Motor simulation method, motor simulation device and motor controller test system

Abstract

The application relates to the technical field of motor controller testing, in particular to a motor simulation method, a motor simulation device and a motor controller testing system. The motor simulation method of the application takes the collected current value as the input of a motor electromagnetic model, does not need to sample voltage, and avoids adding an additional high-frequency voltage sampling module; the application introduces double-path position synchronous simulation, realizes rotor position synchronization of a motor controller to be tested and a simulation-side motor controller, avoids adding a high-speed communication interaction module of the simulation-side motor controller and a position simulation device, and greatly reduces the cost of the testing system.

Description

Technical Field

[0001] This invention relates to the field of motor controller testing technology, and more specifically, to a motor simulation method for simulating a target motor controlled by a motor controller under test through a simulated side motor controller; a motor simulation device using the motor simulation method for simulating a target motor controlled by a motor controller under test; and a single-set motor controller testing system including the motor simulation device, and a multi-channel parallel testing system for motor controllers including several single-set motor controller testing systems. Background Technology

[0002] Motor controllers are a crucial component of new energy electric vehicles, and their development requires extensive functional verification, performance testing, and durability testing. Traditional testing methods primarily rely on mechanical load benches built with real motors, which suffer from numerous challenges, including complex system structures, high mechanical losses, poor reusability, and high costs. To overcome these issues, domestic and international researchers have proposed a motor simulator solution based on power hardware-in-the-loop technology. This solution utilizes high-speed hardware computing modules to perform real-time simulation of the motor model, and then leverages power electronic control technology to simulate the power level of the simulation results. It eliminates the mechanical rotating parts found in traditional test benches, offering advantages such as low energy loss, high flexibility, and enhanced safety and reliability.

[0003] Existing motor simulator solutions all require simultaneous acquisition of the port voltage and current of the motor controller under test. Based on different implementation methods, they can be divided into two categories:

[0004] Solution ①: Based on closed-loop control of the reference current, it first calculates the reference current output using the acquired port voltage and the motor model, and then completes the tracking control of the reference current through closed-loop control of the power module. The corresponding representative patent is: A motor simulator device based on a distributed FPGA architecture (CN113589734A). Since the port voltage is generally a high-frequency square wave of 10kHz, in order to ensure the sampling accuracy of the port voltage, the simulation accuracy of the motor model, and the reference current tracking performance at high speed, the system is generally composed of a high-speed FPGA hardware computing module and a SiC wideband power module to achieve high-frequency signal acquisition, model simulation, closed-loop control, and voltage modulation up to 50kHz. As a result, its cost is not significantly advantageous compared to traditional mechanical test benches.

[0005] Option ②: Open-loop voltage control based on equal current change rate. This involves directly calculating the output voltage of the motor simulator using the collected port voltage, port current, motor model parameters, and external impedance parameters. The output voltage is then modulated using a power module. A representative patent for this is: A Simulation Device and Control Method for a Permanent Magnet Three-Phase AC Motor and its Load (CN114499334A). This option eliminates model simulation and closed-loop control of the reference current, reducing the frequency requirements for system control and voltage modulation. However, it still requires accurate acquisition of high-frequency square wave voltage, necessitating the addition of extra high-frequency voltage sampling in the general-purpose motor controller. Furthermore, to accurately simulate the position changes of the motor under high-speed conditions, a high-speed communication module for interaction with the position simulation device is added to the general-purpose motor controller, resulting in no significant cost advantage. Summary of the Invention

[0006] Therefore, it is necessary to address the issue of high costs associated with existing motor simulator solutions by providing a motor simulation method, motor simulation device, and motor controller testing system that eliminates the need for additional high-frequency voltage sampling modules and high-speed position communication modules, thereby reducing costs.

[0007] This invention is achieved using the following technical solution:

[0008] In a first aspect, the present invention discloses a motor simulation method, which simulates the target motor controlled by the motor controller under test through a simulation-side motor controller.

[0009] The motor simulation method includes the following steps:

[0010] S1, Establish the electromagnetic model of the target motor, and input the real-time three-phase current value i a i b i c and the rotor electrical angle value θ r As input to the electromagnetic model of the target motor, the electrical port voltage of the target motor is obtained. and the target motor output torque value T e ;Will Converted to analog side motor controller port reference voltage

[0011] S2, Establish a voltage modulation optimization model, The signal is converted into an initial switching signal, and the nonlinear characteristics are actively compensated. At the same time, the zero-sequence current component is actively suppressed to obtain an optimized switching signal to achieve accurate output of the target motor electrical port voltage value.

[0012] S3. Based on the simulated load loading mode, establish a motor motion model to obtain the rotor electric angular velocity value of the target motor.

[0013] S4, combining the target motor's rotor initialization position and the obtained... Calculate the rotor electrical angle value Will The position is converted into an analog electrical signal and synchronously output to the motor controller under test and the analog motor controller to achieve rotor position synchronization between the motor controller under test and the analog motor controller.

[0014] This motor simulation method implements the method or process disclosed in the embodiments of the present invention.

[0015] Secondly, the present invention discloses a motor simulator device for simulating a target motor controlled by a motor controller under test.

