switch back to its own power to drive itself out of the track and drive along the track line to the defective product processing area for inspection by staff.

[0045] When the motor controller 25 under test needs to be subjected to extreme aging, the pallet 1 undergoes routine testing and aging on the track, then drives out of the track and autonomously enters the extreme aging zone along the track line. After being connected to the magnetic powder tensioner through the coupling, the clutch located at the rear drive selects the motor power output torque mode to drive the magnetic powder tensioner to perform an extreme aging test. After the test is completed and the motor controller under test cools to room temperature, it autonomously drives to the track exit for marking and packaging. This process does not require human intervention.

[0046] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, an electrical connection, or mutual communication; it can be a direct connection, internal communication between two elements, or an interaction relationship between two elements. For ordinary technicians in this field, the meanings of the above terms in this application can be understood according to specific circumstances.

[0047] The motor controller performance detection device and system provided in the embodiments of the present application are introduced in detail above. Specific examples are used in this article to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the technical solution and core idea of ​​the present application. Ordinary technicians in this field should understand that they can still modify the technical solutions recorded in the aforementioned embodiments, or replace some of the technical features therein with equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A motor controller performance detection device, comprising a tray (1), Features: A testing device (2) is installed on the top surface of the tray (1), a testing fixture (3) is installed on the upper surface of the testing device (2), anti-collision detection mechanisms (4) are installed on the four sides of the tray, and a four-wheel drive and steering mechanism is installed on the lower end of the tray (1); The top surface of the tray (1) is also equipped with a display screen (5), a warning light (6), a counterweight box (7) and a power distribution bracket; A four-wheel drive is installed below the tray (1), which is divided into two groups of front and rear drive mechanisms. The front drive mechanism includes a dual-wheel hub motor (15) and a dual driver (16), which cooperate with each other to enable synchronous forward / reverse movement, differential speed and reverse steering support, and the two rear drive mechanisms include a load motor (17), a multi-stage speed change structure (18) and a clutch (19). The load motor (17) is of a quick-release design, which allows for quick replacement of permanent magnet synchronous motors and AC asynchronous motors to adapt to testing of different types of motor drivers; The load motor (17) is electrically connected to the test fixture (3), and the tray (1) is equipped with a lithium battery compartment and a lithium battery charging management module.

2. A motor controller performance detection device according to claim 1, Features: The testing device comprises a testing module (9), a testing fixture (3) and a safety device (11); The test fixture is designed to be quickly replaceable and is used to test motor controllers of different shapes and structures. A safety device is installed below the test fixture (3), and the safety device includes a circuit breaker, an AC / DC arc extinguisher, a temperature sensor and a flame sensor, an aerosol fire extinguishing module, a fire extinguishing nozzle, an air cooling channel (12) and a cooling fan (13). The air cooling channels (12) are arranged on both sides of the test fixture (3), and the fire extinguishing nozzle is arranged inside the air cooling channel (12).

3. A motor controller performance detection device according to claim 1, Features: The anti-collision detection mechanism comprises an anti-collision column (4) and an obstacle avoidance module (21). The surface of the anti-collision column (4) is made of rubber material. The four sides of the tray (1) are provided with obstacle avoidance modules (21). Photoelectric tracking modules (22) are arranged at the front and rear sides of the bottom of the tray (1). A visual recognition module (23) is installed in front of the tray (1) for identifying the working area. A main control device (24) is arranged at the bottom of the tray (1) for overall control of the travel, testing, communication, human-computer interaction, etc. of the tray. A load box (7) is also designed on the tray (1) to be able to hold a counterweight iron ingot for simulating loading tests on motor controllers at different powers.

4. A motor controller performance detection device according to claim 1, Features: The detection device also includes a track and an operating area: the track is divided into two types, one is a physical test track, which is composed of a steel double track and a power supply line, and can be raised and lowered to adjust the angle to simulate the operation of uphill and downhill; The other is a virtual track, which is composed of a ground with tracking reflective strips and power supply lines installed. It is used for the autonomous tracking of the pallet and driving it along the ground to the work area. The work area includes a code scanning and test parameter binding area, a defective product processing area, a packaging and warehousing area, a parking and charging area, an extreme aging area and a control center.

5. The detection system of the motor controller performance detection device according to claim 3, Features: The main control device (24) is electrically connected to the display control screen (5) and the warning light (6); The main control device (24) comprises a main control processor, a wireless communication module, a power distribution box, and a cable interface. The main control device (24) is also electrically connected to the front drive mechanism. The test device (2) has a cable interface, and the main control processor is connected to the cable interface. A power receiving device (8) is arranged in front of the tray (1), and a lithium battery charger (26) is arranged at the bottom of the tray (1); A motor controller (25) is provided inside the testing device (2); The wireless communication module is used to exchange data with the control center and to display relevant information on the display control screen (5).

6. A detection system for a motor controller performance detection device according to claim 5, Features: The motor controller (25) comprises a motor controller input / output port detection module, a data transmission module, a test processor, and a current detection module; The motor controller input / output port detection module is used to simulate various signal lines and control harnesses connected to the periphery when the motor controller is actually working, and detect the response of each port; The test processor is a main controller, used to test various electrical properties of the motor controller, to monitor the safety of the test process, and to be controlled by a main control device (24) of the tray (1) to exchange data with the main control device (24); The data transmission module is used to transmit the detection data parameters and instructions from the main control device (24) to the test processor, and to perform data interaction with the motor controller under test, control the motor controller under test to make a corresponding test response, and transmit the instruction result back to the main control device; The test fixture (3) is connected to the motor controller (25) via a cable; A safety device (11) is arranged inside the testing device.

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