A performance test system for brushless motor controllers

Abstract

This application discloses a performance testing system for a brushless motor controller, used for performance evaluation of the controller under test. The testing system includes a microcomputer system, a main control board, a multi-sensor detection system, a load simulator, and a standard brushless motor connected to the controller under test. The load simulator is connected to the main control board and serves as the load for the standard brushless motor. The main control board is connected to the controller under test, controlling the operation of the standard brushless motor through the controller under test. This testing system uses a standard brushless motor to conduct separate tests on the technical performance and reliability of the controller under test. By collecting various sensor signals from the output of the standard brushless motor, a controller performance evaluation index system based on static and dynamic parameter analysis is established.

Description

Technical Field

[0001] This application relates to the field of brushless motor system tests, and more particularly to a performance test system for a brushless motor controller. Background Art

[0002] Permanent magnet brushless motors have the advantages of high power density, high reliability, long service life, and low mechanical noise, and are widely used in electronic instruments, new energy vehicles, and automation equipment. A brushless motor system includes a brushless motor and its supporting drive controller. The performance of the motor system depends not only on the motor but more on the drive controller. Traditional motor system test equipment is designed according to relevant motor standards and can complete characteristic tests such as torque-speed, current-speed, current-torque, and motor efficiency, and evaluate the performance and reliability of the entire motor system based on this. However, the permanent magnet brushless motor and its drive controller are two independent products. From the perspectives of their respective production quality control, application selection, and supplier management, their own performance quality evaluation standards should be established. Matching the controller for the brushless motor by general experience is difficult to discover deep technical problems in the motor system and is also likely to cause commercial disputes.

[0003] The difficulty in establishing relevant technical standards for the brushless motor and its supporting drive controller separately lies in that the two products belong to one motor system. The output load of the drive controller is the brushless motor. Its working principle and performance description are inseparable from the motor, and its performance is presented through connecting to the brushless motor to work. The rotating magnetic field that enables the brushless motor to generate rotation of the rotor comes from the combined control of the currents in the respective winding coils of the motor by the drive controller. Without the drive controller, it is also difficult to establish the operating performance evaluation standard for the brushless motor product. The quality of the brushless motor mainly depends on its structure, materials, and manufacturing process. For a motor system with a defined brushless motor object, its operating performance mainly depends on the drive controller. Combining the working principle of the motor system, sorting out the correlation between the hardware and software algorithms of the drive controller and motor drive, and relying on semi-physical simulation test technology, establishing a relatively complete controller technical performance evaluation index system under the condition of standardizing the definition of the controller output load is of great significance for the adaptation and selection of brushless motors. Summary of the Invention

[0004] This application provides a test system and test method for a brushless motor controller, aiming to establish a technical performance evaluation index system for the drive controller supporting the permanent magnet brushless motor, and solve problems such as the lack of quantitative evaluation indicators for the selection of the drive controller for the permanent magnet brushless motor and the inability to distinguish the quality responsibility of the motor or controller in the motor system test.

[0005] This application is achieved through the following technical measures: a brushless motor controller performance testing system for performance evaluation of the controller under test. The testing system includes a microcomputer system, a main control board, a multi-sensor detection system, a load simulator, a general-purpose controller, a switching switch, and a standard brushless motor. The standard brushless motor is adapted to the controller under test. The load simulator is connected to the main control board and serves as the load for the standard brushless motor. The main control board is connected to either the general-purpose controller or the controller under test. The standard brushless motor operates according to the drive control algorithm of the general-purpose controller or receives control signals from the controller under test. The microcomputer system communicates with the main control board and the general controller. The microcomputer system sends predetermined standard signals to the main control board to drive the load simulator, simulating various standard loads on the output shaft of the standard brushless motor. The microcomputer system imports an adapted drive control algorithm into the general controller, which then drives the standard brushless motor according to the algorithm. The switching switch is used to select whether the general controller or the controller under test is connected to the test circuit. The multi-sensor detection system detects the sensing signals of the standard brushless motor, and the performance evaluation of the controller under test is obtained by comparing the sensing signals of the standard brushless motor driven by the general controller and the controller under test.

[0006] Preferably, the test system performs a controller inertial start-up test to compare the bidirectional inertial hysteresis rates of the general controller and the controller under test; and / or, performs a controller load start-up test to compare the load start-up performance of the general controller and the controller under test; and / or, performs a controller step load / unload test to compare the speed and stability of the forward torque adjustment control algorithm of the general controller and the controller under test; and / or, performs a controller alternating torque test to compare the torque frequency characteristics of the general controller and the controller under test; and / or, performs a controller alternating speed test to compare the speed frequency characteristics of the general controller and the controller under test; and / or, performs a drive current stability test to compare the drive current amplitude stability of the general controller and the controller under test; and / or, performs a drive angle difference change rate test to compare the current drive angle stability of the general controller and the controller under test; and / or, performs a controller temperature rise test to compare the thermal stability of the general controller and the controller under test.

