A method, device and system for testing the durability of a vehicle starter
By using an automated starter testing method, target data under multiple operating conditions is acquired and tested under each condition, solving the problems of low efficiency and insufficient accuracy in the durability testing of vehicle starters, and achieving efficient automated durability testing.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- CHINA FAW CO LTD
- Filing Date
- 2023-09-18
- Publication Date
- 2026-07-31
AI Technical Summary
In the existing technology, the durability testing of vehicle starters is inefficient and cannot accurately reflect their performance, and requires manual operation, which leads to low efficiency.
By acquiring multiple starting conditions and target starting data, the test controller performs starting tests under each condition, including automatic control of target motor torque, target gear, and target vehicle speed, thereby achieving automatic durability testing of the vehicle starter.
It improves the efficiency and accuracy of durability testing, simplifies the testing process, and avoids the inefficiency and inaccurate performance reflection caused by manual operation.
Smart Images
Figure CN117214699B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of vehicle starter technology, and in particular to a method, apparatus and system for testing the durability of vehicle starters. Background Technology
[0002] With the rapid development of vehicle technology, the durability of vehicle starter motors has become an important indicator for judging vehicle performance. The starter motor, through the principle of electromagnetic induction, converts electrical energy into mechanical energy to start the engine, and is a crucial component of a car.
[0003] Currently, for hybrid powertrain configurations equipped with a starter motor, the lifespan of the starter motor needs to be rigorously tested. Starter motor durability testing typically involves installing the starter motor on the matched engine and manually testing and counting the motor's components. This method is inefficient and cannot accurately reflect the starter motor's performance. Summary of the Invention
[0004] This invention provides a method, apparatus, and system for testing the durability of a vehicle starter motor, thereby enabling automated durability testing of the vehicle starter motor, simplifying the durability testing process, and improving the efficiency and accuracy of durability testing.
[0005] In a first aspect, embodiments of the present invention provide a durability testing method for a vehicle starter motor, applied to a test controller, comprising:
[0006] Acquire multiple starting conditions and target starting data corresponding to each starting condition. The target starting data includes: target motor torque, target gear, target vehicle speed, and target number of starts.
[0007] Each of the aforementioned starting conditions is taken as the current starting condition, and the starting test of the crane starter is carried out under each condition.
[0008] Based on the target motor torque and target gear corresponding to the current starting condition, a target torque request and a target gear request are sent to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control, and sends the target gear request to the transmission controller for gear control.
[0009] When the starting conditions under the current starting conditions are met based on the current actual gear, current actual vehicle speed, and target vehicle speed corresponding to the current starting condition returned by the transmission controller, a starting request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform starting control through the engine controller.
[0010] When the start-up completion signal is received from the vehicle controller, a stop request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform stop control through the engine controller.
[0011] When the shutdown completion signal sent by the vehicle controller is received, it is determined that the current start-up is completed, and the next start-up is performed based on the target number of start-ups corresponding to the current start-up condition, and the start-up test result under the current start-up condition is determined.
[0012] Based on the start-up test results under each start-up condition, the durability test results of the vehicle starter are determined.
[0013] Secondly, embodiments of the present invention also provide a durability testing device for a vehicle starter motor, integrated into a test controller, comprising:
[0014] The target start-up data acquisition module is used to acquire multiple start-up conditions and target start-up data corresponding to each start-up condition. The target start-up data includes: target motor torque, target gear, target vehicle speed, and target number of start-ups.
[0015] The start-up test module is used to take each of the aforementioned start-up conditions as the current start-up condition and perform start-up tests on the crane starter under each condition.
[0016] The request sending module is used to send a target torque request and a target gear request to the vehicle controller based on the target motor torque and target gear corresponding to the current starting condition, so that the vehicle controller sends the target torque request to the motor controller for torque control and the target gear request to the transmission controller for gear control.
[0017] The starter control module is used to send a starter request to the vehicle controller when the starter conditions under the current starter condition are met based on the current actual gear, current actual vehicle speed and target vehicle speed corresponding to the current starter condition returned by the transmission controller, so that the vehicle controller can perform starter control through the engine controller.
[0018] The shutdown control module is used to send a shutdown request for the vehicle starter to the vehicle controller when it receives a start-up completion signal from the vehicle controller, so that the vehicle controller can perform shutdown control through the engine controller.
[0019] The test result determination module is used to determine the completion of the current start-up when it receives the shutdown completion signal sent by the vehicle controller, and to perform the next start-up based on the target number of start-ups corresponding to the current start-up condition, and determine the start-up test result under the current start-up condition.
[0020] The durability test result determination module is used to determine the durability test results of the crane starter based on the starter test results under each starter condition.
[0021] Thirdly, embodiments of the present invention also provide a durability testing system for a vehicle starter motor, the system comprising: a test controller, a vehicle controller, a motor controller, a transmission controller, and an engine controller; wherein,
[0022] The test controller is used to implement the durability test method for the vehicle starter provided in any embodiment of the present invention.
