A test device for an integrated motor controller

Abstract

The present invention discloses a test device for an integrated motor controller, which includes a motor and an auxiliary circuit board. An angle sensor and a sensor adapter board are arranged on the upper part of the motor. Signal terminals are arranged at the upper end of the sensor adapter board. The signal terminals are provided with wiring terminals through signal lines. The input end of the wiring terminal is electrically connected to a power line, and a motor power supply terminal is arranged at the electrical connection end of the power line. A drive board, a control board, an interface board, test points and expansion interfaces are arranged on the auxiliary circuit board. Heat dissipation blocks are arranged on the lower surfaces of both the drive board and the control board. Heat dissipation ribs are arranged on both sides of the upper surfaces of the two heat dissipation blocks. The present invention uses an auxiliary circuit board as a bridge to connect each module, disassembles the integrated controller into individual circuit boards, and there are support columns and circuit connection parts between each individual part and the auxiliary circuit board, so that the controller can drive the motor when separated.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive applications, and specifically to a test device for an integrated motor controller. Background Art

[0002] With the trend of automotive chassis electrification, more and more electronic actuators are being used, including EPS (Electric Power Steering), ESC (Electronic Stability Control), EPB (Electronic Parking Brake), and so on. In these systems, an electric motor is generally used as the power source, so the motor controller has become an essential device. Considering miniaturization, lightweight, and cost savings, integrating the controller circuit board and the motor together (powerpack) has become the development trend of such devices, as Figure 1 shown. This solution occupies less space and eliminates a lot of wiring harnesses. However, during the development process, certain points on the controller need to be tested, and the phase current of the motor also needs to be detected and analyzed by external devices (such as a dynamometer and an oscilloscope). The motor terminals and various components of such an integrated controller are encapsulated in an integrated structure, making it difficult to detect. In addition, for the quality inspection during the production process of such circuit boards, special equipment is also required to expose the key test points while the circuit board is operating normally. Currently, there is a lack of effective equipment for the testing and quality inspection of integrated motor controllers.

[0003] After retrieval, it is found that in the patent CN 216718978 U, a brushless motor controller test device is designed, and the advantage is that multiple motor controllers can be detected simultaneously. However, this solution uses a large number of external analog signals and cannot better restore the operating conditions of the motor; the patent CN 113655769 A establishes an external injection signal mechanism that can simulate various fault states of the motor; the patent CN 217256119 U designs a motor controller test bench, focusing on the layout of power supply and torque detection devices, etc., and the force stability, mainly solving the force test problem during motor operation, without involving the detection of electronic controllers; the test device designed in the patent CN 217386207 U includes a water cooling cycle, as well as motor power supply and anti-interference devices, and gives the heat dissipation method and some circuit connection methods; in the motor controller test device of the patent CN 217484763 U, the rotor position is simulated using an external resolver signal, and the data conversion and filtering processing methods are given.

[0004] For redundant steering controllers, a multi-layer circuit board layout form is required to occupy less cross-sectional area, as Figure 2 shown. The development, debugging, and quality testing of this controller have the following difficulties:

[0005] 1) When the controller is working, the phase current, voltage, etc. of the motor cannot be measured by devices such as a dynamometer and an oscilloscope;

[0006] 2) During operation, it is difficult to measure the electrical signals at key points such as power supply and communication.

[0007] 3) It is difficult to detect the on - off performance of key pins after assembly.

[0008] 4) When a fault occurs in the overall controller, if you want to narrow down the scope to find the fault area, you can only disassemble the controller, and the steps are cumbersome. Summary of the Invention

[0009] The purpose of the present invention is to provide a test device for an integrated motor controller to solve the problems raised in the above - mentioned background technology.

[0010] To achieve the above - mentioned purpose, the present invention provides the following technical solution: A test device for an integrated motor controller, including a motor and an auxiliary circuit board. An angle sensor is arranged on the upper mounting surface of the motor. A sensor adapter board is arranged at the upper end of the angle sensor. A signal terminal is arranged at the upper end of the sensor adapter board. The output end of the signal terminal is provided with a wiring terminal through a signal line. The input end of the wiring terminal is electrically connected to a power line. The electrically connected end of the power line is provided with a motor power supply terminal, and the motor power supply terminal is arranged on the motor. A current sensor is arranged on the power line. The output end of the current sensor is provided with an analysis device. The auxiliary circuit board is electrically connected to the motor through the wiring terminal, signal line, power line, signal terminal and motor power supply terminal. A drive board, a control board and an interface board are arranged on the auxiliary circuit board. Heat dissipation blocks are arranged on the lower surfaces of the drive board and the control board. Electronic connectors are respectively arranged at the lower parts of the end faces of the drive board, the control board and the interface board. Heat dissipation ribs are arranged on both sides of the upper surfaces of the two heat dissipation blocks. Test points are arranged on the upper part and the lower right side of the surface of the auxiliary circuit board. An expansion interface is arranged at one place on the upper surface of the auxiliary circuit board;

[0011] The angle sensor is directly and closely attached to the upper mounting surface of the motor. The test points are concentratedly arranged on the upper part and the lower right side of the auxiliary circuit board. The heat dissipation blocks are inserted between the auxiliary circuit board and the circuit board to be detected and are in close contact with the heat - generating components of the circuit board to be detected.

