Motor controller automated testing method and system

Abstract

The present application relates to the technical field of motor controller testing, and specifically relates to a motor controller automatic testing method and system. The method comprises the following steps: appearance inspection is performed on the assembled motor controller; the motor controller is transported to a first airtight workstation to perform waterway airtightness detection; the motor controller is transported to a first program burning station to perform test program burning and program burning version comparison; the motor controller is transported to a first safety regulation workstation to perform insulation resistance and voltage resistance tests of the controller; the motor controller is transported to an aging workstation to perform aging tests; the motor controller is transported to an EOL online testing workstation to perform EOL tests; the motor controller is transported to a second safety regulation workstation to perform insulation resistance and voltage resistance tests of the aged controller; the motor controller is transported to a second airtight workstation to perform cavity airtightness tests; the motor controller is transported to a second program burning station to perform client program burning and program burning version comparison, and finally a factory qualified label is printed. The method realizes comprehensive testing of the motor controller, has high reliability and high automation degree, and improves testing efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of motor controller testing, and particularly relates to a motor controller automatic testing method and system. BACKGROUND

[0002] With the development of society, people pay more and more attention to the environment, and pure electric vehicles play an increasingly important role in daily life. The electric drive system in the pure electric vehicle system is an important part of the vehicle system, and its basic performance and control effect have a great influence on the performance indicators of the vehicle. The motor controller is the brain of the three-electricity system, and with the development of new energy vehicles, there are higher requirements for the switching frequency, torque control accuracy, test efficiency and the like of the motor controller.

[0003] The motor controller is composed of various parts, including metal and non-metal parts, sensor parts, and electronic components. Traditional motor controller testing technology usually uses dynamometer bench, motor load, water tank, temperature chamber, motor controller, etc. to test separately. The test automation degree is low, the efficiency is low, the cost is high, the noise is large, and the dynamometer rotation is very dangerous. And the above test equipment only checks part of the test items of the motor controller, and the detection is not comprehensive, and the reliability of the motor controller is low.

[0004] Therefore, a test process capable of more comprehensive detection of the motor controller is needed to achieve comprehensive monitoring and improve the reliability of the motor controller. At the same time, it is also important to improve the automation degree of the test process and improve the test efficiency. SUMMARY

[0005] The present application is aimed at the defects of the prior art, and provides a motor controller automatic testing method and system, which realizes comprehensive testing of the motor controller, improves the reliability of the motor controller, and has high automation degree in the test process and improves the test efficiency.

[0006] The present application provides a motor controller automatic testing method, comprising:

[0007] Performing appearance inspection on the assembled motor controller;

[0008] After the appearance inspection is qualified, the motor controller is placed on a drag chain and transported to a code scanning workstation for code scanning, and after the code scanning, the motor controller is transported to a first air tightness workstation with the drag chain for water channel air tightness detection;

[0009] After the water channel air tightness detection is qualified, the motor controller is transported to a first program burning station with the drag chain for test program burning and program burning version comparison;

[0010] After the program burning version comparison is completed, the motor controller is transported to a first safety work station along with a chain to perform insulation resistance and voltage resistance tests on the controller;

[0011] After the insulation resistance and voltage resistance tests on the controller are passed, the motor controller is transported to an aging work station along with the chain to perform an aging test;

[0012] After the aging test is passed, the motor controller is transported to an EOL online test work station along with the chain to perform an EOL test;

[0013] After the EOL test is passed, the motor controller is transported to a second safety work station along with the chain to perform an insulation resistance test after aging and a voltage resistance test after aging on the controller;

[0014] After the insulation resistance test after aging and the voltage resistance test after aging are passed, the motor controller is transported to a second air tightness work station along with the chain to perform a cavity air tightness test;

[0015] After the cavity air tightness test is passed, the motor controller is transported to a second program burning station along with the chain to perform client program burning and program burning version comparison, and if the program burning version comparison is passed, a factory qualified label is printed on the motor controller.

[0016] The motor controller is sequentially subjected to appearance inspection, waterway air tightness detection, test program burning, insulation resistance and voltage resistance tests, aging test, EOL test, insulation resistance test after aging and voltage resistance test after aging, cavity air tightness test, and client program burning according to the scheme, so that comprehensive detection of the motor controller is realized, thereby improving the factory reliability of the motor controller. The motor controller is transported by the chain throughout the test, and after the controller is placed on the chain, no manual intervention is required in the test. After the test at the current work station is completed, the chain transports the controller to the next work station for subsequent test items, until the motor controller is burned with the client software and the software historical faults are cleared, and the motor controller can be factory shipped. The degree of automation is high, and the test efficiency is improved. Compared with the traditional test method in which multiple tools are used to test various functions, different test work stations are pre-built to test related contents, and the integration degree of each test station is high, thereby further improving the degree of automation of the entire test process.

[0017] Preferably, the appearance inspection includes:

[0018] Appearance cleaning, no extrusion and no scratches, no rust, no scratches are inspected;

[0019] Traceability label, high-voltage warning label, label position, label content meet the drawing and packaging requirements are inspected, and the inscription on the nameplate is clear, and the content of the nameplate meets the drawing requirements.