[0023] The technical solution of this invention involves acquiring multiple starting conditions and target starting data corresponding to each starting condition; taking each starting condition as the current starting condition, and performing a starting test on the vehicle starter motor under each condition. Specifically, based on the target motor torque and target gear corresponding to the current starting condition, a target torque request and a target gear request are sent to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control, and sends the target gear request to the transmission controller for gear control; when the transmission controller returns the current actual gear, current actual vehicle speed, and the starting data corresponding to the current starting condition... Upon reaching the target vehicle speed and determining that the starting conditions for the current starting operation are met, a start request for the travel starter is sent to the vehicle controller, enabling the vehicle controller to control the starter operation via the engine controller. Upon receiving a start completion signal from the vehicle controller, a stop request for the travel starter is sent to the vehicle controller, enabling the vehicle controller to control the stop operation via the engine controller. Upon receiving a stop completion signal from the vehicle controller, the starter operation is confirmed as complete, and the next start is initiated based on the target number of starts corresponding to the current starting condition. The starter test result for the current starting condition is determined, thus completing an automatic durability test for one starting condition. Based on the starter test results for each starting condition, the durability test result of the travel starter can be accurately determined. By testing durability under different starting conditions, the testing process can be simplified, achieving automatic durability testing of the travel starter without manual operation. This avoids the low efficiency and inaccurate performance reflection issues caused by manual testing, thereby improving the efficiency and accuracy of durability testing.
[0024] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description
[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0026] Figure 1 This is a flowchart of a durability test method for a vehicle starter provided according to Embodiment 1 of the present invention;
[0027] Figure 2 This is an architecture diagram of a hybrid vehicle according to an embodiment of the present invention;
[0028] Figure 3 This is a low-voltage power supply structure diagram of a starter power supply circuit according to Embodiment 1 of the present invention;
[0029] Figure 4 This is a flowchart of a durability test method for a vehicle starter provided according to Embodiment 2 of the present invention;
[0030] Figure 5 This is a schematic diagram of the structure of a vehicle starter durability testing device according to Embodiment 3 of the present invention;
[0031] Figure 6 This is a schematic diagram of the structure of a durability testing system for a vehicle starter provided in Embodiment 4 of the present invention. Detailed Implementation
[0032] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 should fall within the scope of protection of the present invention.
[0033] It should be noted that the terms "target," "current," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.
[0034] Example 1
[0035] Figure 1 This is a flowchart illustrating a durability testing method for a vehicle starter motor according to Embodiment 1 of the present invention. This embodiment is applicable to testing the durability of a vehicle starter motor used in hybrid vehicles during startup. For example, Figure 2 An architecture diagram of a hybrid vehicle is given, such as... Figure 2 As shown, the vehicle includes: an engine, a starter, an electric motor, a clutch, a transmission, a power battery, and a direct current converter (DCDC). The starter is used to start the engine, the transmission is used to adjust gears, the power battery provides power to the vehicle's electrical system, and the DCDC supplies power to the electrical loads.
[0036] like Figure 1 As shown, this method can be performed by a durability testing device for a vehicle starter motor. This device can be implemented in hardware and / or software and can be configured within a test controller, such as the ControlDesk of a dynamometer. Figure 1 As shown, the method specifically includes the following steps:
[0037] S110. Obtain multiple starting conditions and target starting data corresponding to each starting condition. The target starting data includes: target motor torque, target gear, target vehicle speed, and target number of starts.
[0038] Here, "starting condition" refers to the operating state of equipment associated with the starter when starting the engine using a starter motor. "Target starting data" refers to the operating parameters of the associated equipment under the starting condition. "Target motor torque" refers to the motor torque under the starting condition. "Target gear" refers to the output gear of the transmission under the starting condition. "Target vehicle speed" refers to the vehicle speed achievable under this starting condition. "Target number of starts" refers to the number of starts required using the starter motor under the starting condition.
[0039] Specifically, the test controller acquires multiple starting conditions and corresponding operating parameters of equipment directly related to starting during the vehicle's mileage, and uses these operating parameters as target starting data. The motor torque during the starting condition is used as the target motor torque, the transmission output gear during the starting condition as the target gear, the achievable vehicle speed during the starting condition as the target vehicle speed, and the number of starts by the starter motor during the starting condition as the target number of starts, thus obtaining the target starting data for each starting condition.
[0040] For example, one of the driving conditions acquired by the test controller can be the New European Driving Cycle (NEDC) test condition (a commonly used test condition). Under this condition, the target start-up data includes 4 start-ups, a target motor torque of 60 Nm, a target gear of 3, and a target vehicle speed of 50 km / h. Other conditions can be obtained similarly. The start-up condition statistics are shown in Table 1 below.
[0041] Table 1. Start-up durability data.
[0042]
[0043]
[0044] S120. Take each of the aforementioned starting conditions as the current starting condition and perform a starting test on the crane starter under each condition.
[0045] Specifically, the test controller takes each of the multiple starting conditions obtained as the current starting condition for testing, and performs starting tests on the vehicle starter under each condition by executing the following steps S130-S160, based on the target starting data under each starting condition.
[0046] S130. Based on the target motor torque and target gear corresponding to the current starting condition, send a target torque request and a target gear request to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control, and sends the target gear request to the transmission controller for gear control.
[0047] The Vehicle Control Unit (VCU) coordinates the various control units to provide macroscopic control of the vehicle. The target torque requirement can refer to the actual motor torque required at the target motor torque and target gear. The Microcontroller Unit (MCU) controls the motor torque. The Transmission Control Unit (TCU) controls the gear selection.