[0012] Preferably, support columns are respectively arranged at the lower end corners of the drive board, the control board and the interface board.

[0013] Preferably, the analysis device adopts an oscilloscope and a dynamometer device.

[0014] Preferably, the wiring terminal is connected to the control board through a signal line, and the rotor angle is measured through the angle sensor on the signal line connected to the wiring terminal and the control board.

[0015] Preferably, the control board is respectively connected to the drive board and the interface board through signal lines.

[0016] Preferably, the terminal block is connected to the drive board through a power line, and the drive board and the interface board are connected through a power line.

[0017] Preferably, a test point is connected through a branch signal line on the signal line connecting the drive board and the control board.

[0018] Preferably, the expansion interface communicates with other devices through protocols such as SPI and CAN, and can be used to receive instructions or export data.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] 1. The present invention uses an auxiliary circuit board as a bridge to connect each module, disassembles the integrated controller into individual circuit boards, and there are support columns and circuit connection parts between each individual part and the auxiliary circuit board, so that the controller can drive the motor when separated, solving the problem that the key test points of the original integrated controller are exposed on the outside, which is convenient for electronic probes to collect signals;

[0021] 2. The present invention also simultaneously sets heat dissipation blocks and heat dissipation rib plates on the drive board and the control board. Since some components on the drive board and the control board generate a large amount of heat, considering cost and utility, the present invention does not use water cooling, but designs heat dissipation blocks and heat dissipation rib plates for them to dissipate heat, and at the same time uses air cooling to assist in cooling;

[0022] 3. The present invention also designs test points and expansion interfaces on the auxiliary circuit board. The test points can gather the common test positions on the circuit board for convenient simultaneous detection, and the expansion interface communicates with other devices through protocols such as SPI and CAN, and can be used to receive instructions or export data. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Schematic diagram of an integrated motor controller in a test device for an integrated motor controller of the present invention;

[0024] Figure 2 Schematic diagram of the multi-layer PCB layout of a test device for an integrated motor controller of the present invention;

[0025] Figure 3 Hardware layout diagram of a test device for an integrated motor controller of the present invention;

[0026] Figure 4 Circuit connection diagram of the auxiliary circuit board in a test device for an integrated motor controller of the present invention;

[0027] Figure 5 Schematic diagram of the structural design of the auxiliary circuit board in a test device for an integrated motor controller of the present invention.

[0028] In the figure: 1, motor; 2, auxiliary circuit board; 3, angle sensor; 4, sensor adapter board; 5, signal terminal; 6, wiring terminal; 7, motor power supply terminal; 8, current sensor; 9, analysis device; 10, drive board; 11, control board; 12, interface board; 13, heat sink; 14, electronic connector; 15, heat dissipation rib; 16, support column; 17, test point; 18, expansion interface. Specific embodiments

[0029] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0030] Please refer to Figures 1-5 , the present invention provides a technical solution: a test device for an integrated motor controller, including a motor 1 and an auxiliary circuit board 2. An angle sensor 3 is fitted and installed on the upper mounting surface of the motor 1. A sensor adapter board 4 is installed at the upper end of the angle sensor 3. The angle sensor 3 and the sensor adapter board 4 are designed to collect position signals. A signal terminal 5 is installed at the upper end of the sensor adapter board 4. The signal output end of the signal terminal 5 is connected to a wiring terminal 6 through a signal line. One input end of the wiring terminal 6 is electrically connected to a power line. The electrically connected end of the power line is connected to a motor power supply terminal 7, and the motor power supply terminal 7 is installed on the motor 1. A current sensor 8 is connected to the power line. The output end of the current sensor 8 is connected to an analysis device 9 through a signal line. The auxiliary circuit board 2 is connected to the motor 1 through the wiring terminal 6, the signal line, the power line, the signal terminal 5, and the motor power supply terminal 7. After leading out the phase wires of the motor 1, they are connected to the wiring terminal 6 of the auxiliary circuit board 2 and controlled by the bridge of the drive board 10. In the whole process, the programs and controller circuit boards used are exactly the same as those of the original integrated controller to ensure the effectiveness of the detection device. A drive board 10, a control board 11, and an interface board 12 are installed on the auxiliary circuit board 2. Heat sinks 13 are installed on the lower surfaces of the drive board 10 and the control board 11. Electronic connectors 14 are respectively installed at the lower parts of the end faces of the drive board 10, the control board 11, and the interface board 12. Heat dissipation ribs 15 are installed on both sides of the upper surfaces of the two heat sinks 13. Test points 17 are installed on the upper part of the surface and the lower right side of the auxiliary circuit board 2. An expansion interface 18 is installed at one place on the upper surface of the auxiliary circuit board 2.