[0020] Check the connector without damage, the installation position meets the drawing requirements, check the installation of the upper and lower cover shells, the installation of the wiring cover, and whether the self-checking marks of the signal connector and the upper cover fastening bolt are clear and complete.

[0021] The method preferentially visually detects the appearance, label, connector, and bolt connection of the motor controller. The detection process is the simplest, which can first eliminate the products with unqualified appearance, avoid unnecessary subsequent testing of unqualified products, save the testing process, and improve the testing efficiency.

[0022] More preferably, the waterway airtightness detection includes:

[0023] After the first airtightness station reads the electronic tag signal of the motor controller, the first PLC controls the cylinder to move the airtight tool to automatically block the air valve of the motor controller. After the first airtightness station executes the automatic blocking instruction, the first PLC detects the state jump signal and controls the airtightness leak detector to perform the test action. The airtightness leak detector automatically performs the waterway airtightness test on the motor controller. After the waterway airtightness test is completed, a test completion signal is fed back to the first PLC, and the first PLC controls the airtight tool to separate from the motor controller.

[0024] The first airtightness station is pre-set in the scheme, and the waterway airtightness test is automatically completed by the PLC, cylinder, and airtightness leak detector, which improves the degree of automation and efficiency of the test.

[0025] More preferably, the insulation resistance and voltage resistance test of the motor controller performed by the first safety station includes:

[0026] The first safety station automatically docks the product bus bar, the motor controller, and the device bus bar. The product bus bar and the device bus bar have pre-connected the DC end and three-phase end of the motor controller together, and the LV end of the motor controller and the shell together.

[0027] After the second PLC of the first safety station receives the docking completion signal, the safety analyzer first performs the insulation test of the motor controller power end to the shell and signal line, and then performs the voltage resistance test. After the test is completed, the test completion signal is fed back to the second PLC, the second PLC issues an automatic separation instruction of the tool, and controls the bus bar to separate from the motor controller.

[0028] More preferably, the aging test includes:

[0029] The motor controller enters the temperature chamber, and the aging workstation connects the DC terminal of the motor controller to high voltage, the low voltage terminal to low voltage, the three-phase terminal to the inductive load, and the water channel of the motor controller to the water channel of the chiller, and circulates coolant.

[0030] Measure whether the terminating resistance between the CAN high and CAN low of the motor controller is within the set resistance range and whether normal communication is possible;

[0031] Perform rated operating condition testing;

[0032] Perform peak operating condition testing;

[0033] After the rated operating condition test and peak operating condition test are cycled several times, if the aging workstation determines that the motor controller is normally outputting rated current and peak current, then the aging test is qualified.

[0034] This solution provides a test system for implementing automated testing methods for motor controllers, including:

[0035] The barcode scanning workstation is used to scan the barcodes on the motor controller.

[0036] The first airtight workstation is used to test the airtightness of the waterway in the motor controller;

[0037] The first programming station is used to program the motor controller for testing and to compare the programmed versions.

[0038] The first safety workstation is used to perform insulation resistance and withstand voltage tests on motor controllers.

[0039] An aging workstation is used for aging tests on motor controllers.

[0040] EOL online test workstation, used for EOL testing of motor controllers;

[0041] The second safety workstation is used to test the insulation resistance and withstand voltage of the motor controller after aging.

[0042] The second airtight workstation is used to perform cavity airtightness testing on the motor controller;

[0043] The second programming station is used to program the motor controller with client software and compare the programmed versions.

[0044] The scheme pre-builds different test workstations for testing related contents, each test station has high integration, and further improves the automation degree of the whole test process. Through the different test workstations pre-built, the motor controller can be sequentially subjected to appearance inspection, waterway air tightness detection, test program burning, insulation resistance and voltage resistance test, aging test, EOL test, insulation resistance and voltage resistance test after aging, cavity air tightness test, and client program burning. The motor controller can be comprehensively detected, so that the reliability of the motor controller in factory is improved. The motor controller is conveyed by the drag chain throughout the test, after the controller is placed on the drag chain, no manual intervention is needed in the test, after the test at the current work station is completed, the drag chain conveys the controller to the next work station for subsequent test items, until the client software is burned and the software historical fault is cleared, the motor controller can be factory shipped. The automation degree is high, and the test efficiency is improved.

[0045] More preferably, the first air tightness workstation comprises a first PLC, a cylinder, an air tightness tooling, a first reader-writer, and an air tightness tester;

[0046] The first reader-writer is configured to read the electronic tag of the motor controller;

[0047] The cylinder is configured to drive the air tightness tooling to block the air valve of the motor controller;

[0048] The air tightness tester is configured to perform waterway air tightness test on the motor controller;

[0049] The first PLC is configured to control the cylinder to move the air tightness tooling, control the air tightness tester to perform test action after detecting a state jump signal, and control the air tightness tooling to separate from the motor controller after receiving a test completion signal.

[0050] The scheme pre-provides the first air tightness workstation, and automatically performs waterway air tightness test through the PLC, the cylinder, and the air tightness tester, so that the test automation degree is improved, and the test efficiency is improved.