[0016] The motor simulator device includes: a simulated motor controller, a three-phase inductor module, and a position simulation device. The DC port of the simulated motor controller is connected to a DC power supply. One end of the three-phase inductor module is connected to the three-phase AC terminal of the simulated motor controller, and the other end serves as the electrical port of the target motor, used to connect to the three-phase AC terminal of the controller of the motor under test.

[0017] The analog-side motor controller includes an analog-side current acquisition module. This module is connected to the three-phase AC terminals of the analog-side motor controller and is used to acquire the three-phase current at these terminals. The analog-side motor controller also includes a position acquisition module for acquiring rotor electrical angle values.

[0018] The position simulation device is used for synchronous simulation of dual-channel position signals. It includes a communication module, a calculation module, and a signal simulation module. The communication module interacts with the simulated motor controller. The calculation module calculates the rotor position value in real time. One output of the signal simulation module connects to the motor position sampling terminal of the simulated motor controller, and the second output serves as the mechanical port of the target motor, connecting to the motor position sampling terminal of the motor controller under test. The signal simulation module converts the rotor position value into a position analog electrical signal recognizable by the position sensor and outputs it synchronously to both the simulated motor controller and the motor controller under test.

[0019] The simulated motor controller contains an MCU. The MCU stores a computer program, which is read and executed by the MCU to perform the motor simulation method disclosed in the first aspect. In a third aspect, this invention discloses a single-set motor controller testing system, including a motor controller under test and a motor simulator device as disclosed in the second aspect. The DC port of the motor controller under test is connected to a DC power supply. The electrical port of the motor simulator device is connected to the three-phase AC terminal of the motor controller under test. The mechanical port of the motor simulator device is connected to the motor position sampling terminal of the motor controller under test.

[0020] This invention also discloses a multi-channel parallel testing system for motor controllers, comprising several of the aforementioned single-set motor controller testing systems. These single-set motor controller testing systems are connected in parallel and share the same DC power supply. The motor controller under test and the motor simulator device within each single-set motor controller testing system also share the same DC power supply; the simulation-side motor controller within each single-set motor controller testing system reuses the hardware of the motor controller under test.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. The motor simulation method of the present invention uses the collected current value as the input of the motor electromagnetic model, without the need to sample the voltage, thus avoiding the need to add an additional high-frequency voltage sampling module; the present invention introduces dual-channel position synchronization simulation to realize the rotor position synchronization between the motor controller under test and the simulation side motor controller, thus avoiding the need to add a high-speed communication interaction module between the simulation side motor controller and the position simulation device, and greatly reducing the cost of the test system.

[0023] 2. The motor simulation method of this invention provides two types of motor electromagnetic models when constructing the motor electromagnetic model. The first model considers the magnetic saturation effect of the target motor and, combined with the AC voltage drop across the three-phase inductor, obtains a more comprehensive analog-side motor controller port reference voltage. Furthermore, in the port reference voltage modulation output stage, the influence of power device nonlinearity and zero-sequence current on voltage modulation is fully considered, achieving high-precision output of the port reference voltage.

[0024] 3. The motor simulation device provided by this invention can directly use existing motor controller hardware. Only software adjustments are needed. Combined with the position simulation device proposed in this invention, it performs synchronous simulation of dual-channel position signals to simulate the target motor. This device can be used for power level testing of the motor controller under test, significantly reducing testing costs.

[0025] 4. Because the invention reuses the hardware of the motor controller, the proposed multi-parallel scheme can enable multiple motor controllers under test to share a single DC power supply, which is suitable for durability testing of a large number of motor controllers of the same specifications. Attached Figure Description

[0026] Figure 1 This is a structural diagram of the motor simulator device of the present invention;

[0027] Figure 2 for Figure 1 Schematic diagram of zero-sequence current suppression using a medium voltage modulation optimization model;

[0028] Figure 3 for Figure 1 A flowchart of the construction process for simulating the electromagnetic model of an electric motor, considering the effects of magnetic saturation.

[0029] Figure 4 for Figure 1 A structural diagram of the single-set motor controller test system used in the motor simulator device;

[0030] Figure 5 for Figure 4 A structural diagram of a multi-channel parallel test system for motor controllers, composed of a single set of motor controller test systems;

[0031] Figure 6 For use Figure 4 The speed / torque response results during simulation testing of a single motor controller test system.

[0032] Figure 7 For use Figure 4 The dq axis current response results during simulation testing of a single motor controller test system;

[0033] Figure 8 For use Figure 4 The dq axis voltage response results during simulation testing of a single motor controller test system;

[0034] Figure 9 For use Figure 4 The A-phase voltage filtering results during simulation testing of a single motor controller test system. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] It should be noted that when a component is described as "installed on" another component, it can be on the other component or it can also be in a central component. When a component is described as "set on" another component, it can be set on the other component or it may also be in a central component. When a component is described as "fixed to" another component, it can be fixed on the other component or it may also be in a central component.

[0037] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "or / and" as used herein includes any and all combinations of one or more of the associated listed items.

[0038] Example 1

[0039] Please refer to Figure 1 , Figure 1 This is a structural diagram of the motor simulator device of the present invention. Figure 1 As shown, the motor simulator device includes a simulation-side motor controller, a three-phase connected inductor module, and a position simulation device.