[0048] Specifically, the test controller calculates the target torque requirement based on the target motor torque and target gear corresponding to the current starting condition, and sends the target torque requirement request and target gear request to the vehicle controller. The vehicle controller then sends the target torque requirement request to the motor controller for torque control and the target gear request to the transmission controller for gear control.
[0049] For example, S130 may include: determining a target required torque based on the target motor torque corresponding to the current starting condition and the transmission ratio corresponding to the target gear, and sending a target required torque request to the vehicle controller, so that the vehicle controller sends the target required torque request to the motor controller, and the motor controller controls the motor torque to the target required torque; and sending a target gear request to the vehicle controller based on the target gear corresponding to the current starting condition, so that the vehicle controller sends the target gear request to the transmission controller, and the transmission controller controls the gear to the target gear.
[0050] Among them, the transmission speed ratio can refer to the gear speed ratio of the main reducer in the vehicle's drive axle.
[0051] For example, the dynamometer operates in road resistance simulation mode, and the input rolling resistance is based on an empirical formula obtained from vehicle coasting. The motor is powered by a battery simulator; F = a + b * u + c * u * u (a, b, c are the fitting coefficients of the vehicle coasting resistance curve, u is the vehicle speed). The test controller, based on the target motor torque TM_T1 corresponding to the current starting condition and the gear ratio Gear1Ratio corresponding to the target gear, takes TM_T1 * Gear1Ratio as the target required torque and sends the target required torque request to the VCU. The VCU controls the motor in torque mode and sends the target required torque request to the MCU. The MCU controls the motor torque to the target required torque. Based on the target gear Gear1 corresponding to the current starting condition, the target gear request is sent to the VCU, so that the VCU sends the target gear request to the TCU. The TCU controls the gear to the target gear.
[0052] S140. When the starting conditions under the current starting condition are determined based on the current actual gear, current actual vehicle speed and target vehicle speed corresponding to the current starting condition returned by the transmission controller, a starting request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform starting control through the engine controller.
[0053] The current actual gear refers to the actual gear the vehicle is currently in while driving. The current actual vehicle speed refers to the actual vehicle speed while driving. The engine controller (ECU) is used to control the engine start-up.
[0054] Specifically, the test controller, based on the current actual gear, current actual vehicle speed, and target vehicle speed corresponding to the current starting condition returned by the transmission controller, sends a starting request for the vehicle starter to the vehicle controller when it is determined that the current actual operating condition of the vehicle meets the starting conditions. The vehicle controller then performs starting control through the engine controller.
[0055] For example, in S140, "determining the starting conditions that meet the current starting conditions based on the current actual gear, current actual vehicle speed, and target vehicle speed corresponding to the current starting condition returned by the transmission controller" may include: determining the current vehicle speed difference between the current actual vehicle speed and the target vehicle speed corresponding to the current starting condition; if the current actual gear returned by the transmission controller is the target gear corresponding to the current starting condition and the current vehicle speed difference is less than a preset threshold, then it is determined that the starting conditions meet the current starting conditions.
[0056] Specifically, the test controller determines the current speed difference between the current actual vehicle speed and the target vehicle speed corresponding to the current starting condition. If the current actual gear is the same as the target gear corresponding to the current starting condition and the difference between the current actual vehicle speed and the target vehicle speed corresponding to the current starting condition is less than a preset threshold, then the starting conditions under the current starting condition are determined to be met.
[0057] For example, if ControlDesk receives a transmission actual gear signal from VCU that is equal to Gear1, and |target vehicle speed - current actual vehicle speed| < preset threshold (vehicle speed condition threshold), then the current vehicle operating condition meets the starting conditions under the current starting condition.
[0058] For example, in S140, "the vehicle controller performs start-up control through the engine controller" may include: the vehicle controller sending the start-up request to the engine controller and controlling the start-up relay to disconnect; after receiving the start-up request, the engine controller controlling the start-up relay to engage, and the vehicle starter motor to drive the engine to start and run automatically; the vehicle controller sending a torque command to the engine to control the engine speed to synchronize with the motor speed, and after the engine speed and motor speed are synchronized, controlling the clutch to engage, so that the engine is driven; when the vehicle controller detects that the torque of the engine and the drive motor has been alternately completed, it determines that the start-up is complete and sends a start-up completion signal to the test controller.
[0059] The starter relay is used to control the disconnection of the starter circuit from the low-voltage circuit.
[0060] For example, the VCU sends a starter motor start request to the ECU and controls the starter relay to disconnect (disconnecting the starter circuit from the low-voltage circuit). Upon receiving the VCU command, the ECU automatically engages the starter relay, causing the starter motor to pull the engine and run independently. The VCU sends a torque command to the engine to synchronize the engine speed with the motor speed. Once the engine and motor speeds are synchronized, the VCU engages the clutch, connecting the engine to the drive system. When the VCU determines that the torque alternation between the engine and the drive motor is complete (the engine handles both TM_T1 and the motor's torque requirements, with the motor torque being the target torque calculated internally by the VCU), it sends a start completion signal to the ControlDesk. It should be noted that the VCU has a bench mode, in which it prioritizes responding to start requests and target torque requests from the ControlDesk. The starter relay can address the issue of a momentary voltage drop at the low-voltage load end caused by the starter motor's high current demand, disconnecting the starter circuit from the normal power supply circuit and isolating the starter from interference with the low-voltage system. The working principle is as follows: Figure 3 As shown, switch 1 and the 80Ah battery form the starter circuit in the low-voltage power network. Under normal circumstances, both switches 1 and 2 are closed, and the DC / DC converter supplies power to the electrical load. During vehicle start-up, the high current demand of the starter motor causes the voltage at the low-voltage load end to drop momentarily, which can interfere with the operation of various controller components in the low-voltage system. To solve this problem, a dual-battery low-voltage system is used, with 80Ah and 36Ah batteries supplying power to the low-voltage load. When the vehicle starter motor starts, the VCU actively controls the relay to open switch 1. At this time, the starter motor circuit is disconnected from the normal power supply circuit, isolating the starter motor from interference with the low-voltage system.