[0007] Preferably, the controller under test drives a standard brushless motor to perform inertial / load start-up and step loading / unloading tests to obtain the time-domain characteristics of the controller under test; and performs alternating torque and alternating speed tests to obtain the frequency-domain characteristics of the controller under test.

[0008] Preferably, the test system establishes a controller performance evaluation index system based on static and dynamic parameter analysis by collecting the controller's time-domain and frequency-domain sensing signals.

[0009] Preferably, the multi-sensor detection system synchronously collects the current of each phase of the motor, the real-time torque on the output shaft, and the rotation angle when the test controller drives the standard brushless motor, so as to obtain the relative relationship between the composite vector of the driving current of each phase and the spatial position of the motor rotor angle required for the test controller to drive control performance evaluation.

[0010] Preferably, the test controller is equipped with a standard motor interface; the general controller is equipped with multiple position sensor interfaces.

[0011] Preferably, the electromechanical parameters of the standard brushless motor are predictable or statically measurable.

[0012] Preferably, the load simulator selects a servo motor or magnetic powder brake with shaft-end rated parameters higher than those of a standard brushless motor as the standard execution device.

[0013] As a preferred approach, during the various tests of the controller under test, the relative relationship between the synchronously acquired rotor or sensor installation position signals and the current, speed, torque, etc. of each phase is displayed on the same time axis; the zero-crossing point of the three-phase current signal, the spatial zero-crossing point of the motor rotor, and the basic technical parameters are defined, and a series of technical evaluation indicators are given in combination with the basic electromechanical parameters of the standard brushless motor.

[0014] The beneficial effects of this application are:

[0015] (1) This test system uses a standard brushless motor to conduct separate tests on the technical performance and reliability of the test controller. By collecting various sensor signals from the output of the standard brushless motor, a controller performance evaluation index system based on static and dynamic parameter analysis is established.

[0016] (2) The general controller equipped in this test system drives the same standard brushless motor as the test controller under the same test conditions. By comparing the multiple sensor signals of the standard brushless motor driven by different controllers, the advantages and disadvantages of the test controller and the direction of improvement are obtained.

[0017] (3) The multi-sensor acquisition module equipped in this test system can simultaneously acquire multiple signals such as motor operating current I(t), motor rotor space (shaft angle) position α(t), and resistor shaft end output torque T(t), so as to analyze the dynamic performance of the controller driving the motor from the working principle level and provide technical support for the formation of controller performance test methods.

[0018] (4) This test system proposes multiple test items for controller performance reliability analysis, and derives multiple technical performance evaluation quantitative indicators in the time domain and frequency domain of the controller based on the method model, laying the foundation for establishing technical standards for brushless motor controllers and similar controller products. Attached Figure Description

[0019] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings:

[0020] Figure 1 The architecture of the controller performance testing system provided in this application embodiment;

[0021] Figure 2 This is a schematic diagram of system startup characteristics provided in an embodiment of this application;

[0022] Figure 3 The system step loading test curve provided in the embodiments of this application;

[0023] Figure 4 The system alternating torque test curve provided in the embodiments of this application;

[0024] Figure 5 The alternating torque frequency response diagram of the controller provided in the embodiments of this application

[0025] Figure 6 This is a schematic diagram of the synthesized vector fluctuation of motor phase current provided in an embodiment of this application;

[0026] Figure 7 The graph showing the rate of change of the synthetic vector current and the motor rotor angle difference is provided for the embodiments of this application.

[0027] Figure 8 A flowchart of the test system provided in this application embodiment. Detailed Implementation

[0028] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0029] Based on control theory, a controller can be analyzed to evaluate its characteristics by analyzing its output response under standard input signal excitation. The basic function of a brushless motor drive controller is to provide drive current to each phase of the motor in a sequential manner to form a rotating magnetic field. The control of the timing and current is closely related to the speed and torque control of the motor's mechanical shaft end. Therefore, the drive controller is essentially a closed-loop control system for speed and torque. Based on this, the speed control performance of the controller can be analyzed under fixed torque conditions and with a standard speed given; and the torque control performance can be analyzed under fixed speed conditions and with a standard torque given.

