Electric drive system calibration test system and test method

Abstract

The application relates to an electric drive system calibration test system and a test method. The electric drive system calibration test system comprises: a first test bench comprising a first controller; a first test electric drive; the first controller is configured to: acquire the temperature of a first rotor assembly; acquire the temperature of a first stator assembly; the electric drive system calibration test system further comprises: a second test bench comprising a second controller; a second test electric drive; the second controller is configured to: control a second dynamometer to drive the second test electric drive to operate, the rotating speed of the second test electric drive being the same as that of the first test electric drive; and acquire the spraying image of cooling oil in the second electric drive shell. Through comprehensive judgment on the acquired temperature distribution information and the spraying image of the cooling oil, the related cooling structure can be quickly and accurately positioned in a manner of analysis, elimination and comparison, thereby guiding the improvement of the cooling oil circuit.

Description

Technical Field

[0001] This application relates to the field of calibration and testing technology, and in particular to a calibration and testing system and method for an electric drive system. Background Technology

[0002] The electric drive system of new energy vehicles includes a motor and a transmission. Both the motor and transmission can be oil-cooled, and their cooling systems can be centralized. During cooling, cooling oil circulates within the cooling structures and internal cavities of the motor and transmission. The cooling structures for the motor and transmission include oil passages and holes located on components such as the motor housing, rotor assembly, and transmission housing, as well as an oil pump and oil guide rings. The oil pump pumps oil, and its output directly affects the amount of cooling oil in the cooling circuit. The oil guide rings distribute the amount of cooling oil in different cooling circuits, such as the circuit cooling the stator assembly and the circuit cooling the rotor assembly, or the circuit cooling the motor and the circuit cooling the transmission.

[0003] To ensure the cooling structure effectively cools the electric drive system across all operating zones, its design often requires verification during the initial design phase—a calibration test. This calibration includes calibrating the oil pump output, the oil distribution within the guide ring, and verifying parameters such as the diameter and angle of oil passages and orifices. Existing calibration methods typically employ multiple temperature sensors to acquire temperatures at various test points within the electric drive system, thus obtaining temperature distribution information. This information is then used to determine whether the current oil pump output, the guide ring's distribution of cooling oil, and the parameters of the oil passages and orifices meet design requirements. However, due to the inherent heat transfer between components in an electric drive system, localized high temperatures are difficult to accurately determine solely from temperature distribution data. Consequently, the test results offer limited guidance for oil pump calibration, guide ring improvements, and parameter adjustments for oil passages and orifices. Summary of the Invention

[0004] Based on this, this application provides an electric drive system calibration test system and test method to improve the problem in the prior art that the test results of electric drive system calibration tests are difficult to guide the improvement and adjustment of cooling structure.

[0005] In a first aspect, this application provides an electric drive system calibration and testing system for calibrating and testing an electric drive system, the electric drive system calibration and testing system comprising:

[0006] The first test bench includes a first controller, a plurality of rotor temperature acquisition modules and a plurality of stator temperature acquisition modules, wherein the plurality of rotor temperature acquisition modules and the plurality of stator temperature acquisition modules are electrically connected to the first controller.

[0007] The first test electric drive uses the same cooling oil circuit as the electric drive system and includes a first rotor assembly and a first stator assembly. The first rotor assembly is the same as the rotor assembly of the electric drive system, and the first stator assembly is the same as the stator assembly of the electric drive system.

[0008] The first controller is configured to: control the rotor temperature acquisition module to acquire the temperature of the first rotor assembly; and control the stator temperature acquisition module to acquire the temperature of the first stator assembly.

[0009] The electric drive system calibration and testing system also includes:

[0010] The second test bench includes a second controller, a second dynamometer, and several image acquisition modules, wherein the second dynamometer and several image acquisition modules are electrically connected to the second controller.