[0051] More preferably, the first safety workstation comprises a second reader-writer, a second PLC, a first lifting and moving device, a first insulation lifting device, a device busbar, a product busbar, and a safety analyzer;

[0052] The second reader-writer is configured to read the electronic tag of the motor controller;

[0053] The second cylinder is configured to drive the busbar to automatically dock with or separate from the motor controller,

[0054] The first lifting and moving device is configured to lift and move the motor controller to a test position;

[0055] The first insulation jacking device is used for jacking and positioning the motor controller;

[0056] The equipment end bus bar and the product end bus bar are used for short-circuiting the motor controller DC end and three-phase end together, and short-circuiting the LV end of the motor controller and the shell together;

[0057] The safety analysis instrument is used for firstly performing insulation test on the motor controller power end to the shell and signal line, then performing voltage resistance test, and feeding back a test completion signal to the second PLC after the test is completed.

[0058] The second PLC is used for controlling the first jacking and transplanting device and the first insulation jacking device to horizontally move the motor controller to a test position and perform jacking and positioning, controlling the equipment end bus bar and the product end bus bar to automatically dock with the motor controller, and controlling the safety analysis instrument to perform insulation test and voltage resistance test.

[0059] The first safety work station is provided in advance, and the second reader-writer, the second PLC, the first jacking and transplanting device, the first insulation jacking device, the equipment end bus bar, the product end bus bar and the safety analysis instrument are integrated in the work station. The PLC controls the first jacking and transplanting device and the first insulation jacking device to horizontally move the motor controller to a test position and perform jacking and positioning, controls the equipment end bus bar and the product end bus bar to automatically dock with the motor controller, and controls the safety analysis instrument to perform insulation test and voltage resistance test. The work station realizes full-automatic test of product insulation test and voltage resistance test through the above components and control logic, has high integration, can realize comprehensive and reliable test, and has high automation degree without manual participation in the whole process.

[0060] More preferably, the aging work station comprises a third reader-writer, a third PLC, a stacker crane, an aging cabinet, a reactor, a water cooler, a direct-current power supply, an electric control cabinet, a conveying line body, a display, a feeding rotary machine and a discharging rotary machine;

[0061] The third reader-writer is arranged on the aging cabinet, the feeding rotary machine is used for conveying the motor controller to the conveying line body, the stacker crane is arranged behind the aging cabinet, and the conveying line body is arranged below the aging cabinet;

[0062] After the third PLC receives the electronic tag signal read by the third reader-writer, an instruction is output to control the aging cabinet to open the door to move the tested product out from behind the aging cabinet, the stacker crane below the aging cabinet jacks up the motor controller to be tested into the cabinet, the PLC sends a door closing instruction, and the aging test is started. The stacker crane moves the tested product to the discharging rotary machine.

[0063] The scheme pre-provides an aging workstation, and integrates a third read-write device, a third PLC, a stacking and transplanting machine, an aging cabinet, a reactor, a water cooling machine, a direct current power supply, an electric control cabinet, a conveying line body, a display, a feeding rotary machine and a discharging rotary machine in the workstation. After the PLC receives the electronic tag signal read by the third read-write device, an instruction is output to control the aging cabinet to open the door to move the tested product out from the rear of the aging cabinet, the stacking and transplanting machine under the aging cabinet lifts the motor controller to be tested into the cabinet, the PLC sends a door closing instruction to start the aging test, and the stacking and transplanting machine moves the tested product to the discharging rotary machine. Thus, the full-automatic aging test of the product is realized, the whole process does not need manual participation, the product can be automatically fed and discharged, and the automation degree is high.

[0064] More preferably, the EOL online test workstation comprises a fourth read-write device, a fourth PLC, a second lifting and transplanting device, a second insulation lifting device, a high-voltage power supply, a low-voltage power supply, a high-precision digital multimeter and a rotary transformer simulator.

[0065] The fourth read-write device is used to read the electronic tag of the motor controller.

[0066] The second lifting and transplanting device is used to lift and move the motor controller to a test position.

[0067] The second insulation lifting device is used to lift and position the motor controller.

[0068] The low-voltage power supply high-precision digital multimeter is used to read the static current of the motor controller in the EOL test.

[0069] The rotary transformer simulator is used to connect with the rotary transformer connector of the motor controller to complete the rotary transformer test.

[0070] The fourth PLC is used to control the second lifting and transplanting device and the second insulation lifting device to move the motor controller to the test position and perform the lifting and positioning, and the EOL online test workstation performs the EOL test.

[0071] The scheme pre-provides an EOL online test workstation, and integrates a fourth read-write device, a fourth PLC, a second lifting and transplanting device, a second insulation lifting device, a high-voltage power supply, a low-voltage power supply high-precision digital multimeter and a rotary transformer simulator in the workstation. The second lifting and transplanting device and the second insulation lifting device can be controlled by the PLC to move the motor controller to the test position and perform the lifting and positioning, and the EOL online test workstation performs the EOL test. The test process can be fully automatic, without manual participation, and the automation degree of the test process is greatly improved.