[0030] Considering the close integration of the controller and motor in a brushless motor system, to establish an experimental system for evaluating the performance of the brushless motor drive controller involved in this application, the controller still needs to form an operating system with the brushless motor that can represent its output characteristics. However, to independently represent the controller's performance, the connected brushless motor is a 'standard' brushless motor (i.e., without quality defects, and whose basic electromechanical parameters are clear and stable). In the semi-physical simulation torque closed-loop system, the torque standard signal is provided by the load simulator. Although there is a certain lag difference with the ideal given signal, the analysis error is manageable under the same source conditions in a specific test bench system. In the semi-physical simulation speed closed-loop system, the speed given signal can be configured by software code. The control output detection of the closed-loop control system can be completed by the speed (angle) / torque sensors configured on the test bench.

[0031] Based on this, this application proposes a performance testing system for a brushless motor controller, used for performance comparison and evaluation of the tested controller. The testing system includes a microcomputer system, a main control board, a multi-sensor detection system, a load simulator, a general controller, a switching switch, and a standard brushless motor.

[0032] Among them, the electromechanical parameters of the standard brushless motor are predictable or statically measurable, and the standard brushless motor is compatible with the controller under test.

[0033] The load simulator connects to the main control board to provide a standard torque signal for the torque closed-loop system, serving as the load for a standard brushless motor. To evaluate the controller's rapid torque tracking capability, standard torque signals such as step and alternating torques are used as a benchmark to compare the controller's torque adjustment response and other performance characteristics. The load simulator uses a servo motor or magnetic powder brake with shaft-end rated parameters higher than those of the standard brushless motor as the standard execution device. When a magnetic powder brake is used as the load simulator, the brake's on-shaft braking force control characteristics serve as the standard torque signal; when a servo motor system is used as the load simulator, the stall characteristics at the servo motor's shaft end serve as the standard torque signal. The on-shaft load torque simulated by the load simulator can be programmed by a microcomputer system using digital signal generation and implemented through corresponding drive modules.

[0034] The main control board is connected to a general controller or a controller under test. The standard brushless motor operates according to the drive control algorithm of the general controller or the first control signal, or it operates by receiving a second control signal from the controller under test.

[0035] The microcomputer system communicates with the main control board and the general-purpose controller. The microcomputer system sends predetermined standard signals to the main control board to drive the load simulator to work, simulating various standard loads at the output shaft of the standard brushless motor. The microcomputer system is equipped with multiple sets of controller software that integrate motor optimization drive algorithms, imports adapted drive control algorithms into the general-purpose controller, and the general-purpose controller drives the standard brushless motor according to the drive control algorithms.

[0036] The comparative test used the same standard brushless motor as the output load of the general controller and the controller under test. In each test item, the performance difference between the controller under test and the general controller was compared to determine the advantages and disadvantages of the controller under test and the direction of improvement. The difference in control effect between signal control and optimization control algorithms was compared to create conditions for the improvement of the driving algorithm of the controller under test.

[0037] The switch is used to select whether the general controller or the controller under test is connected to the test circuit.

[0038] The multi-sensor detection system is used to detect sensor signals from a standard brushless motor, including three-phase current and voltage signals, torque and speed signals, bus current and voltage signals, and temperature signals. The performance of the controller under test (DUT) is evaluated by comparing the sensor signals of the standard brushless motor driven by a general-purpose controller and a DUT. The multi-sensor detection system simultaneously acquires the current in each phase of the motor, the real-time torque on the output shaft, and the rotation angle when the standard brushless motor is driven by either the general-purpose controller or the DUT. This allows for the determination of the relative relationship between the composite vector of the phase drive currents required for performance evaluation of both the general-purpose controller and the DUT and the spatial position of the motor rotor rotation angle.

[0039] After determining the standard brushless motor compatible with the controller under test (DUT), the DUT is connected to the test system. The relevant physical quantities required for each test item are collected by a multi-sensor detection system. The DUT is equipped with a standard brushless motor interface. The general-purpose controller is equipped with various position sensor interfaces, such as Hall sensors and encoder sensors, to meet the connection needs of various permanent magnet brushless motors, including those with sensing (with Hall sensors (BLDC / PMSM), with encoders) and those without sensing (FOC).

[0040] The controller under test drives a standard brushless motor with the corresponding configuration to perform no-load / full-load start-up, step loading / unloading, and other tests to obtain the controller's time-domain characteristics; unidirectional alternating torque loading and unidirectional alternating speed regulation tests are then performed to obtain the controller's frequency-domain characteristics. This process can also be completed by importing an adapted and optimized drive algorithm program into the system's built-in general controller, allowing for comparative analysis to identify areas for improvement in the hardware and software of the controller under test.