[0061] S150. When the start-up completion signal is received from the vehicle controller, a stop request for the starter motor is sent to the vehicle controller so that the vehicle controller can perform stop control through the engine controller.
[0062] Specifically, when the test controller receives the start-up completion signal from the vehicle controller, the test controller sends a stop request for the starter motor to the vehicle controller, and the vehicle controller controls the engine to stop the engine by controlling the engine controller.
[0063] For example, in S150, "the vehicle controller performs shutdown control through the engine controller" may include: when the actual torque of the engine is zero, the vehicle controller controls the clutch to disengage and stops sending fuel injection requests to the engine controller, so that the engine controller cuts off fuel and shuts down; when the vehicle controller detects that the engine speed is lower than a preset speed, it determines that the shutdown is complete and sends a shutdown completion signal to the test controller.
[0064] For example, the VCU first controls the engine torque to be 0. When the actual torque fed back by the engine is 0, the VCU controls the clutch to disengage and stops sending fuel injection requests to the engine. At this time, the ECU cuts off fuel and shuts down. When the engine speed reported by the ECU is 50 RPM lower than the preset speed, the VCU considers the shutdown to be complete and sends a shutdown completion signal to the test controller.
[0065] S160. When the shutdown completion signal sent by the vehicle controller is received, it is determined that the current start-up is completed, and the next start-up is performed based on the target number of start-ups corresponding to the current start-up condition, and the start-up test result under the current start-up condition is determined.
[0066] Specifically, when the test controller receives the shutdown completion signal sent by the vehicle controller, it determines that the start-up is complete, compares the current number of start-ups with the target number of start-ups, and determines whether the target number of start-ups corresponding to the current operating condition has been completed, thereby determining the start-up test result under the current start-up operating condition.
[0067] For example, S160, "performing the next start based on the target number of start-ups corresponding to the current start-up condition, and determining the start-up test result under the current start-up condition," may include: comparing the current number of start-ups accumulated under the current start-up condition with the target number of start-ups corresponding to the current start-up condition; if the current number of start-ups is less than the target number of start-ups, then performing the next start-up by returning to execute the operation of sending a start-up request to the vehicle controller; if the current number of start-ups is equal to the target number of start-ups, then ending the start-up test under the current start-up condition, and determining the start-up test result under the current start-up condition as a test success result.
[0068] Exemplarily, the current number of starting operations accumulated under the current starting condition is 3 times, and the target number of starting operations corresponding to the current starting condition is 4 times. At this time, since the current number of starting operations is less than the target number of starting operations, the operation of sending a starting request for the vehicle starter to the VCU is returned to perform the next starting; if the current number of starting operations is equal to the target number of starting operations, the starting test under the current starting condition is ended, and the starting test result under the current starting condition is determined to be a test success result. If the target number of starting operations corresponding to the current starting condition is not completed due to a failure in the vehicle starter starting system, the starting test result under the current starting condition is determined to be a test failure result. [[ID=**2**]]
[0069] S170. Determine the durability test result of the vehicle starter based on the starting test results under each starting condition.
[0070] Specifically, the test controller determines the durability of the vehicle starter starting system according to the starting test results of the target number of starting operations under each starting condition.
[0071] Exemplarily, S170 may include: if the starting test results under each starting condition are all test success results, the durability test result of the vehicle starter is determined to be a qualified result; if the starting test result under the current starting condition is a test failure result, the durability test result of the vehicle starter is determined to be an unqualified result.
[0072] Exemplarily, when all the starting test results of the starting conditions received by the ControlDesk are test success results, the test result of the durability of the vehicle starter starting system can be determined to be a qualified result. As long as the starting test result under the current starting condition is a test failure result, the test result of the durability of the vehicle starter starting system can be directly determined to be an unqualified result. At this time, the durability test of the vehicle starter starting system ends, and the starting conditions that have not been tested are no longer tested.