[0072] The beneficial effects of the present application are that the scheme pre-constructs different test workstations for testing related content, each test station has high integration, and further improves the automation degree of the whole test process. Through the pre-constructed different test workstations, the appearance inspection, waterway air tightness detection, test program burning, insulation resistance and voltage resistance test, aging test, EOL test, insulation resistance after aging and voltage resistance test after aging, cavity air tightness test, and client program burning of the motor controller can be sequentially performed according to the progress of the drag chain. The comprehensive detection of the motor controller can be realized, so as to improve the reliability of the motor controller out of the factory. The motor controller is conveyed by the drag chain throughout the test, and the controller is placed on the drag chain without manual participation in the test. After the test at the current work station is completed, the drag chain will convey the controller to the next work station for subsequent test items. After the client software is burned and the software historical fault is cleared, the motor controller can be out of the factory. The automation degree is high, and the test efficiency is improved. BRIEF DESCRIPTION OF DRAWINGS

[0073] Figure 1 The present application is a test flow diagram. DETAILED DESCRIPTION

[0074] In order to make the technical problems, technical solutions and beneficial effects of the present application clearer, the present application will be further described in detail below in combination with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and not to limit the present application.

[0075] In the following description, specific details are set forth in order to provide a thorough understanding of the embodiments of the present application. However, persons skilled in the art should understand that the present application can also be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the present application with unnecessary details.

[0076] It should be understood that when used in the specification and the appended claims of the present application, the term "comprising" indicates the presence of the described features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or sets thereof.

[0077] It should also be understood that the term "and / or" used in the specification and the appended claims of the present application means any combination of one or more of the associated listed items and all possible combinations, and includes these combinations.

[0078] As used in the specification and the appended claims, the term "if' can be interpreted as meaning "when" or "upon" or "in response to determining" or "in response to detecting" depending on the context. Similarly, the phrase "if it is determined" or "if [the described condition or event] is detected" can be interpreted to mean "upon determining" or "in response to determining" or "upon detecting [the described condition or event]" or "in response to detecting [the described condition or event]" depending on the context.

[0079] In addition, in the description of the present application and the appended claims, the terms "first", "second", "third", etc. are used only to distinguish descriptions, and cannot be understood as indicating or implying relative importance.

[0080] In the present application, the reference "one embodiment" or "some embodiments" and the like means that the specific features, structures or characteristics described in connection with the embodiment are included in one or more embodiments of the present application. Therefore, the statements "in one embodiment", "in some embodiments", "in other some embodiments", "in further some embodiments" and the like appearing in different places in the specification are not necessarily all referring to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized. The terms "include", "contain", "have" and their variants mean "include but not limited to", unless otherwise specifically emphasized. "Multiple" means "two or more".

[0081] Embodiment one

[0082] Figure 1 The preferred embodiment of the present application is shown Figure 1 The flowchart of the motor controller automatic test method provided by the first embodiment of the present application is shown. For the convenience of description, only the part related to the present embodiment is shown, and the details are as follows:

[0083] Step 1, appearance inspection of the assembled motor controller.

[0084] Step 2, after the appearance inspection is qualified, the motor controller is placed on the drag chain and transported to the code scanning station for code scanning. After the code scanning, the motor controller is transported to the first air tightness station with the drag chain for waterway air tightness detection.

[0085] Step 3, after the waterway air tightness detection is qualified, the motor controller is transported to the first program burning station with the drag chain for test program burning and program burning version comparison.

[0086] Step 4, after the program burning version comparison is completed, the motor controller is transported to the first safety regulation station with the drag chain for controller insulation resistance and voltage resistance test.

[0087] Step 5, after the insulation resistance and voltage resistance test of the controller is qualified, the motor controller is transported to the aging workstation along with the chain to perform the aging test.

[0088] Step 6, after the aging test is qualified, the motor controller is transported to the EOL online test workstation along with the chain to perform the EOL test.

[0089] Step 7, after the EOL test is qualified, the motor controller is transported to the second safety workstation along with the chain to perform the insulation resistance and voltage resistance test after aging of the controller.

[0090] Step 8, after the insulation resistance and voltage resistance test after aging are qualified, the motor controller is transported to the second airtight workstation along with the chain to perform the cavity airtight test.

[0091] Step 8, after the cavity airtight test is qualified, the motor controller is transported to the second program burning station along with the chain to perform the client program burning and program burning version comparison, and if the program burning version comparison passes, a factory qualified label is printed on the motor controller.

[0092] In one embodiment, the implementation of step 1 is as follows:

[0093] Appearance cleaning, no extrusion, no scratch, no rust, no scratch inspection is performed;

[0094] Traceability label, high-voltage warning label, label position, label content meet the drawing and packaging requirements inspection, clear characters on the nameplate, and the nameplate content meets the drawing requirements inspection are performed;

[0095] The connector is checked for no damage, and the installation position meets the drawing requirements, and the upper and lower cover shells are checked for fixed bolt installation, wiring cover installation, signal connector and upper cover fastening bolt self-checking identification whether clear and no omission.

[0096] The appearance detection can adopt visual inspection, and the visual inspection is mainly checked by artificial inspection.