[0041] This application provides a brushless motor controller testing system, which can perform the following tests on the controller:

[0042] (1) Controller inertial start test. The standard brushless motor is unloaded or equipped with an inertial load. The controller drives the standard brushless motor in the forward and reverse directions respectively. A speed step signal (motor rated speed) is given. The torque and speed signals from the motor start to the steady state are tested. The rise time, overshoot rate and steady state time during the no-load start process are obtained. The bidirectional inertial hysteresis rate of the controller is obtained based on the above data.

[0043] (2) Load start test. The standard brushless motor is configured with the rated load generated by the load simulator. The controller drives the motor from zero speed to the set speed. The torque and speed signals from the motor start to steady state are tested. The rise time, overshoot rate and steady state time during the load start process are obtained, as well as the peak-to-valley difference fluctuation rate of the start speed adjustment. The load start performance of the controller is obtained based on the above data.

[0044] (3) Controller step load test. Under the light load (or no load) constant speed stable operation state of the system, the load simulator suddenly applies a quantitative load and tests the speed and torque signal of the motor at this time. Analyze the instantaneous speed drop rate, the time to return to torque and speed stability, the amplitude and period of the return torque oscillation, and other indicators to evaluate the speed and stability of the controller's positive torque adjustment control algorithm.

[0045] (4) Controller step unloading test. Under the constant speed stable operation state of heavy load (or full load), the load simulator suddenly unloads a certain amount of load, and the speed and torque signals of the motor are tested at this time. The instantaneous speed rise rate, the time to return to torque and speed stability, the amplitude and period of the return torque oscillation, and other indicators are analyzed to evaluate the speed and stability of the controller's positive torque adjustment control algorithm.

[0046] (5) Controller alternating torque test. The load simulator drives the standard brushless motor to run in a constant speed and stable state. The test (or general) controller is given a sinusoidal alternating torque and its frequency is gradually increased. The phase of the response torque lags down until the response torque lags the given torque by 3dB. The frequency response bandwidth at this point is obtained to evaluate the controller torque frequency characteristics.

[0047] (6) Controller alternating speed test. Disconnect the load simulator from the standard brushless motor, input a sinusoidal alternating given speed to the test (or general) controller and gradually increase its frequency. The phase of the response speed will lag until the response speed lags the given speed by 3dB. Obtain the frequency response bandwidth at this point and evaluate the controller speed frequency characteristics.

[0048] (7) Drive current stability test. The test system operates under constant load and rated speed conditions, collects the current of each phase, compares the consistency of the current amplitude under steady-state operation conditions, and evaluates the stability of the drive current amplitude by the rate of change of the current composite vector amplitude.

[0049] (8) Drive angle difference change rate test. Set up constant speed operation under several load conditions, collect the current of each phase and rotor angle position (sensor) signals, compare the stability of the current composite vector and the relative position of the rotor under steady-state operation conditions, and evaluate the stability of the controller current drive angle.

[0050] (9) Controller temperature rise test. The controller is started up to full load or specific overload conditions at room temperature. The heat dissipation capacity or thermal stability of the controller is evaluated by the continuous steady-state temperature value and temperature change gradient value of the main chip and drive module of the tested controller.

[0051] The test controller and the general controller were subjected to the above tests respectively, and the test results of the two controllers were obtained. The test results of the test controller and the general controller were then compared and analyzed to determine the advantages and disadvantages of the test controller's performance and to objectively evaluate the performance of the test controller.

[0052] As an extension of functionality, this test system, when equipped with motor characteristic test software, can also perform characteristic tests on motor systems such as torque-speed, current-speed, current-torque, and motor efficiency.

[0053] During the various tests of the controller under test, the relative relationship between the synchronously acquired rotor or sensor installation position signals and the phase currents, speeds, torques, etc. is displayed on the same time axis; the zero-crossing point of the three-phase current signal, the zero-crossing point of the motor rotor space, and the basic technical parameters are defined, and a series of technical evaluation indicators are given in combination with the basic electromechanical parameters of the standard brushless motor.

[0054] On the other hand, after removing the general controller and the switching switch, this test system uses the controller under test (DUT) to drive a standard brushless motor for inertial / load start-up and step load / unload tests to obtain the time-domain characteristics of the DUT; alternating torque and alternating speed tests are conducted to obtain the frequency-domain characteristics of the DUT. By acquiring various sensor signals from the output of the standard brushless motor, the time-domain and frequency-domain sensor signals of the DUT are obtained; a temperature rise test is conducted to obtain the thermal stability index of the DUT. A performance evaluation index system for the DUT based on static and dynamic parameter analysis is established. The individual tests can be considered as the minimum standard tests performed on the DUT to determine its qualification.