[0040] The DC port of the analog motor controller is connected to a DC power supply.

[0041] One end of the three-phase connection inductor module is connected to the three-phase AC terminal of the analog motor controller, and the other end serves as the electrical port of the target motor, used to connect to the three-phase AC terminal of the motor controller under test.

[0042] The analog-side motor controller is equipped with an analog-side current acquisition module. The analog-side current acquisition module is connected to the three-phase AC terminals of the analog-side motor controller and is used to acquire the three-phase current of the three-phase AC terminals of the analog-side motor controller; the analog-side motor controller is also equipped with a position acquisition module, which is used to acquire the rotor electrical angle value and the rotor electrical angle value.

[0043] The position simulation device is used for synchronous simulation of dual-channel position signals. It includes a communication module, a calculation module, and a signal simulation module. The communication module is used for information exchange with the simulation-side motor controller. The calculation module is used for real-time calculation of the rotor position value. One output terminal of the signal simulation module is connected to the motor position sampling terminal of the simulation-side motor controller, and the second output terminal serves as the mechanical port of the target motor, used to connect to the motor position sampling terminal of the tested motor controller. The signal simulation module converts the rotor position value into an analog electrical signal recognizable by the position sensor and synchronously outputs this analog electrical signal to both the simulation-side motor controller and the tested motor controller.

[0044] The analog motor controller has an MCU; the MCU stores a computer program, which is read and run by the MCU to execute the motor simulation method.

[0045] In short, a motor simulator device is used to simulate the target motor controlled by the motor controller under test. Figure 1 The part inside the frame is equivalent to the target motor.

[0046] The simulated motor controller used in this motor simulator is the same as existing motor controllers in terms of hardware; the only difference is the built-in software program. The built-in software program can be modified simply by burning it into the firmware, making the operation straightforward.

[0047] For motor simulation methods, the target motor controlled by the motor controller under test is simulated through a simulated motor controller on the simulation side, thus simulating the electromagnetic and mechanical characteristics of the target motor. The electromagnetic characteristics are the target motor's port reference voltage and electromagnetic output torque. The mechanical characteristics are the motor rotor position (electric angle) and electrical angular velocity.

[0048] Specifically, the motor simulation method includes the following steps:

[0049] S1, Establish the electromagnetic model of the target motor, and input the real-time three-phase current value i a i b i c and the rotor electrical angle value θ r As input to the electromagnetic model of the target motor, the electrical port voltage of the target motor is obtained. and the target motor output torque value T e ; Target motor electrical port voltage Converted to analog side motor controller port reference voltage

[0050] S1 involves constructing the electromagnetic model of the target motor and performing calculations using current values, rotor electrical angles, etc. For example... Figure 1 As shown, the electromagnetic model of the target motor has a three-phase inductor module connected to its input terminal one to generate a voltage drop, and an inductor module connected to its input terminal two to provide the real-time rotor electrical angle value θ. r Position simulation device.

[0051] The electromagnetic model of the target motor can be established in two ways: basic electromagnetic model II and improved electromagnetic model I. The former (basic electromagnetic model II) is based on lumped parameters, while the latter (improved electromagnetic model I) is based on matrix parameters. The latter takes into account the influence of the target motor's inductance parameters on the magnetic saturation of the iron core, thus the electromagnetic model established by the latter is more accurate.

[0052] (I) The process for establishing the second basic electromagnetic model is known and will not be described in detail here. The reference voltage at the analog-side motor controller port is obtained using the second basic electromagnetic model. and the target motor output torque value T e The methods include:

[0053] Acquire real-time three-phase current values ​​i a i b i c and the rotor electrical angle value θ r Perform coordinate transformation to obtain the current value i in the rotor synchronous coordinate system. d i q :

[0054]

[0055] Among them, the real-time three-phase current value i a i b i c The three-phase current flows through the three-phase connected inductor module;

[0056] Combining the lumped parameters of the target motor and the parameters of the three-phase connected inductor module, the second port voltage of the target motor is obtained based on the established Model 2. And the target motor torque value two

[0057] in,

[0058]

[0059]

[0060]

[0061] Based on the voltage drop of the three-phase connected inductor module, according to Convert analog side motor controller port voltage 2

[0062] in,

[0063]

[0064]

[0065] Among them, the lumped parameters of the target motor include the stator resistance R of the target motor. s d-axis inductance L d q-axis inductance L q Rotor flux ψ f Number of pole pairs P of the motor n The parameters of the three-phase connected inductor module include the inductance value L. cEquivalent resistance value R c .