[0097] In one embodiment, the implementation of step 2 is as follows:

[0098] After visually inspecting the appearance of the controller, the controller is placed on the drag chain, and the controller reaches the code scanning station. To save production line space, the code scanning station can be integrated into the first airtight station. After the first airtight station reads the electronic tag signal of the motor controller, the first PLC controls the cylinder to move the airtight tool to automatically block the air valve of the motor controller. After the first airtight station executes the automatic blocking instruction, the first PLC detects the state jump signal and controls the airtight leak detector to perform test action. The airtight leak detector automatically performs waterway airtight test (including inflation, holding, and testing steps) on the motor controller. After the waterway airtight test is completed, a test completion signal is fed back to the first PLC, and the first PLC controls the airtight tool to separate from the motor controller.

[0099] In one embodiment, step 3 is implemented as follows:

[0100] After the waterway airtight test is passed, the tool automatically connects the low-voltage terminal of the controller. After the low-voltage power is turned on, the CAN box performs a dedicated test program burning on the controller. After the burning is completed, the workstation compares whether the program burning version is consistent.

[0101] In one embodiment, step 4 is implemented as follows:

[0102] The first safety workstation automatically docks the product end bus bar, the motor controller, and the device end bus bar. The product end bus bar and the device end bus bar short together the DC end and the three-phase end of the motor controller, and short together the LV end of the motor controller and the shell.

[0103] After the first safety workstation receives the docking completion signal, the safety analyzer first performs an insulation test on the motor controller power end to the shell and signal line, and then performs a withstand voltage test. After the test is completed, a test completion signal is fed back to the second PLC, and the second PLC issues a tool automatic separation instruction to control the bus bar to separate from the motor controller.

[0104] In one embodiment, step 5 is implemented as follows:

[0105] The qualified product enters the aging workstation along with the drag chain. The working station environment temperature is high temperature 85℃, and the cooling liquid temperature is 65℃. After the motor controller enters the oven, the aging workstation connects the DC end of the motor controller to high voltage, the low-voltage end to low voltage, the three-phase end to inductive load, and the waterway of the motor controller to the waterway of the water chiller, and turns on the cooling liquid.

[0106] Measure the terminal resistance between the CAN high and CAN low of the motor controller to see if it is in the set resistance range and can communicate normally. In this embodiment, the terminal resistance between the CAN high and CAN low needs to be 90Ω-150Ω and can communicate normally (use a low-voltage wiring harness with a 120Ω terminal resistance).

[0107] Perform rated operating condition operation detection. In this embodiment, the rated bus voltage, rated low voltage, cooling liquid flow rate 8-12 L / min, ambient temperature 85°C, water temperature 65°C, rated output current, and 30s continuous mode are used to perform rated operating condition operation detection.

[0108] Perform peak operating condition operation detection. In this embodiment, the rated bus voltage, rated low voltage, cooling liquid flow rate 8-12 L / min, ambient temperature 85°C, water temperature 65°C, peak output current, and 10s continuous mode are used to perform peak operating condition operation detection.

[0109] After the rated operating condition operation detection and the peak operating condition operation detection are performed three times, if the aging workstation determines that the motor controller normally outputs rated current and peak current, the aging test is qualified.

[0110] In one embodiment, step 6 is implemented as follows:

[0111] The workstation fixture connects the high voltage to the DC end of the controller and the low voltage to the low voltage end.

[0112] After the connection is completed, the IG OFF uses an ammeter (microampere level) to read the static current of the controller;

[0113] Then, the resolver fixture in the workstation is connected to the resolver connector of the controller, and the host computer reads the resolver angle and speed to complete the resolver test.

[0114] The host computer reads the IGBT temperature at room temperature, and the motor temperature sensor signal is connected to a small resistance, and the host computer reads the motor temperature.

[0115] After the high voltage and low voltage are applied, the host computer reads the DC end voltage of the controller and determines whether it meets the sampling accuracy requirements.

[0116] Finally, active and passive discharge is performed. The passive discharge counts the time for the high-voltage DC bus support capacitor to be discharged from the highest working voltage to a safe voltage (60V) or below, and the active discharge counts the time for the high-voltage DC bus support capacitor to be discharged from the highest working voltage to a safe voltage (60V) or below.

[0117] If each of the above obtained data is within the respective set qualified range, the EOL test is qualified.

[0118] In one embodiment, the implementation of step 7 is exactly the same as the implementation process of step 4.

[0119] In one embodiment, the implementation of step 8 is as follows:

[0120] The workstation connects the controller to the cavity airtight tooling, and the workstation uses the airtightness leak detector to inflate, hold, test, etc. After the cavity airtightness test is completed, the workstation will determine whether it is qualified according to the test results.

[0121] In one embodiment, the implementation of step 9 is as follows:

[0122] The cavity airtight qualified product will be programmed and burned, and the tooling will automatically connect the low-voltage terminal of the controller. After the low-voltage power is turned on, the CAN box will burn the product client software of the controller. After the burning is completed, the workstation will read the software version to confirm the version, and then clear the software historical fault information.

[0123] The controller that completes the above test content and passes can be used as a factory product, and a factory qualified label is printed. After the label is pasted, it is placed in the warehouse.