[0055] Figure 1The brushless motor controller performance testing system shown consists of three parts: a test bench, a system control board, and a microcomputer system. The test bench includes a metal tray housing basic equipment components such as a standard brushless motor, torque / speed sensors, and a load simulator (magnetic powder brake or servo motor). The motor output shaft is connected to the torque / speed sensor via a coupling, and the torque / speed sensor is then coaxially connected to the load simulator. The load includes not only the mechanical torque generated by the load simulator but also the frictional damping and rotational inertia of the sensor and connecting shaft. The system control board includes a main control board, a general-purpose controller, and a multi-sensor detection system. The main control board collects signals from the multi-sensor detection system and sends them to the host microcomputer system. It also connects to (drives) the load simulator and communicates with the general-purpose controller, establishing a collaborative working relationship with the controller under test through sensor signals. The microcomputer system includes a PC and built-in software for control system management, test item management, sensor system data processing and analysis, test load simulation, and a brushless motor drive algorithm library. The microcomputer system maintains communication with the main control board and the general-purpose controller via a USB interface.

[0056] Specifically, the experimental items conducted by the brushless motor controller test system described in this application are as follows:

[0057] (1) Inertial start-up test

[0058] Experimental objective: Since different motors have different moments of inertia, which have different impacts on the performance evaluation of the controller, it is necessary to standardize the moment of inertia of the standard brushless motor.

[0059] Principles and methods:

[0060] Mechanical equations of an electric motor system (ignoring friction):

[0061] Where T e T L —Motor torque, load torque

[0062] ω m J m —Motor angular velocity and moment of inertia

[0063] When the load torque T L =0:

[0064] Where C e C m — Back electromotive force coefficient; torque constant

[0065] U m — Armature voltage of the motor

[0066] R m Lm — Coil resistance; coil inductance

[0067] According to equation (2), for a second-order system, under given input conditions, the output response of the motor system can be obtained. The actual step output of the motor system is shown below. Figure 2 .

[0068] The controller drives a standard brushless motor in both forward and reverse directions, with or without a load (or with an inertial load). A speed step signal (from zero to rated speed) is given, and the torque and speed changes of the standard brushless motor from start-up to steady state are tested under no-load and with different inertial loads. The rise time t of the speed and torque is obtained. r Overshoot δ and settling time to steady state t s The study also summarized the impact of motor inertia on the controller's fast response performance.

[0069] Performance metrics: Inertial hysteresis

[0070]

[0071] (2) Load start test

[0072] Experimental objective: The operation of a brushless motor depends on the determination of the relative position between the rotor and the rotating magnetic field. The ability to start under load / heavy load is an important evaluation item for the drive algorithm of the brushless motor controller.

[0073] Principles and methods:

[0074] A standard brushless motor is configured with a rated load generated by a load simulator. A speed step signal (from zero to rated speed) is given, and the torque and speed changes from motor start-up to steady state are tested to obtain the speed rise time t. r Overshoot δ and settling time to steady state t s The number of speed fluctuations *n* and the peak-to-valley speed fluctuation rate for each fluctuation are obtained. Based on these parameters, the load-bearing starting performance of the tested controller is determined.

[0075] The impact on the inherent rotational inertia of the motor system can be addressed by using an algorithm to suppress excess torque of rotational inertia when simulating a standard load in a load simulator.

[0076] Performance metrics: rise time t r Overshoot δ and settling time to steady state t s .(See Figure 2 )

[0077] n = 1, 2...i, peak-to-valley fluctuation rate of rotational speed

[0078] Where n pi n ViThese represent the peak and trough speeds of the i-th speed fluctuation, respectively.

[0079] (3) Step loading test

[0080] Experimental objective: To investigate the control and adjustment capabilities of the tested controller under constant speed control and instantaneous loading conditions.

[0081] Principles and methods:

[0082] In a stable constant-speed operation under light load (or no load), a load simulator suddenly applies a fixed load to test the changes in motor speed and torque. The instantaneous speed drop rate, the time to recover to a stable torque and speed, the amplitude and period of the recovery torque oscillation, etc., are analyzed to evaluate the speed and stability of the controller's positive torque adjustment control algorithm.

[0083] Figure 3 In the graph, the dashed line represents speed, the solid line represents torque, the horizontal axis represents time (s), and the vertical axis represents speed (r / min) and torque (N / m).

[0084] Performance metrics:

[0085] Speed ​​reduction rate

[0086] Speed ​​stabilization rate

[0087] Torque oscillation rate

[0088] Torque Stabilization Rate

[0089] in

[0090] T n n e —Rated torque and rated speed;

[0091] t1, t2 — torque settling time, speed settling time;

[0092] C n C te n e —Speed ​​stabilization rate, torque stabilization rate;

[0093] n min Δn — minimum speed, speed decrease;

[0094] T, T max , ΔT, T L —Pre-rise torque, maximum torque, torque increase, applied fixed load;

[0095] The speed drop rate and torque oscillation rate represent the controller's stability capability after receiving a step load; the speed and torque stabilization rate represent the controller's torque adjustment rate and stability after receiving a step load.