[0031] Support columns 16 are respectively installed at the lower end corners of the drive board 10, the control board 11, and the interface board 12.

[0032] The analysis device 9 uses an oscilloscope and a dynamometer device for analysis and testing.

[0033] The terminal block 6 is connected to the control board 11 through a signal line, and the rotor angle is tested through an angle sensor 3 on the signal line connected to the terminal block 6 and the control board 11.

[0034] The control board 11 is respectively connected to the drive board 10 and the interface board 12 through signal lines.

[0035] The terminal block 6 is connected to the drive board 10 through a power line, and the drive board 10 and the interface board 12 are connected through a power line.

[0036] A test point 17 is connected through a branch signal line on the signal line connecting the drive board 10 and the control board 11.

[0037] The expansion interface 18 communicates with other devices through protocols such as SPI and CAN, and can be used to receive instructions or export data.

[0038] The heat sink 13 is inserted between the auxiliary circuit board 2 and the circuit board to be detected, and is in close contact with the heat-generating components of the circuit board to be detected.

[0039] Working principle: When in use, the invention uses an auxiliary circuit board 2 as a bridge to connect each module, disassembles the integrated controller into individual circuit boards, and there are support columns 16 and circuit connection parts between each individual part and the auxiliary circuit board 2, so that the controller can drive the motor 1 when separated. In addition, during operation, some components on the drive board 10 and the control board 11 generate relatively large amounts of heat. Through the design of the heat sink 13 and the heat dissipation ribs 15, the water-cooled heat dissipation method is replaced for effective heat dissipation, and at the same time, an air-cooled method is supplemented. There are also test points 17 and expansion interfaces 18 designed and installed on the auxiliary circuit board 2. Among them, the test points 17 can gather the common test positions on the circuit board for convenient simultaneous detection, and the expansion interface 18 communicates with other devices through protocols such as SPI and CAN, and can be used to receive instructions or export data.

[0040] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0041] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A test device for an integrated motor controller, comprising a motor (1) and an auxiliary circuit board (2), characterized in that: An angle sensor (3) is provided on the upper mounting surface of the motor (1). A sensor adapter board (4) is provided at the upper end of the angle sensor (3). A signal terminal (5) is provided at the upper end of the sensor adapter board (4). The output end of the signal terminal (5) is provided with a wiring terminal (6) through a signal line. The input end of the wiring terminal (6) is electrically connected to a power line. The electrical connection end of the power line is provided with a motor power supply terminal (7), and the motor power supply terminal (7) is provided on the motor (1). A current sensor (8) is provided on the power line. The output end of the current sensor (8) is provided with an analysis device (9). The auxiliary circuit board (2) is electrically connected to the motor (1) through the wiring terminal (6), the signal line, the power line, the signal terminal (5), and the motor power supply terminal (7). A drive board (10), a control board (11), and an interface board (12) are provided on the auxiliary circuit board (2). Heat dissipation blocks (13) are provided on the lower surfaces of the drive board (10) and the control board (11). Electronic connectors (14) are respectively provided at the lower parts of the end faces of the drive board (10), the control board (11), and the interface board (12). Heat dissipation rib plates (15) are provided on both sides of the upper surfaces of the two heat dissipation blocks (13). Test points (17) are provided on the upper part and the lower right side of the surface of the auxiliary circuit board (2). An expansion interface (18) is provided at one place on the upper surface of the auxiliary circuit board (2); The angle sensor (3) is directly and closely mounted on the upper mounting surface of the motor (1). The test points (17) are concentratedly arranged on the upper part and the lower right side of the auxiliary circuit board (2). The heat dissipation blocks (13) are inserted between the auxiliary circuit board (2) and the circuit board to be detected and are in close contact with the heat generating components of the circuit board to be detected.

2. The test device for an integrated motor controller according to claim 1, characterized in that: Support columns (16) are respectively provided at the lower end corners of the drive board (10), the control board (11), and the interface board (12).

3. The test device for an integrated motor controller according to claim 1, characterized in that: The analysis device (9) adopts an oscilloscope and a dynamometer device.

4. The test device for an integrated motor controller according to claim 1, characterized in that: The wiring terminal (6) is connected to the control board (11) through a signal line. The rotor angle is tested through the angle sensor (3) on the signal line connected to the wiring terminal (6) and the control board (11).

5. The test device for an integrated motor controller according to claim 4, wherein: The control board (11) is connected to the drive board (10) and the interface board (12) respectively through signal lines.

6. The test device for an integrated motor controller according to claim 1, wherein: The wiring terminal (6) is connected to the drive board (10) through a power line. The drive board (10) and the interface board (12) are connected through a power line.

7. The test device for an integrated motor controller according to claim 5, characterized in that: The test point (17) is connected through a branch signal line on the signal line connecting the drive board (10) and the control board (11).

8. The test device for an integrated motor controller according to claim 1, characterized in that: The expansion interface (18) communicates with other devices through SPI and CAN protocols and can be used to receive instructions or export data.

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