[0124] Embodiment two

[0125] The embodiment provides a preferred implementation of a test system, which comprises

[0126] The code scanning workstation is used for scanning the motor controller;

[0127] The first airtightness workstation is used for waterway airtightness detection of the motor controller;

[0128] The first program burning station is used for testing program burning and program burning version comparison of the motor controller;

[0129] The first safety workstation is used for insulation resistance and voltage resistance test of the motor controller;

[0130] The aging workstation is used for aging test of the motor controller;

[0131] The EOL online test workstation is used for EOL test of the motor controller;

[0132] The second safety workstation is used for insulation resistance and voltage resistance test of the motor controller after aging;

[0133] The second airtightness workstation is used for cavity airtightness test of the motor controller;

[0134] The second program burning station is used for client program burning and program burning version comparison of the motor controller.

[0135] In one embodiment, the first airtight workstation (which can integrate code scanning and software burning functions) is composed of an airtight tool, a first reader / writer, a clamp jaw, a low-voltage power supply, a low-voltage wire harness tool, a first PLC, and a cylinder. The workstation can give instructions to the cylinder and the clamp jaw according to position information, adjust the position of the control tool, and make the airtight tool and the wire harness tool reliably connected to the controller, so as to perform code scanning, airtightness testing, and software burning. The controller and the tray move with the drag chain. After the first reader / writer senses the electronic tag of the controller entering the station, the workstation performs positioning RFID reading. After reading the signal, the first PLC gives the workstation an instruction to move the airtight tool to automatically block the breather valve of the controller through the cylinder. After the workstation executes the automatic blocking instruction, there is a state jump. After the first PLC detects the state jump, the airtightness tester performs a test action. The airtightness tester automatically performs airtightness testing on the controller. After the airtightness testing is completed, the PLC is fed back. At this time, the PLC gives an automatic separation instruction of the tool. Subsequently, the airtight tool and the controller are separated. Then, the tray is released to the next station.

[0136] In one embodiment, the first safety workstation / second safety workstation includes a second reader / writer, a second PLC, a first lifting and moving device, a first insulating lifting device, a device-end busbar, a product-end busbar, a cylinder, and a safety analyzer. The controller and the tray move with the drag chain. After the second reader / writer senses the electronic tag of the controller entering the station, the workstation performs positioning RFID reading. After reading the signal, the second PLC gives an instruction to lift and move the controller and send it to the test position for positioning. After the PLC receives the positioning completion signal, the PLC gives an automatic docking instruction to the test mechanism. The product-end busbar, the controller, and the device busbar are automatically docked through the cylinder. The product-end busbar and the device-end busbar have pre-connected the five points of the DC end and the three-phase end of the controller together, and have pre-connected the LV end of the controller and the shell together. After the PLC receives the docking completion signal, the safety analyzer first performs an insulation test on the controller power end and the shell and the signal line. Subsequently, a withstand voltage test is performed. After the test is completed, the PLC is fed back. At this time, the PLC gives an automatic separation instruction of the tool. Subsequently, the busbar and the controller are separated. The controller is lowered to the drag chain. Then, the tray is released to the next station.

[0137] In one embodiment, the aging workstation includes a third reader-writer, a third PLC, a palletizing and transplanting machine, an aging cabinet, a reactor, a water chiller, an electric control cabinet, a conveying line body, a display, an upper feeding rotary machine, a lower feeding rotary machine, an inductance load, an inductance load test tool, a low-voltage wire harness tool, a high-voltage power supply, a low-voltage power supply, a multimeter, a cylinder, and a camera. The conveying line body is located below the aging cabinet, and there is a palletizing and transplanting machine behind the aging cabinet. The tray flows into the upper feeding rotary machine and is transferred to the conveying line body. The aging cabinet contains a reader-writer. After the third reader-writer senses the electronic tag of the controller entering the station, the aging cabinet will perform positioning RFID reading. After reading the signal, the third PLC will issue an instruction to open the door and preferentially remove the completed test product from behind the cabinet. The controller is lifted into the cabinet below the aging cabinet. After the product is put into the cabinet, the PLC will issue a door closing instruction. The palletizing and transplanting machine moves the completed test product to the lower feeding rotary machine. The tray continues to the main line body for the next process. The display is used by employees to monitor the working condition of the aging cabinet. Among them, the camera captures the position of the key part and feeds back to the workstation. The workstation can issue instructions to the cylinder, clamping jaw, etc. according to the position information to adjust the position of the control tool, so that the high-voltage power supply, low-voltage power supply, inductance load, and water chiller can reliably connect with the controller. The inductance load test tool of the workstation is equipped with a current sensor and a voltage sensor, which can monitor the state of the controller in real time, so as to perform related tests of the aging workstation.

[0138] In one embodiment, the EOL online test workstation includes a fourth reader-writer, a fourth PLC, a second lifting and transplanting device, a second insulation lifting device, a high-voltage power supply, a low-voltage power supply, a high-precision digital multimeter, and a rotary transformer simulator. The controller moves with the tray along the chain. After the fourth reader-writer senses the electronic tag of the controller entering the station, the workstation will perform positioning RFID reading. After reading the signal, the fourth PLC will issue an instruction to lift and move the controller to the test position and position the controller. After receiving the positioning completion signal, the PLC will issue an automatic docking instruction to the test mechanism. After docking is completed, the EOL workstation will receive the PLC instruction to automatically test. After testing is completed, the PLC will be fed back. At this time, the PLC will issue an automatic separation instruction for the tool. Subsequently, the bus bar is separated from the controller, the controller is lowered to the chain, and the tray is released to the next station.