[0066] (II) For the improved electromagnetic model one, see Figure 3 The construction of the improved electromagnetic model one includes the following steps:

[0067] Step 1: Obtain the numerical solution for the flux linkage along the dq axis;

[0068] Step one includes:

[0069] Set the stator current amplitude I s The combination with torque angle β (I) s (β) represents a current operating point such that (I s ,β) and dq axis current i d i q satisfy:

[0070]

[0071] Among them, i d Let i be the d-axis current. q This is the q-axis current;

[0072] set up For the maximum stator current amplitude, in Divide the range into equal parts to obtain γ. I There are several different stator current amplitude points; the torque angle β ranges from [0, 2π], and after dividing it equally, we obtain γ. β A different torque angle;

[0073] Get γ I ×γ β Different current operating points (I) s Stator flux linkage values ​​along the dq axis under (β) conditions:

[0074]

[0075] Step 2: Establish the analytical model of the flux linkage along the dq axis;

[0076] Step two includes:

[0077] For the same I s All different β operating points are merged to obtain a fixed I. s The following dq axis flux linkage sequence:

[0078]

[0079] For fixed I s Fourier series expansions of the dq-axis flux linkage sequences yield the flux linkage expression with β as the independent variable:

[0080]

[0081]

[0082] N1 is the highest order of the selected Fourier series. and For the corresponding The Fourier series coefficients of the amplitude, ω β ω is the fundamental angular frequency in the β direction;

[0083] Given the same Fourier series order and all different I... s By combining the Fourier series coefficients, we obtain a Fourier series sequence of fixed order:

[0084] d k ,q k k = -N1, -N1+1, ..., N1-1, N1;

[0085] Polynomial fitting is performed on a fixed k-order Fourier series sequence to obtain the result with I s The expression for the Fourier series coefficients of the independent variable:

[0086]

[0087] N2 is the highest order of the selected polynomial. and These are the polynomial coefficients;

[0088] By combining the coefficients of polynomials of the same order into a polynomial coefficient vector, the target motor matrix parameters can be obtained.

[0089]

[0090]

[0091] Transform to obtain I s The expression for the parameters of the dq-axis flux linkage matrix with β as independent variables is as follows:

[0092]

[0093]

[0094] in,

[0095] Step 3: Establish the electromagnetic model of the target motor based on matrix parameters;

[0096] Step three includes:

[0097] Establish the motor voltage equation to obtain the target motor port voltage. Establish the motor torque equation to obtain the target motor torque value. in,

[0098]

[0099]

[0100]

[0101] Among them, R s P is the stator resistance of the target motor. n The target number of pole pairs;

[0102] Combining the voltage drop across the three-phase connection inductor module, Converted to analog side motor controller port voltage

[0103]

[0104]

[0105] Among them, R c L represents the equivalent resistance of the three-phase connected inductor module. c This is the inductance value of the three-phase connected inductor module.

[0106] The difference between Model 1 and Model 2 lies in the fact that Model 1 specifies the d-axis inductance L of the target motor. d q-axis inductance L q and rotor flux ψ f The parameters were matrixed to achieve a more comprehensive simulation.

[0107] The reference voltage at the analog-side motor controller port was obtained using an improved electromagnetic model. and the target motor output torque value T e The methods include:

[0108] Acquire real-time three-phase current values ​​i a i b i c and the rotor electrical angle value θ r Perform coordinate transformation to obtain the current value i in the rotor synchronous coordinate system. d i q :

[0109]

[0110] Among them, the real-time three-phase current value i a i b ic The three-phase current flows through the three-phase connected inductor module;

[0111] Based on the established model, the target motor port voltage is obtained. and the target motor torque value

[0112]

[0113]

[0114]

[0115] Based on the voltage drop of the three-phase connected inductor module, according to Convert analog side motor controller port voltage 1

[0116] in,

[0117]

[0118]

[0119] R s For the stator resistance of the target motor, P n L is the number of pole pairs of the motor. c The inductance value and R of the three-phase connected inductor module c This is the equivalent resistance value of the three-phase connected inductor module.

[0120] It should be noted that in this embodiment, a simulated side current acquisition module is used to acquire the real-time three-phase current value i. a i b i c The real-time rotor electrical angle value θ is acquired through the motor position sampling terminal of the analog side motor controller. r .

[0121] S2, Establish a voltage modulation optimization model, and adjust the reference voltage at the analog side motor controller port. The signal is converted into an initial switching signal, and the nonlinear characteristics are actively compensated while the zero-sequence current component is actively suppressed to obtain an optimized switching signal to achieve accurate output of the target motor electrical port voltage value.

[0122] In short, S2 is to build a voltage modulation optimization model to ensure accurate output of the target motor electrical port voltage.

[0123] Specifically, S2 includes:

[0124] Will Convert to voltage value in stationary coordinate system

[0125]

[0126] in, To account for the rotor equivalent electrical angle due to switching cycle delay, T s This is the voltage modulation period.

[0127] Using SVPWM voltage vector modulation method based on Calculate the initial conduction time T of the three-phase bridge arm a T b T c And serve as the initial switching signal;

[0128] Active compensation was performed to address the nonlinear characteristics of the inverter, resulting in three-phase arm compensation times ΔT. a ΔT b ΔT c This allows us to obtain the conduction time of the three-phase bridge arm after nonlinear compensation.

[0129] in,

[0130] It should be noted that inverter nonlinear characteristics include, but are not limited to, switching delay, switching dead time, and power device voltage drop. SVPWM voltage vector modulation and methods for actively compensating for inverter nonlinear characteristics are existing and mature methods, and will not be elaborated upon here.

[0131] Then comes the suppression of zero-sequence current, see [link / reference] Figure 2 , Figure 2 Schematic diagram for zero-sequence current suppression:

[0132] Construct a proportional resonant controller to suppress zero-sequence harmonic current, with the controller referencing the target. When the input is zero, the controller feedback input is the sum of the three-phase currents, and the controller output is the zero-sequence voltage control quantity u0. Normalizing u0 yields the compensation time for suppressing the zero-sequence current.