[0073] It should be noted that in the original text, the tag
[0069] is misspelled as in the subsequent text. I have corrected it in the translation for consistency. If this is not allowed according to your strict requirements, please let me know.The technical solution of this invention involves acquiring multiple starting conditions and target starting data corresponding to each starting condition; taking each starting condition as the current starting condition, and performing a starting test on the vehicle starter motor under each condition. Specifically, based on the target motor torque and target gear corresponding to the current starting condition, a target torque request and a target gear request are sent to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control, and sends the target gear request to the transmission controller for gear control; when the transmission controller returns the current actual gear, current actual vehicle speed, and the starting data corresponding to the current starting condition... Upon reaching the target vehicle speed and determining that the starting conditions for the current starting operation are met, a start request for the travel starter is sent to the vehicle controller, enabling the vehicle controller to control the starter operation via the engine controller. Upon receiving a start completion signal from the vehicle controller, a stop request for the travel starter is sent to the vehicle controller, enabling the vehicle controller to control the stop operation via the engine controller. Upon receiving a stop completion signal from the vehicle controller, the starter operation is confirmed as complete, and the next start is initiated based on the target number of starts corresponding to the current starting condition. The starter test result for the current starting condition is determined, thus completing an automatic durability test for one starting condition. Based on the starter test results for each starting condition, the durability test result of the travel starter can be accurately determined. By testing durability under different starting conditions, the testing process can be simplified, achieving automatic durability testing of the travel starter without manual operation. This avoids the low efficiency and inaccurate performance reflection issues caused by manual testing, thereby improving the efficiency and accuracy of durability testing.
[0074] Example 2
[0075] Figure 4 This is a flowchart of a durability testing method for a vehicle starter provided in Embodiment 2 of the present invention. Based on the above embodiments, this embodiment optimizes the step of "acquiring multiple starter operating conditions and target starter data corresponding to each starter operating condition". Explanations of terms that are the same as or corresponding to those in the above embodiments are not repeated here.
[0076] See Figure 4 Another durability testing method for a vehicle starter provided in this embodiment specifically includes the following steps:
[0077] S210. Based on various test conditions, perform a starting simulation test on the vehicle starter to obtain simulated starting data of the vehicle starter when starting under each test condition.
[0078] The test conditions can refer to commonly used test conditions for a vehicle starter motor. For example, ...
[0079] Specifically, the test controller simulates the starting of the vehicle starter based on various vehicle starter test conditions and captures the working parameters of the starter when it starts.
[0080] For example, based on the composition of the vehicle test conditions, the starting data of the vehicle starter is simulated and tested, and information such as the gear position and motor torque are captured when the starter is started.
[0081] S220. The test conditions are taken as starting conditions, and the simulated starting data corresponding to each test condition is subjected to enhanced statistical processing to obtain the target starting data corresponding to each starting condition. The target starting data includes: target motor torque, target gear, target vehicle speed and target number of starts.
[0082] Specifically, the test controller uses the test conditions in the simulated test as the starting conditions, obtains the simulated starting data of the vehicle starter motor when starting under each starting condition, performs enhanced statistical processing on the simulated starting data corresponding to each test condition, obtains the starter motor starting characteristic points (including motor torque, gear, and vehicle speed when the starter motor starts), and counts the number of starts, converts it into the number of starts in the total simulated driving distance, and obtains the target starting data corresponding to each starting condition.
[0083] For example, simulating a total driving mileage of 240,000 kilometers, the starting condition is based on the NEDC cycle (a commonly used test cycle), with a mileage of 10km (accounting for 10% of all starting conditions). The gear is 3rd gear, and the starter motor starts 4 times under this condition (with drive motor torques of 60Nm, 80Nm, 100Nm, and 120Nm respectively). At this point, the number of starts over the 240,000 kilometers is 0.96 million. To shorten the experimental process, a characteristic starting point in 3rd gear can be enhanced using statistical analysis tools (such as SPSS) (which can be enhanced to a drive motor torque of 120Nm). The three starts under this enhanced torque are equivalent to the original four starts, resulting in 0.72 million starts over the 240,000 kilometers. This significantly reduces the time required to complete a starter motor durability test. It should be noted that the number of starts required in the enhanced start-up condition is less than that required in the original start-up condition, and the enhanced start-up condition has the same impact on the durability of the starter motor as the original start-up condition, thereby further shortening the test time and improving the test efficiency.
[0084] S230. Take each of the aforementioned starting conditions as the current starting condition and perform a starting test on the crane starter under each condition.
[0085] S240. Based on the target motor torque and target gear corresponding to the current starting condition, send a target torque request and a target gear request to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control and the target gear request to the transmission controller for gear control.
[0086] S250. When the starting conditions under the current starting condition are determined based on the current actual gear, current actual vehicle speed and target vehicle speed corresponding to the current starting condition returned by the transmission controller, a starting request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform starting control through the engine controller.
[0087] S260. When the start-up completion signal is received from the vehicle controller, a stop request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform stop control through the engine controller.
[0088] S270. When the shutdown completion signal sent by the vehicle controller is received, it is determined that the current start-up is completed, and the next start-up is performed based on the target number of start-ups corresponding to the current start-up condition, and the start-up test result under the current start-up condition is determined.
[0089] S280. Based on the start-up test results under each start-up condition, determine the durability test results of the crane starter.
[0090] The technical solution of this invention simulates starting tests on a vehicle starter motor under various test conditions to obtain simulated starting data for each test condition. These test conditions are then used as starting conditions, and the simulated starting data for each test condition undergoes enhanced statistical processing to reduce the number of starts during the simulation test. This achieves the same starting effect as before the enhancement process with fewer starts, greatly simplifying the vehicle starter motor durability test process while ensuring durability test results. This further improves test efficiency and provides a more convenient option for existing vehicle starter motor starting tests.