[0139] It should be understood that the specific order or hierarchy of steps in the processes disclosed is an example of exemplary approaches. Based upon design preferences, it should be understood that the specific order or hierarchy of steps in the processes can be re-arranged while remaining within the scope of the present disclosure. The accompanying method claims present elements of the various steps in exemplary order and are not intended to be limited to the specific order or hierarchy presented.

[0140] In the detailed description above, various features are grouped together in single embodiments for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting a necessity to more features than are expressly recited in each claim. Rather, inventive embodiments are defined solely by those parts expressly recited in the claims. Accordingly, the claims are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separately utility- patentable invention.

[0141] The disclosed embodiments are to be considered merely illustrative of the principles of the application, and various modifications can be made by those skilled in the art to the application without departing from the scope and spirit of the application. Therefore, the scope of the application is not intended to be limited to the examples described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0142] The above description includes one or more examples of the embodiments. Of course, not all possible combinations of components or methods described above will be described to not obscure the disclosure. However, one of ordinary skill in the art will recognize that further combinations and permutations of various embodiments are possible. Accordingly, the embodiments described herein are intended to embrace all such alterations, modifications and variations which fall within the scope of the appended claims. Furthermore, to the extent that the term "includes" is used in either the detailed description or the claims, such term is intended to be interpreted as "comprising" rather than "consisting of. Also, any use of the term "or" in the claims is intended to be interpreted as "and / or," such that when a claim element is preceded by "or," the element is a disjunctive term that means any of the referenced elements can be used, and the reference to "or" should not be interpreted as a limitation to only the disjunctive term.

[0143] The above-described embodiments are merely illustrative of the present application, and the present application is not limited thereto. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art will understand that the technical solutions of the foregoing embodiments can be modified or equivalent replacements can be made to some technical features without departing from the spirit and scope of the present application, and such modifications or replacements shall fall within the scope of the present application.

Claims

1. An automated testing method for a motor controller, characterized in that, include: Perform a visual inspection on the assembled motor controller; After the appearance inspection is qualified, the motor controller is placed on the cable chain and transported to the barcode scanning workstation for barcode scanning. After barcode scanning, the motor controller is transported to the first airtight workstation for waterway airtightness testing. After the waterway airtightness test is passed, the motor controller is transported by cable chain to the first programming station for test program programming and test program version comparison. After the test program is burned and the version is compared, the motor controller is transported by cable chain to the first safety workstation for insulation resistance and withstand voltage testing of the controller. After the insulation resistance and withstand voltage tests of the controller are passed, the motor controller is transported to the aging workstation by cable chain for aging test. After the aging test is passed, the motor controller is transported by cable chain to the EOL online testing workstation for EOL testing; After the EOL test is passed, the motor controller is transported by cable chain to the second safety workstation for insulation resistance and withstand voltage tests after aging. After the insulation resistance and withstand voltage tests after aging are passed, the motor controller is transported by cable chain to the second airtight workstation for cavity airtightness test. After the cavity airtightness test is passed, the motor controller is transported to the second programming station by cable chain for client program programming and client program version comparison. If the client program version comparison is passed, a factory qualified label is printed on the motor controller. The insulation resistance and withstand voltage tests performed on the controller by the first safety workstation / second safety workstation include: The first safety workstation / second safety workstation automatically connects the product-side bus, the motor controller, and the equipment-side bus. The product-side bus and the equipment-side bus have pre-connected the DC and three-phase terminals of the motor controller and the LV terminal of the motor controller to the housing. After the second PLC of the first safety workstation / second safety workstation receives the docking completion signal, the safety analyzer first performs an insulation test on the motor controller's power end to the housing and signal line, and then performs a withstand voltage test. After the test is completed, the test completion signal is fed back to the second PLC, and the second PLC issues an automatic tooling separation command to control the bus to separate from the motor controller. The aging test includes: The motor controller enters the temperature chamber. The aging workstation connects the DC terminal of the motor controller to high voltage, the low voltage terminal to low voltage, and the three-phase terminal to the inductive load. The water channel of the motor controller is connected to the water channel of the chiller and is supplied with coolant. The ambient temperature of the aging workstation is 85°C (high temperature) and the coolant temperature is 65°C. Measure whether the terminating resistance between the CAN high and CAN low of the motor controller is within the set resistance range and whether normal communication is possible; Perform rated operating condition testing; Perform peak operating condition testing; After the rated operating condition test and peak operating condition test are cycled several times, if the aging workstation determines that the motor controller is normally outputting rated current and peak current, then the aging test is qualified.