[0096] (4) Step unloading test

[0097] Test objective: To examine the controller's control and adjustment capabilities under heavy load (or full load) constant speed control working state and instantaneous unloading conditions.

[0098] Principles and methods:

[0099] In a system under heavy load (or full load) constant speed stable operation state, the load simulator suddenly unloads a fixed load, and the changes in motor speed and torque are tested at this time. The instantaneous speed rise rate, the time to return to torque and speed stability, the amplitude and period of the return torque oscillation, etc. are analyzed to evaluate the speed and stability of the controller's positive torque adjustment control algorithm.

[0100] Performance indicators: Refer to formulas (6)(7)(8)(9).

[0101] (5) Alternating torque test

[0102] Experimental objective: To investigate the frequency characteristics of the alternating torque adjustment control that the controller can achieve at a specific operating speed of the motor system.

[0103] Principles and methods:

[0104] The general-purpose (or tested) controller drives a standard brushless motor under a set sinusoidal alternating torque control program, meaning the test system operates in torque closed-loop mode. Simultaneously, the standard brushless motor is driven by a load simulator in a constant-speed steady state. The phase lag of the system's output response torque is tested and compared at each alternating torque frequency until the output response torque drops to 3 dB of the input given torque amplitude. The cutoff frequency point and phase lag of the torque frequency characteristic are then determined.

[0105] Figure 4 In the diagram, the dashed line represents the given torque, and the solid line represents the feedback torque.

[0106] Multiple tests were conducted to obtain test data on the alternating torque of the controller at various frequencies, and a Bode plot was plotted on the relationship between amplitude attenuation factor, phase lag angle, and frequency (as shown below). Figure 5 ).

[0107] Performance metrics:

[0108]

[0109] T ref —Given torque amplitude;

[0110] T – Feedback torque amplitude (motor output torque).

[0111] Cutoff frequency: The given frequency at which the phase amplitude drops to -3dB, such as... Figure 5 As shown.

[0112] Phase lag: The phase lag when the phase amplitude drops to -3dB, such as Figure 5 As shown.

[0113] (6) Alternating speed test

[0114] Experimental objective: To investigate the frequency characteristics of the alternating torque adjustment control that the controller can achieve at a specific operating speed of the motor system.

[0115] Principles and methods:

[0116] Disconnect the load simulator from the standard brushless motor. The general-purpose (or test) controller drives the standard brushless motor under a set sinusoidal alternating speed control program; that is, the test system operates in speed closed-loop mode. Test and compare the phase lag of the system output speed response at each alternating speed frequency until the output speed response drops to 3 dB of the input given speed amplitude. Determine the cutoff frequency point and phase lag of the speed frequency characteristic.

[0117] Performance metrics:

[0118]

[0119] n ref —Given a given rotational speed range;

[0120] n — Feedback speed amplitude.

[0121] Cutoff frequency: The given frequency at which the phase amplitude drops to -3dB (refer to...) Figure 5 ).

[0122] Phase lag: The phase lag when the phase amplitude drops to -3dB (refer to...) Figure 5 ).

[0123] (7) Drive current amplitude stability test (amplitude stability)

[0124] Experimental objective: To investigate the amplitude stability of the rotating magnetic field of the motor established by the coordinated drive currents of each phase of the controller.

[0125] Principles and methods:

[0126] The rotating magnetic field of a brushless motor is generated by the controller introducing current into each phase winding of the motor. The stability of the rotating magnetic field is closely related to the stability of the current in each phase and their coordination relationship, that is, it is related to the composite current vector of the motor drive.

[0127] A constant load is applied to the motor and it is run to its rated speed steady state. Three-phase current signals are continuously acquired and vector synthesized. The amplitude of the synthesized vector is dynamically recorded as W, and the rate of change W of the synthesized vector amplitude under stable operating conditions is analyzed. Δ .

[0128] Figure 6 The waveform diagram shows the relationship between the phase current and the rotating magnetic field generated by the motor windings. The black line represents the vector amplitude W.

[0129] Performance metrics:

[0130] Rate of change of the magnitude W of the driving current vector

[0131] W t —The magnitude of the composite vector at time t;

[0132] —The average value of the vector magnitude W.