[0133]

[0134] Among them, u smax This represents the maximum value of the modulation voltage.

[0135] The on-time of the three-phase bridge arm for suppressing the zero-sequence current component is calculated as follows: As an optimized switching signal.

[0136] S3. Based on the simulated load loading mode, establish a motor motion model to obtain the rotor electric angular velocity value of the target motor.

[0137] The simulated load loading mode is actually just a different load form, and the corresponding electrode operation model is divided into two modes: speed control and torque control.

[0138] 1) The simulated load is applied in speed control mode, and the constructed motor motion model directly sets the rotor electric angular velocity value of the target motor.

[0139] 2) If the simulated load is applied in torque control mode, the constructed motor operation model is combined with the target motor output torque value T. e and simulated load parameter T L Determine the rotor electric angular velocity value of the target motor J is the set moment of inertia of the transmission system, T L For the set load torque, This is the initial electric angular velocity value.

[0140] In other words, in case 1), the output of the electromagnetic model of the target motor is not input to the motor motion model. In case 2), the torque value T output by the electromagnetic model of the target motor... e It needs to be input into the motor motion model for auxiliary calculation.

[0141] S4, combining the target motor's rotor initialization position and the obtained rotor electric angular velocity value of the target motor. (For example, the rotor electrical angular velocity value output by the analog-side motor controller can be obtained using high-speed CAN bus communication.) ), calculate the rotor electrical angle value Rotor electrical angle value The position is converted into an analog electrical signal and synchronously output to the motor controller under test and the analog motor controller to achieve rotor position synchronization between the motor controller under test and the analog motor controller.

[0142] The purpose of S4 is to achieve rotor position synchronization between the motor controller under test and the analog motor controller.

[0143] Specifically, S4 includes:

[0144] Obtain the rotor electric angular velocity value of the target motor Calculate the rotor electrical angle value θ r :

[0145]

[0146] Where θ0 is the initial rotor electric angular velocity value;

[0147] The rotor electrical angle value θ rIt is converted into two analog electrical signals and output synchronously to the motor controller under test and the analog motor controller.

[0148] The form of the analog electrical signal is determined by the position sensor used by the corresponding motor controller. For example, if the corresponding motor controller uses a rotary transformer as the position sensor, the analog electrical signal is a high-frequency signal with a sine and cosine envelope containing rotor electrical angle information; if the corresponding motor controller uses a photoelectric encoder as the position sensor, the analog electrical signal is a pulse signal containing rotor electrical angle information.

[0149] It should be noted that the rotor electric angular velocity value of the target motor The rotor electric angular velocity value ω is obtained by acquiring the analog electrical signal from the controller side of the motor under test. r That is, the real-time rotor electric angular velocity value ω to be used in step 1. r In this embodiment, θ0 is the initial value, which can be set to 0, or it can be configured by manual calibration.

[0150] In this embodiment, the communication module acquires the rotor electrical angular velocity value of the target motor. The calculation module uses an integral method to calculate the rotor electrical angle value θ. r The signal simulation module then converts the rotor electrical angle value θ. r It is converted into two analog electrical signals and output synchronously to the motor controller under test and the analog motor controller.

[0151] Furthermore, it should be noted that, among the above parameters, except for the target motor parameters, the three-phase connection inductor module parameters, and the preset initialization parameter values, all other parameters are time-related values, such as the three-phase current value i. a i b i c A more accurate representation should be i a (t), i b (t), i c (t), rotor electrical angle value θ r A more accurate representation should be θ r (t). However, for the sake of simplicity, the above formula is not expressed in the form of t, which will be explained here.

[0152] Example 2

[0153] This embodiment 2 provides a single motor controller test system for testing a single motor controller under test.

[0154] See Figure 4 , Figure 4 for Figure 1The structural diagram of the single motor controller test system used in the motor simulator device.

[0155] The single-set motor controller test system includes the motor controller under test (TD) and the motor simulator device described in Example 1. The DC port of the TD is connected to a DC power supply. The electrical port of the motor simulator device is connected to the three-phase AC terminal of the TD. The mechanical port of the motor simulator device is connected to the motor position sampling terminal of the TD.

[0156] It should be noted that the analog motor controller in a single motor controller test system can completely reuse the hardware of the motor controller under test, or a different model can be selected, but it must have functions such as MCU, current acquisition module, and position acquisition module.

[0157] Of course, for a single motor controller test system, the analog motor controller and the motor controller under test can share the same DC power supply, or the two can be powered by independent DC power supplies.

[0158] Based on the single-set motor controller test system disclosed in Embodiment 2, it can be further extended to a multi-channel parallel test scheme—that is, to form a multi-channel parallel test system for motor controllers.

[0159] See Figure 5 , Figure 5 for Figure 4 The structural diagram of a multi-channel parallel test system for motor controllers, which is composed of a single set of motor controller test systems.