2. The automated testing method for motor controllers according to claim 1, characterized in that, The visual inspection includes: Perform an external cleaning, check for any signs of squeezing, bumping, rust, or scratches; Check that the traceability label, high-voltage warning label, label location, and label content conform to the drawings and packaging requirements; check that the nameplate lettering is clear and the nameplate content conforms to the drawing requirements. Check that the connectors are undamaged and that the installation position meets the requirements of the drawings. Verify that the installation of the upper and lower cover housing fixing bolts, the wiring cover installation, and the self-inspection markings of the signal connectors and the upper cover fastening bolts are clear and complete.

3. The automated testing method for motor controllers as described in claim 1, characterized in that: The waterway airtightness test includes: After the first airtight workstation reads the electronic tag signal of the motor controller, it controls the cylinder to move the airtight fixture to automatically seal the vent valve of the motor controller through the first PLC. After the first airtight workstation executes the automatic sealing command, the first PLC detects the status jump signal and controls the airtight leak meter to perform the test action. The airtight leak meter automatically performs a waterway airtight test on the motor controller. After the waterway airtight test is completed, it sends a test completion signal back to the first PLC. The first PLC then controls the airtight fixture to separate from the motor controller.

4. A test system for implementing the automated test method for motor controllers as described in claim 1, characterized in that, include: The barcode scanning workstation is used to scan the barcodes on the motor controller. The first airtight workstation is used to test the airtightness of the waterway in the motor controller; The first programming station is used to program the motor controller for testing and to compare the programmed versions. The first safety workstation is used to perform insulation resistance and withstand voltage tests on motor controllers. An aging workstation is used for aging tests on motor controllers. EOL online test workstation, used for EOL testing of motor controllers; The second safety workstation is used to test the insulation resistance and withstand voltage of the motor controller after aging. The second airtight workstation is used to perform cavity airtightness testing on the motor controller; The second programming station is used to program the motor controller with client software and compare the programmed versions.

5. The testing system as described in claim 4, characterized in that: The first airtight workstation includes a first PLC, a cylinder, an airtight fixture, a first reader / writer, and an airtight leak detector; The first reader is used to read the electronic tag on the motor controller; The cylinder is the same as the vent valve of the motor controller that drives the airtight tool sealing motor; The air tightness tester is used to perform waterway air tightness testing on the motor controller; The first PLC is used to control the cylinder to move the airtight fixture, control the airtight leak meter to perform the test action after detecting the state change signal, and control the airtight fixture to separate from the motor controller after receiving the test completion signal.

6. The testing system as described in claim 4, characterized in that: The first safety workstation includes a second reader / writer, a second cylinder, a second PLC, a first lifting and transferring device, a first insulating lifting device, an equipment-side busbar, a product-side busbar, and a safety analyzer; The second reader is used to read the electronic tag on the motor controller; The second cylinder is used to drive the manifold to automatically dock or disconnect from the motor controller. The first lifting and transplanting device is used to lift the transverse motor controller to the test position; The first insulating lifting device is used to lift and position the motor controller; The device-side bus and the product-side bus are used to short-circuit the DC terminal and three-phase terminal of the motor controller together, and to short-circuit the LV terminal of the motor controller to the housing. The safety analyzer is used to first perform insulation tests on the motor controller's power end to the housing and signal lines, then perform withstand voltage tests, and after the tests are completed, feed back the test completion signal to the second PLC. The second PLC is used to control the first lifting and transplanting device and the first insulation lifting device to move the motor controller to the test position and lift and position it. It controls the equipment-side bus and the product-side bus to automatically connect with the motor controller and controls the safety analyzer to perform insulation test and withstand voltage test.

7. The testing system as described in claim 4, characterized in that: The aging workstation includes a third reader / writer, a third PLC, a palletizing and transplanting machine, an aging cabinet, a reactor, a water chiller, a DC power supply, an electrical control cabinet, a conveyor line, a display, a loading rotary machine, and a unloading rotary machine. The third reader is installed on the aging cabinet, the feeding rotary machine is used to transport the motor controller to the conveyor line, the palletizing and transplanting machine is installed behind the aging cabinet, and the conveyor line is installed below the aging cabinet. After receiving the electronic tag signal read by the third reader, the third PLC outputs a command to control the aging chamber to open the door and move the tested product out from the back of the aging chamber. The palletizing and transferring machine under the aging chamber lifts the motor controller to be tested into the chamber. The PLC issues a door closing command to start the aging test. The palletizing and transferring machine moves the tested product to the unloading rotary machine. The display is used by employees to monitor the working status of the aging chamber.

8. The testing system as described in claim 4, characterized in that: The EOL online testing workstation includes a fourth reader / writer, a fourth PLC, a second lifting and transplanting device, a second insulating lifting device, a high-voltage power supply, a low-voltage power supply, a high-precision digital multimeter, and a resolver simulator. The fourth reader is used to read the electronic tag on the motor controller; The second lifting and transplanting device is used to lift the transverse motor controller to the test position; The second insulating lifting device is used to lift and position the motor controller; The low-voltage power supply high-precision digital multimeter is used to read the static current of the motor controller during EOL testing; The resolver simulator is used to connect to the resolver connector of the motor controller to complete the resolver test; The fourth PLC is used to control the second lifting and transplanting device and the second insulating lifting device to move the motor controller to the test position and perform lifting and positioning, as well as to control the various test fixtures in the EOL online test workstation to perform EOL tests.

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