[0133] (8) Drive angle difference change rate test (phase stability)

[0134] Experimental objective: To investigate the relative position and stability of the motor rotating vector current and the motor rotor position established by the coordination of the drive currents of each phase of the controller (the relative position of the motor rotating vector current and the motor rotor position is related to the current and voltage utilization rate during drive, and their relative position and stability are related to the stability of the output torque).

[0135] Principles and methods:

[0136] The motor was operated under three working conditions: no load, rated load / 2, and rated load. The three-phase current signal and rotor position signal were tested. The direction of the current composite vector is the direction of the rotating magnetic field.

[0137] Record the angle θ between the motor rotor position and the direction of the rotating magnetic field, and record the rate of change θ of the motor over a fixed time interval. Δ The stability of the motor rotation vector current and the relative position of the motor rotor established by the coordination of the drive currents of each phase of the controller is obtained.

[0138] To expand the analysis of factors affecting stability, three-phase current signals and (sensory) position sensor signals can be collected simultaneously and continuously. The uniformity of sensor spatial position distribution / delay can be compared with the uniformity of three-phase current distribution / delay, or the rotor angular position can be compared with the uniformity of three-phase current distribution / delay, so as to classify factors such as motor and controller circuit.

[0139] Figure 7 The thin dashed line represents the rotor position, the thick dashed line represents the direction of the rotating magnetic field, and the solid line represents the included angle θ. The horizontal axis represents time (s) and the vertical axis represents angle (°).

[0140] Performance metrics:

[0141] Rate of change of drive current with respect to rotor position angle θ

[0142] θ t —The angle between the motor rotor and the vector current at time t;

[0143] —The average value of θ over a fixed period of time;

[0144] θ Δ —The rate of change of θ over a fixed time interval Δ .

[0145] (9) Controller temperature rise test

[0146] Experimental Objective: To investigate the thermal stability of the controller hardware under startup, full load, or specific overload conditions.

[0147] Under room temperature of 25℃, the controller is operated at full load. The temperature of the controller's main chip T1 and the temperature of the drive module T2 are collected until T1 and T2 reach the warning temperature. The time t at this time is recorded. The time t1 from room temperature T1 to the warning temperature and the time t2 from room temperature T1 to the warning temperature are recorded to evaluate the controller's heat dissipation capacity.

[0148]

[0149] T1 and T2 – Temperature of the controller's main chip and the temperature of the drive module;

[0150] t1, t2 — Temperature rise time of the controller main chip and temperature rise time of the drive module;

[0151] T 1max T 2max —The warning temperatures of the controller's main chip and the driver module;

[0152] C1 and C2 — Controller main chip boundary temperature and driver module heat dissipation capacity.

[0153] Performance metrics:

[0154] Controller main chip temperature T1 and temperature rise gradient; temperature rise time t1

[0155] Drive module temperature T2 and temperature rise gradient; rise time t2

[0156] Controller main chip alarm temperature t3

[0157] For the above test items (1) to (9), the system's built-in general controller can be used for testing; for items (5) and (6), since the software configuration of the controller's input conditions is required, the test controller needs to have the program download port open before the test can be performed. When the test controller performs the above tests alone, the minimum index of the controller can be used as a threshold according to the type of test controller and production requirements to determine whether the test controller meets the minimum production requirements; when the above tests are performed on two controllers respectively, the test results of the two controllers are obtained, and the test results of the test controller and the general controller are compared and analyzed to analyze the advantages and disadvantages of the test controller's performance and to comprehensively and objectively evaluate the performance of the test controller. It should be noted that both the controller under test (DUT) and the general controller can implement step speed and step torque inputs. This input can be directly programmed in the software. Keeping the input signals consistent is simple; just ensure that the magnitudes of the two step torques or speeds are the same. For the alternating torque and speed tests (5) and (6), the DUT may not have this input mode. In this case, control signals can be sent to the DUT via the PC. It is only necessary to keep the amplitude and frequency of the two signals consistent. It is not necessary for the signals to be sent from the same PC or system board to the DUT or the general controller.

[0158] The operation of the test system and the test procedures are as follows: Figure 8 As shown.

[0159] The foregoing description illustrates and describes the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit and basic characteristics. Therefore, these embodiments should be considered exemplary rather than restrictive in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description, and thus all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0160] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity, and those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art. Those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if these modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include these modifications and variations.