[0160] The multi-channel parallel test system for motor controllers comprises several of the aforementioned single-system motor controller test systems. These single-system test systems are connected in parallel, sharing the same DC power supply. The motor controller under test (DUT) and the motor simulator system within each single-system test system also share the same DC power supply. It should be noted that the simulation-side motor controller within each single-system test system reuses the hardware of the DUT. This allows for the direct use of a large number of identical DUT controllers by simply replacing their internal software, significantly reducing the cost of large-scale synchronous testing. In summary, the constructed multi-channel parallel test system for motor controllers, powered by a single DC power supply, enables synchronous and efficient testing, making it particularly suitable for endurance performance testing of large batches of identical motor controllers.

[0161] Furthermore, it should be noted that the present invention is not limited to the application of simulating three-phase permanent magnet synchronous motors as the main target motor. By making local adjustments to the motor model (i.e., software program) or the three-phase connection inductor module and position simulation device in the solution, it can be extended to the power level testing of multi-phase permanent magnet synchronous motors, induction motors, brushless DC motors, etc., which will not be elaborated here.

[0162] Example 3

[0163] This embodiment 3 performs simulation-level testing on the single motor controller test system provided in embodiment 2, and completes the preliminary verification.

[0164] The parameters of the target motor are shown in Table 1:

[0165] Table 1 Target Motor Parameters

[0166]

[0167] The DC bus voltage is used in the voltage modulation optimization model to calculate u. smax .

[0168] The simulation conditions include 1) constant torque at different speeds and 2) constant speed at different torques, as shown in Table 2.

[0169] Table 2 sets the operating parameters for the simulation.

[0170]

[0171] It should be noted that the above simulation industrial control is all in speed control mode.

[0172] See Figure 6 , speed represents the mechanical speed of the motor, TrqFdb represents the actual torque of the simulated target motor, and TrqSet represents the desired torque of the simulated target motor. It can be seen that under both working conditions, the motor controller under test can complete torque tracking in a single motor controller test system.

[0173] See Figure 7 idFdb represents the actual d-axis current of the simulated target motor, idSet represents the expected d-axis current of the simulated target motor, iqFdb represents the actual q-axis current of the simulated target motor, and iqSet represents the expected q-axis current of the simulated target motor. It can be seen that under both working conditions, the motor controller under test can complete the tracking of the dq-axis current in a single motor controller test system.

[0174] See Figure 8ud_UT represents the d-axis output voltage of the motor controller under test, ud_ME represents the d-axis output voltage of the analog motor controller, uq_UT represents the q-axis output voltage of the motor controller under test, and uq_ME represents the q-axis output voltage of the analog motor controller. It can be seen that the amplitude of the dq-axis voltage of the analog motor controller is smaller than that of the motor controller under test. This is because there is a voltage drop on the three-phase connected inductor module.

[0175] See Figure 9 uAFil_UT represents the filtered value of phase A voltage of the motor controller under test, and uAFil_ME represents the filtered value of phase A voltage of the analog motor controller. It can be seen that there is AC voltage drop loss in phase A voltage across the three-phase connected inductor module.

[0176] Example 4

[0177] This embodiment 4 provides a readable storage medium. The readable storage medium stores computer program instructions, which are read and executed by a processor to perform any of the motor simulation methods in embodiment 1.

[0178] When applying the method of Example 1, it can be applied in the form of software, such as by designing it as a program that can run independently on a computer-readable storage medium. The computer-readable storage medium can be a USB flash drive, designed as a USB security token, and the program can be designed to start the entire method through an external trigger.

[0179] Example 5

[0180] This embodiment 5 provides a motor modeling method for constructing a target motor model based on matrix parameters. In fact, it is the improved electromagnetic model 1 of S1 in embodiment 1.

[0181] This motor modeling method that considers core magnetic saturation can be applied to other areas, such as motor model software-in-the-loop simulation, hardware-in-the-loop simulation, and motor control system optimization.

[0182] A motor modeling method for obtaining the electrical port voltage of a target motor. and the target motor output torque value T e The motor modeling method includes the following steps:

[0183] Step 1: Obtain the numerical solution for the flux linkage along the dq axis;

[0184] Step one includes:

[0185] Set the stator current amplitude I s The combination with torque angle β (I) s ,β) represents a current operating point, which is related to the dq-axis current i d i qsatisfy:

[0186]

[0187] Among them, i d Let i be the d-axis current. q This is the q-axis current;

[0188] set up For the maximum stator current amplitude, in Divide the range into equal parts to obtain γ. I There are several different stator current amplitude points; the torque angle β ranges from [0, 2π], and after dividing it equally, we obtain γ. β A different torque angle;

[0189] Get γ I ×γ β Different current operating points (I) s Stator flux linkage values ​​along the dq axis under (β) conditions:

[0190]

[0191] Step 2: Establish the analytical model of the flux linkage along the dq axis;

[0192] Step two includes:

[0193] For the same I s All different β operating points are merged to obtain a fixed I. s The following dq axis flux linkage sequence:

[0194]

[0195] For fixed I s Fourier series expansions of the dq-axis flux linkage sequences yield the flux linkage expression with β as the independent variable:

[0196]

[0197]

[0198] N1 is the highest order of the selected Fourier series. and For the corresponding The Fourier series coefficients of the amplitude, ω β ω is the fundamental angular frequency in the β direction;

[0199] Given the same Fourier series order and all different I... s By combining the Fourier series coefficients, we obtain a Fourier series sequence of fixed order:

[0200] d k ,qk k = -N1, -N1+1, ..., N1-1, N1;

[0201] Polynomial fitting is performed on a fixed k-order Fourier series sequence to obtain the result with I s The expression for the Fourier series coefficients of the independent variable:

[0202]

[0203] N2 is the highest order of the selected polynomial. and These are the polynomial coefficients;

[0204] Combine the coefficients of polynomials of the same order into a polynomial coefficient vector:

[0205]

[0206]

[0207] Transform to obtain I s The expression for the parameters of the dq-axis flux linkage matrix with β as independent variables is as follows:

[0208]

[0209]

[0210] in,

[0211] Step 3: Establish the electromagnetic model of the target motor based on matrix parameters;

[0212] Step three includes:

[0213] Establish the motor voltage equation to obtain the target motor electrical port voltage. The motor torque equation is established to obtain the target motor output torque value T. e ;

[0214] in,

[0215]

[0216]

[0217]

[0218] Among them, R s P is the stator resistance of the target motor. n The target number of pole pairs for the motor.

[0219] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0220] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A motor simulation method, which simulates a target motor controlled by a motor controller under test through a simulation-side motor controller, characterized in that, The motor simulation method includes the following steps: S1, Establish the electromagnetic model of the target motor and record the real-time three-phase current values. , , and rotor electrical angle value As input to the electromagnetic model of the target motor, the electrical port voltage of the target motor is obtained. , and the target motor output torque value ;Will , Converted to analog side motor controller port reference voltage , ; S2, Establish a voltage modulation optimization model, , The signal is converted into an initial switching signal, and the nonlinear characteristics are actively compensated. At the same time, the zero-sequence current component is actively suppressed to obtain an optimized switching signal to achieve accurate output of the target motor electrical port voltage value. S2 includes: Will , Convert to voltage value in stationary coordinate system , : ； in, To account for the rotor equivalent electrical angle due to switching cycle delay, , This is the voltage modulation period; Includes real-time rotor electric angular velocity values information; Using SVPWM voltage vector modulation method based on , Calculate the initial conduction time of the three-phase bridge arm , , And serve as the initial switching signal; Active compensation was performed to address the nonlinear characteristics of the inverter, resulting in the following three-phase bridge arm compensation times: , , This allows us to obtain the conduction time of the three-phase bridge arm after nonlinear compensation. , , , in, , , ; Construct a proportional resonant controller to suppress zero-sequence harmonic current, with the controller referencing the target. When the input is zero, the controller feedback input is the sum of the three-phase currents, and the controller output is the zero-sequence voltage control quantity. ,right After normalization, the compensation time for suppressing zero-sequence current is obtained: ； in, This represents the maximum value of the modulation voltage; The on-time of the three-phase bridge arm for suppressing the zero-sequence current component is calculated as follows: , , , as the optimized switching signal; S3. Based on the simulated load loading mode, establish a motor motion model to obtain the rotor electric angular velocity value of the target motor. ; In S3, if the simulated load is in speed control mode, the constructed motor motion model directly sets the target motor's speed. ; If the simulated load is applied in torque control mode, the constructed motor motion model is combined with... Determine the rotor electric angular velocity value of the target motor using simulated load parameters. , The set moment of inertia of the transmission system, For the set load torque, This is the initial electric angular velocity value; S4, combining the target motor's rotor initialization position and the obtained rotor electric angular velocity value of the target motor. Calculate the rotor electrical angle value ;Will The signal is converted into a position analog electrical signal and synchronously output to the motor controller under test and the analog side motor controller to achieve rotor position synchronization between the motor controller under test and the analog side motor controller.

2. The motor simulation method according to claim 1, characterized in that, The electromagnetic model of the target motor established in S1 is Model 1, which is constructed based on matrix parameters; one input terminal of Model 1 is connected to a three-phase connected inductor module that generates a voltage drop, and the other input terminal is connected to a module that provides real-time rotor electrical angle values. Position simulation device; The construction method of Model 1 includes the following steps: Step 1: Obtain the numerical solution for the flux linkage along the dq axis; Step one includes: Setting based on stator current amplitude With torque angle combination Describes a current operating point, such that With dq axis current , satisfy: ； in, For d-axis current, This is the q-axis current; set up For the maximum stator current amplitude, in Divide the range into equal parts to obtain A number of different stator current amplitude points; The range is After dividing it into equal parts, we get A different torque angle; Get Different current operating points The stator flux linkage value of the dq axis below: ； Step 2: Establish the analytical model of the flux linkage along the dq axis; Step two includes: For the same All the differences The work points are merged to obtain a fixed point. The following dq axis flux linkage sequence: ； For fixed Fourier series expansions of the dq-axis flux linkage sequences were performed respectively to obtain the following results: The expression for the flux linkage with respect to the independent variable: ； ； The highest order of the selected Fourier series is... and For the corresponding Fourier series coefficients of amplitude, for The fundamental angular frequency in the direction; For the same Fourier series order, all different By combining the Fourier series coefficients, we obtain a Fourier series sequence of fixed order: ； For fixed k Polynomial fitting was performed on the sequence of Fourier series of order 1 to obtain the following results: The expression for the Fourier series coefficients of the independent variable: ； The highest order of the selected polynomial. and These are the polynomial coefficients; Combine the coefficients of polynomials of the same order into a polynomial coefficient vector: ； ； Transform to obtain and The expression for the dq-axis flux linkage matrix parameters is as follows: ； ； in, , , ; Step 3: Establish the electromagnetic model of the target motor based on matrix parameters; Step three includes: Establish the motor voltage equation to obtain the target motor port voltage. , The target motor torque value is obtained by establishing the motor torque equation. ; ;in, ； ； ； in, Let be the stator resistance of the target motor. The target number of pole pairs; Combining the voltage drop across the three-phase connection inductor module, , Converted to analog side motor controller port voltage , : ； ； in, This represents the equivalent resistance value of the three-phase connected inductor module. This is the inductance value of the three-phase connected inductor module.