[0091] Example 3
[0092] Figure 5 This is a schematic diagram of a durability testing device for a vehicle starter provided in Embodiment 3 of the present invention. Figure 5 As shown, the device is specifically integrated into the test controller and includes: a target start-up data acquisition module 310, a start-up test module 320, a request sending module 330, a start-up control module 340, a shutdown control module 350, a test result determination module 360, and a durability test result determination module 370.
[0093] The target start-up data acquisition module 310 is used to acquire multiple start-up conditions and target start-up data corresponding to each start-up condition. The target start-up data includes: target motor torque, target gear, target vehicle speed, and target number of start-ups.
[0094] The start-up test module 320 is used to take each of the aforementioned start-up conditions as the current start-up condition and perform start-up tests on the crane starter under each condition.
[0095] The request sending module 330 is used to send a target torque request and a target gear request to the vehicle controller based on the target motor torque and target gear corresponding to the current starting condition, so that the vehicle controller sends the target torque request to the motor controller for torque control and the target gear request to the transmission controller for gear control.
[0096] The starter control module 340 is used to send a starter request to the vehicle controller when the starter conditions under the current starter condition are met based on the current actual gear, current actual vehicle speed and target vehicle speed corresponding to the current starter condition returned by the transmission controller, so that the vehicle controller can perform starter control through the engine controller.
[0097] The shutdown control module 350 is used to send a shutdown request for the vehicle starter to the vehicle controller when it receives a start-up completion signal from the vehicle controller, so that the vehicle controller can perform shutdown control through the engine controller.
[0098] The test result determination module 360 is used to determine that the current start-up is completed when it receives the shutdown completion signal sent by the vehicle controller, and to perform the next start-up based on the target number of start-ups corresponding to the current start-up condition, and determine the start-up test result under the current start-up condition.
[0099] The durability test result determination module 370 is used to determine the durability test result of the crane starter based on the starter test results under each starter condition.
[0100] The technical solution of this embodiment acquires multiple starting conditions and target starting data corresponding to each starting condition; it treats each starting condition as the current starting condition and performs starting tests on the vehicle starter motor under each condition. Specifically, based on the target motor torque and target gear corresponding to the current starting condition, it sends a target torque request and a target gear request to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control and the target gear request to the transmission controller for gear control; when the transmission controller returns the current actual gear, current actual vehicle speed, and target starting data corresponding to the current starting condition... The system sets the vehicle speed and determines if the starting conditions for the current starting operation are met. When this condition is met, it sends a start request to the vehicle controller, enabling the vehicle controller to control the starter operation via the engine controller. Upon receiving a start completion signal from the vehicle controller, it sends a stop request to the vehicle controller, enabling the vehicle controller to control the stop operation via the engine controller. Upon receiving a stop completion signal from the vehicle controller, it determines that the start-up is complete and, based on the target number of starts corresponding to the current starting condition, initiates the next start-up attempt. This determines the start-up test result for the current starting condition, thus completing an automated durability test for that starting condition. Based on the start-up test results for each starting condition, the durability test result of the vehicle starter can be accurately determined. By testing durability under different starting conditions, the testing process is simplified, achieving automated durability testing of the vehicle starter without manual operation. This avoids the low efficiency and inaccurate performance reflection issues caused by manual testing, thereby improving the efficiency and accuracy of durability testing.
[0101] Optionally, the target startup data acquisition module 310 includes:
[0102] The simulation data acquisition unit is used to conduct starting simulation tests on the vehicle starter motor based on various test conditions, and to obtain the simulated starting data of the vehicle starter motor when starting under each test condition;
[0103] The target data acquisition unit is used to take the test conditions as start-up conditions and perform enhanced statistical processing on the simulated start-up data corresponding to each test condition to obtain the target start-up data corresponding to each start-up condition.
[0104] Optionally, the request sending module 330 includes:
[0105] The target torque demand control unit is used to determine the target torque demand based on the target motor torque corresponding to the current starting condition and the transmission ratio corresponding to the target gear, and send the target torque demand request to the vehicle controller, so that the vehicle controller sends the target torque demand request to the motor controller, and the motor controller controls the motor torque to the target torque demand.
[0106] The target gear unit is used to send a target gear request to the vehicle controller based on the target gear corresponding to the current starting condition, so that the vehicle controller sends the target gear request to the transmission controller, and the transmission controller controls the gear to the target gear.
[0107] Optionally, the start-up control module 340 includes:
[0108] The starting condition determination unit is used to determine the current vehicle speed difference between the current actual vehicle speed and the target vehicle speed corresponding to the current starting condition; if the current actual gear returned by the transmission controller is the target gear corresponding to the current starting condition and the current vehicle speed difference is less than a preset threshold, then the starting condition under the current starting condition is determined to be met.
[0109] The starter control unit is used to send the starter request from the vehicle controller to the engine controller and control the starter relay to disconnect; after receiving the starter request, the engine controller controls the starter relay to engage, and the starter motor to drive the engine to start and run automatically; the vehicle controller sends a torque command to the engine to synchronize the engine speed with the motor speed, and after the engine speed and motor speed are synchronized, controls the clutch to engage, so that the engine is driven; when the vehicle controller detects that the torque of the engine and the drive motor has been alternately completed, it determines that the starter is complete and sends a starter completion signal to the test controller.