Claims

1. A performance testing system for a brushless motor controller, used for performance evaluation of the controller under test, characterized in that, The test system includes a microcomputer system, a main test and control board, a multi-sensor detection system, a load simulator, a general controller, a switch, and a standard brushless motor connected to the controller under test. The load simulator is connected to the main control board and serves as the load for a standard brushless motor. The main test and control board is connected to the controller under test, and the controller under test controls the operation of the standard brushless motor. The microcomputer system communicates sequentially with the main control board and the load simulator. The microcomputer system sends predetermined standard signals to the main control board to drive the load simulator to work and simulate various standard loads at the output shaft end of a standard brushless motor. The switching switch is connected in series between the standard brushless motor and the general controller and the controller under test, and is used to selectively connect the standard brushless motor to the general controller or the controller under test, so as to achieve the same source comparison on the same test bench. The microcomputer system imports an adapted drive control algorithm into the general controller, and the general controller drives the standard brushless motor to work according to the drive control algorithm. The multi-sensor detection system is used to detect various sensor signals when the standard brushless motor is working. The multi-sensor detection system synchronously collects the current of each phase of the motor, the real-time torque on the output shaft and the rotation angle when the general controller or the controller under test drives the standard brushless motor to work, so as to obtain the relative relationship between the composite vector of each phase drive current required for the performance evaluation of the general controller and the controller under test and the spatial position of the motor rotor rotation angle.

2. The brushless motor controller performance testing system according to claim 1, characterized in that, It also includes a test of the rate of change of driving angle difference; The test configuration for the rate of change of driving angle difference is as follows: The motor was operated under three working conditions: no load, rated load / 2, and rated load. The three-phase current signal and rotor position signal were tested. The direction of the current composite vector is the direction of the rotating magnetic field. Record the angle θ between the motor rotor position and the direction of the rotating magnetic field, record the rate of change θ of the motor over a fixed time interval θΔ, and obtain the stability of the motor rotating vector current and the relative position of the motor rotor established by the coordination of the drive currents of each phase of the controller. The test controller and the general controller were subjected to the above tests respectively, and the test results of the two controllers were obtained. The test results of the test controller and the general controller were then compared and analyzed to determine the advantages and disadvantages of the test controller's performance and to objectively evaluate the performance of the test controller.

3. The brushless motor controller performance testing system according to claim 1, characterized in that, The test controller drives a standard brushless motor to perform inertial / load start-up and step load / unload tests to obtain the time-domain characteristics of the test controller; alternating torque test and alternating speed test are performed to obtain the frequency-domain characteristics of the test controller, and a controller performance evaluation index system based on static and dynamic parameter analysis is established.

4. The brushless motor controller performance testing system according to claim 3, characterized in that, It also includes a temperature rise test performed by the test controller driving a standard brushless motor.

5. The brushless motor controller performance testing system according to claim 3, characterized in that, The multi-sensor detection system synchronously collects the current of each phase of the motor, the real-time torque on the output shaft, and the rotation angle when the test controller drives the standard brushless motor to work, so as to obtain the relative relationship between the composite vector of the driving current of each phase and the spatial position of the motor rotor angle required for the test controller to drive control performance evaluation.

6. The brushless motor controller performance testing system according to claim 3, characterized in that, During the various tests of the controller under test, the relative relationship between the synchronously acquired rotor or sensor installation position signals and the current, speed and torque of each phase is displayed on the same time axis; the zero-crossing point of the three-phase current signal, the zero-crossing point of the motor rotor space, and the basic technical parameters are defined, and a series of technical evaluation indicators of the controller under test are given in combination with the basic electromechanical parameters of the standard brushless motor.

7. The brushless motor controller performance testing system according to claim 1, characterized in that, The test system performs a controller inertial start-up test to obtain a comparison of the bidirectional inertial hysteresis rates of the general controller and the controller under test; and / or, Perform a load start test on the controller to compare the load start performance of the general controller and the controller under test; and / or, Perform a step load / unload test on the controller to compare the speed and stability of the positive torque adjustment control algorithm of the general controller and the controller under test; and / or, Perform an alternating torque test on the controller to compare the torque-frequency characteristics of the general controller and the controller under test; and / or, Perform an alternating speed test on the controller to compare the speed-frequency characteristics of the general controller and the controller under test; and / or, Perform a drive current stability test to compare the drive current amplitude stability of the general controller and the controller under test; And / or, A controller temperature rise test was performed to compare the thermal stability of the general controller and the tested controller.

8. The brushless motor controller performance testing system according to claim 6, characterized in that, The controller under test is equipped with a standard motor interface; the general-purpose controller is equipped with multiple position sensor interfaces.

9. A performance testing system for a brushless motor controller according to any one of claims 1-8, characterized in that, The electromechanical parameters of the standard brushless motor are predictable or statically measurable.

10. A performance testing system for a brushless motor controller according to any one of claims 1-8, characterized in that, The load simulator selects a servo motor or magnetic powder brake with shaft-end rated parameters higher than those of a standard brushless motor as the standard execution device.

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