3. The motor simulation method according to claim 2, characterized in that, S1 obtained , , The methods include: Acquire real-time three-phase current values , , and rotor electrical angle value The coordinate transformation is performed to obtain the current value in the rotor synchronous coordinate system. , : ； in, , , The three-phase current flows through the three-phase connected inductor module; Based on the established model, the target motor port voltage is obtained. , and the target motor torque value ; ; ； ； ； Based on the voltage drop of the three-phase connected inductor module, according to , Convert analog side motor controller port voltage 1 , ; , ; in, ； ； For the stator resistance of the target motor, This represents the number of pole pairs of the motor. The inductance value of the three-phase connected inductor module, This is the equivalent resistance value of the three-phase connected inductor module.

4. The motor simulation method according to claim 1, characterized in that, The electromagnetic model of the target motor established in S1 is Model 2, constructed based on lumped parameters; one input terminal of Model 2 is connected to a three-phase connected inductor module that generates a voltage drop, and the other input terminal is connected to a module that provides real-time rotor electrical angle values. Position simulation device; S1 obtained , , The methods include: Acquire real-time three-phase current values , , and rotor electrical angle value The coordinate transformation is performed to obtain the current value in the rotor synchronous coordinate system. , : ； in, , , The three-phase current flows through the three-phase connected inductor module; Based on the established model two, the target motor port voltage two is obtained. , and the target motor torque value two ; ; ； ； ； Based on the voltage drop of the three-phase connected inductor module, according to , Convert analog side motor controller port voltage 2 , ; , ; in, ； ； For the stator resistance of the target motor, For d-axis inductance, For q-axis inductance, For rotor flux, This represents the number of pole pairs of the motor. The inductance value of the three-phase connected inductor module, This is the equivalent resistance value of the three-phase connected inductor module.

5. The motor simulation method according to claim 1, characterized in that, S4 include: Get Calculate the rotor electrical angle value : ； in, This is the initial rotor electrical angle value; Will It is converted into two analog position electrical signals and output synchronously to the motor controller under test and the analog side motor controller; The form of the position analog electrical signal is determined by the position sensor used by the corresponding motor controller; the analog-side motor controller samples the position analog electrical signal to obtain... as well as .

6. A motor simulator device for simulating a target motor controlled by a test motor controller, characterized in that, The motor simulator device includes: The analog motor controller has a DC power supply connected to its DC port. The three-phase inductor module has one end connected to the three-phase AC terminal of the analog motor controller, and the other end serves as the electrical port of the target motor for connection to the three-phase AC terminal of the motor controller under test. The simulated motor controller is equipped with a simulated current acquisition module; the simulated current acquisition module is connected to the three-phase AC terminal of the simulated motor controller and is used to acquire the three-phase current of the three-phase AC terminal of the simulated motor controller; the simulated motor controller is equipped with a position acquisition module for acquiring rotor electrical angle value and rotor electrical angle value. A position simulation device is provided for synchronous simulation of dual-channel position signals. The device includes a communication module, a calculation module, and a signal simulation module. The communication module interacts with the simulation-side motor controller. The calculation module calculates the rotor position value in real time. One output terminal of the signal simulation module is connected to the motor position sampling terminal of the simulation-side motor controller, and the other output terminal serves as the mechanical port of the target motor, connecting to the motor position sampling terminal of the tested motor controller. The signal simulation module converts the rotor position value into a position analog electrical signal recognizable by the position sensor and outputs it synchronously to both the simulation-side motor controller and the tested motor controller. The simulated motor controller is equipped with an MCU; the MCU stores a computer program, and when the computer program is read and run by the MCU, it executes the motor simulation method as described in any one of claims 1-5.

7. A single-set motor controller testing system, characterized in that, include: The motor controller under test has a DC power supply connected to its DC port. as well as The motor simulator device as described in claim 6; the electrical port of the motor simulator device is connected to the three-phase AC terminal of the motor controller under test; the mechanical port of the motor simulator device is connected to the motor position sampling terminal of the motor controller under test.

8. A multi-channel parallel testing system for motor controllers, characterized in that, Includes several single-set motor controller test systems as described in claim 7; Several of the aforementioned single-set motor controller test systems are connected in parallel and share the same DC power supply; The motor controller under test and the motor simulator in the single motor controller test system also share the same DC power supply; the simulation side motor controller in the single motor controller test system reuses the hardware of the motor controller under test.

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