[0110] Optionally, the shutdown control module 350 is specifically used for:
[0111] When the actual torque of the engine is zero, the vehicle controller controls the clutch to disengage and stops sending fuel injection requests to the engine controller, causing the engine controller to shut down by cutting off fuel. When the vehicle controller detects that the engine speed is lower than the preset speed, it determines that the shutdown is complete and sends a shutdown completion signal to the test controller.
[0112] Optionally, the test result determination module 360 is specifically used for:
[0113] The current number of starts under the current starting condition is compared with the target number of starts corresponding to the current starting condition. If the current number of starts is less than the target number of starts, the operation of sending a start request to the vehicle controller to start the vehicle is returned to start the next start. If the current number of starts is equal to the target number of starts, the start test under the current starting condition ends and the start test result under the current starting condition is determined to be a successful test result.
[0114] Optionally, the durability test result determination module 370 is specifically used for:
[0115] If the start-up test result under each start-up condition is a successful result, then the durability test result of the vehicle starter is determined to be a qualified result; if the start-up test result under the current start-up condition is a failed result, then the durability test result of the vehicle starter is determined to be a failed result.
[0116] The vehicle starter durability testing device provided in this embodiment of the invention can execute the vehicle starter durability testing method provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the method.
[0117] Figure 6 This is a schematic diagram of a durability testing system for a vehicle starter provided in Embodiment 4 of the present invention. Figure 6 As shown, the system specifically includes: a test controller 410, a vehicle controller 420, a motor controller 430, a transmission controller 440, and an engine controller 450.
[0118] The test controller 410 is used to implement the durability test method for the vehicle starter provided in any embodiment of the present invention.
[0119] like Figure 6 As shown, the test controller 410 can be used to send starter motor start requests, motor torque requests, and gear requests to the vehicle controller; the vehicle controller 4 2 0 can be used to achieve coordinated control between various controllers. Motor controller 430 can receive mode requests, motor torque requests, and speed requests sent by the vehicle controller, and report the actual motor mode, actual speed, and actual torque to the VCU. Transmission controller 440 can receive gear requests sent by the vehicle controller and report the actual gear. Engine controller 450 can receive start requests, speed requests, torque requests, and fuel injection requests sent by the vehicle controller, and send the actual speed and actual torque to the vehicle controller.
[0120] The technical solution of this invention involves acquiring multiple starting conditions and target starting data corresponding to each starting condition; taking each starting condition as the current starting condition, and performing a starting test on the vehicle starter motor under each condition. Specifically, based on the target motor torque and target gear corresponding to the current starting condition, a target torque request and a target gear request are sent to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control, and sends the target gear request to the transmission controller for gear control; when the transmission controller returns the current actual gear, current actual vehicle speed, and the starting data corresponding to the current starting condition... Upon reaching the target vehicle speed and determining that the starting conditions for the current starting operation are met, a start request for the travel starter is sent to the vehicle controller, enabling the vehicle controller to control the starter operation via the engine controller. Upon receiving a start completion signal from the vehicle controller, a stop request for the travel starter is sent to the vehicle controller, enabling the vehicle controller to control the stop operation via the engine controller. Upon receiving a stop completion signal from the vehicle controller, the starter operation is confirmed as complete, and the next start is initiated based on the target number of starts corresponding to the current starting condition. The starter test result for the current starting condition is determined, thus completing an automatic durability test for one starting condition. Based on the starter test results for each starting condition, the durability test result of the travel starter can be accurately determined. By testing durability under different starting conditions, the testing process can be simplified, achieving automatic durability testing of the travel starter without manual operation. This avoids the low efficiency and inaccurate performance reflection issues caused by manual testing, thereby improving the efficiency and accuracy of durability testing.
[0121] Those skilled in the art will understand that the modules or steps of the present invention described above can be implemented using general-purpose computing devices. They can be centralized on a single computing device or distributed across a network of multiple computing devices. Optionally, they can be implemented using computer-executable program code, thereby allowing them to be stored in a storage device for execution by a computing device, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. Thus, the present invention is not limited to any particular combination of hardware and software.
[0122] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.
Claims
1. A method of testing the durability of a starter, characterized by, Applications to test controllers include: Acquire multiple starting conditions and target starting data corresponding to each starting condition. The target starting data includes: target motor torque, target gear, target vehicle speed, and target number of starts. Each of the aforementioned starting conditions is taken as the current starting condition, and the starting test of the crane starter is carried out under each condition. Based on the target motor torque and target gear corresponding to the current starting condition, a target torque request and a target gear request are sent to the vehicle controller, so that the vehicle controller sends the target torque request to the motor controller for torque control, and sends the target gear request to the transmission controller for gear control. When the starting conditions under the current starting conditions are met based on the current actual gear, current actual vehicle speed, and target vehicle speed corresponding to the current starting condition returned by the transmission controller, a starting request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform starting control through the engine controller. When the start-up completion signal is received from the vehicle controller, a stop request for the vehicle starter is sent to the vehicle controller so that the vehicle controller can perform stop control through the engine controller. When the shutdown completion signal sent by the vehicle controller is received, it is determined that the current start-up is completed, and the next start-up is performed based on the target number of start-ups corresponding to the current start-up condition, and the start-up test result under the current start-up condition is determined. Based on the start-up test results under each start-up condition, the durability test results of the vehicle starter are determined.
2. The method of claim 1, wherein, Acquire multiple startup conditions and target startup data corresponding to each startup condition, including: Based on various test conditions, a starting simulation test was conducted on the vehicle starter to obtain simulated starting data of the vehicle starter when starting under each test condition. The test conditions are used as start-up conditions, and the simulated start-up data corresponding to each test condition are subjected to enhanced statistical processing to obtain the target start-up data corresponding to each start-up condition.
3. The method of claim 1, wherein, Based on the target motor torque and target gear corresponding to the current starting condition, a target torque request and a target gear request are sent to the vehicle controller. This enables the vehicle controller to send the target torque request to the motor controller for torque control, and the target gear request to the transmission controller for gear control. This includes: Based on the target motor torque corresponding to the current starting condition and the transmission ratio corresponding to the target gear, the target required torque is determined, and the target required torque request is sent to the vehicle controller, so that the vehicle controller sends the target required torque request to the motor controller, and the motor controller controls the motor torque to the target required torque. Based on the target gear corresponding to the current starting condition, a target gear request is sent to the vehicle controller, so that the vehicle controller sends the target gear request to the transmission controller, and the transmission controller controls the gear to the target gear.
4. The method of claim 1, wherein, Based on the current actual gear, current actual vehicle speed, and target vehicle speed corresponding to the current starting condition returned by the transmission controller, the starting conditions that meet the current starting conditions are determined, including: Determine the current speed difference between the current actual vehicle speed and the target vehicle speed corresponding to the current start-up condition; If the current actual gear returned by the transmission controller is the target gear corresponding to the current starting condition and the current vehicle speed difference is less than a preset threshold, then it is determined that the starting conditions under the current starting condition are met.
5. The method according to claim 1, characterized in that, The vehicle controller controls the engine start-up via the engine controller, including: The vehicle controller sends the start request to the engine controller and controls the start relay to disconnect; After receiving the start request, the engine controller controls the start relay to engage, and the vehicle starter motor pulls the engine to start and run automatically. The vehicle controller sends a torque command to the engine to control the engine speed to synchronize with the motor speed, and after the engine speed and motor speed are synchronized, controls the clutch to engage so that the engine can be driven. When the vehicle controller detects that the torque of the engine and drive motor is alternately completed, it determines that the start-up is complete and sends a start-up completion signal to the test controller.
6. The method according to claim 1, characterized in that, The vehicle controller performs shutdown control via the engine controller, including: When the actual torque of the engine is zero, the vehicle controller controls the clutch to disengage and stops sending fuel injection requests to the engine controller, thereby causing the engine controller to shut down due to fuel cut-off. When the vehicle controller detects that the engine speed is lower than the preset speed, it determines that the shutdown is complete and sends a shutdown completion signal to the test controller.
7. The method according to claim 1, characterized in that, The next start-up is performed based on the target number of starts corresponding to the current start-up condition, and the start-up test results under the current start-up condition are determined, including: Compare the current number of startups accumulated under the current startup condition with the target number of startups corresponding to the current startup condition; If the current number of start-ups is less than the target number of start-ups, then the operation of sending a start-up request to the vehicle controller to start the engine will be performed for the next start-up. If the current number of startups equals the target number of startups, then the startup test under the current startup condition ends, and the startup test result under the current startup condition is determined as a successful test result.
8. The method according to any one of claims 1 to 7, characterized in that, Based on the starter test results under each starter condition, the durability test results of the crane starter are determined, including: If the start-up test result is a successful result under each start-up condition, then the durability test result of the vehicle starter is determined to be a qualified result. If the start-up test result under the current start-up condition is a test failure result, then the durability test result of the vehicle starter is determined to be an unqualified result.
9. A durability testing device for a vehicle starter motor, characterized in that, Integrated into the test controller, including: The target start-up data acquisition module is used to acquire multiple start-up conditions and target start-up data corresponding to each start-up condition. The target start-up data includes: target motor torque, target gear, target vehicle speed, and target number of start-ups. The start-up test module is used to take each of the aforementioned start-up conditions as the current start-up condition and perform start-up tests on the crane starter under each condition. The request sending module is used to send a target torque request and a target gear request to the vehicle controller based on the target motor torque and target gear corresponding to the current starting condition, so that the vehicle controller sends the target torque request to the motor controller for torque control and the target gear request to the transmission controller for gear control. The starter control module is used to send a starter request to the vehicle controller when the starter conditions under the current starter condition are met based on the current actual gear, current actual vehicle speed and target vehicle speed corresponding to the current starter condition returned by the transmission controller, so that the vehicle controller can perform starter control through the engine controller. The shutdown control module is used to send a shutdown request for the vehicle starter to the vehicle controller when it receives a start-up completion signal from the vehicle controller, so that the vehicle controller can perform shutdown control through the engine controller. The test result determination module is used to determine the completion of the current start-up when it receives the shutdown completion signal sent by the vehicle controller, and to perform the next start-up based on the target number of start-ups corresponding to the current start-up condition, and determine the start-up test result under the current start-up condition. The durability test result determination module is used to determine the durability test results of the crane starter based on the starter test results under each starter condition.
10. A durability testing system for a vehicle starter motor, characterized in that, The system includes: a test controller, a vehicle controller, a motor controller, a transmission controller, and an engine controller; wherein, The test controller is used to implement the durability test method for the vehicle starter as described in any one of claims 1 to 8.