[0011] The second test electric drive uses the same cooling oil circuit as the electric drive system and is connected to the second dynamometer. The second test electric drive includes a second electric drive housing and a second rotor assembly. The second electric drive housing is the same as the electric drive housing of the electric drive system. The second rotor assembly is a model of the rotor assembly of the electric drive system. Several of the image acquisition modules are disposed on the second electric drive housing.

[0012] The second controller is configured to: control the second dynamometer to drive the second test electric drive, wherein the rotational speed of the second dynamometer driving the second test electric drive is the same as the rotational speed of the first test electric drive, and the second test electric drive does not experience electromagnetic induction when it is driven; and control the image acquisition module to acquire the spray image of the cooling oil inside the housing of the second electric drive.

[0013] In one embodiment, the second electric drive housing is provided with a countersunk hole and a through hole. The countersunk hole is located inside the second electric drive housing, and the through hole is located through the second electric drive housing. The image acquisition module includes a wired endoscope and a wireless endoscope. The wired endoscope is located inside the through hole, and the wireless endoscope is embedded in the countersunk hole.

[0014] In one embodiment, the cooling oil circuit of the electric drive system includes a rotor oil passage, the rotor oil passage of the first test electric drive is axially disposed within the first rotor assembly, the rotor temperature acquisition module includes a wireless temperature sensor disposed within the rotor oil passage, and the stator temperature acquisition module includes a wired temperature sensor disposed on the first stator assembly.

[0015] In one embodiment, the wireless temperature sensor is configured to be arc-shaped or annular along the cross-section of the first rotor assembly.

[0016] In one embodiment, the rotor temperature acquisition module includes a temperature sensing component, which includes a temperature transmitter and a temperature receiver. The temperature transmitter is disposed on the first rotor assembly. The first test electric drive also includes a first electric drive housing. The first stator assembly and the first rotor assembly are disposed inside the first electric drive housing. The temperature receiver is disposed on the inner wall of the first electric drive housing. When the first rotor assembly rotates, the temperature transmitter and the temperature receiver are positioned opposite each other.

[0017] In one embodiment, the temperature sensing transmitter is threadedly connected to the first rotor assembly, and the temperature sensing receiver is threadedly connected to the first electric drive housing. Both the temperature sensing transmitter and the temperature sensing receiver have a turning groove on their sides that are close to each other.

[0018] In one embodiment, the rotor assembly of the electric drive system is a permanent magnet rotor, and the second rotor assembly includes a magnet model made of a non-magnetic material.

[0019] In one embodiment, the rotor assembly of the electric drive system is an induction rotor. The second rotor assembly includes a rotor core, a rotor shaft, guide bar models, and end ring models. The rotor core is sleeved on the rotor shaft. Two end ring models are provided and are respectively provided at both ends of the rotor core. The guide bar models pass through the rotor core and connect the two end ring models. A plurality of guide bar models are provided along the circumference of the rotor core. The guide bar models and the end ring models are made of plastic material.

[0020] Secondly, this application provides a calibration test method for an electric drive system. The calibration test method uses any one of the electric drive system calibration test systems provided in this application to calibrate and test the electric drive system. The electric drive system calibration test method includes:

[0021] The first test electric drive operates on its own using the principle of electromagnetic induction, controls the rotor temperature acquisition module to acquire the temperature of the first rotor assembly, and controls the stator temperature acquisition module to acquire the temperature of the first stator assembly.

[0022] The second controller controls the second dynamometer to drive the second test electric drive, and the rotational speed of the second dynamometer driving the second test electric drive is the same as the rotational speed of the first test electric drive; the control image acquisition module obtains the spraying image of the cooling oil inside the housing of the second electric drive.

[0023] Based on the temperature of the first rotor assembly, the temperature of the first stator assembly, and the spray image, determine whether the cooling oil circuit of the electric drive system currently meets the design requirements;

[0024] If the cooling oil circuit of the current electric drive system does not meet the design requirements, the cooling oil circuit of the electric drive system shall be improved.

[0025] Adjust the rotational speeds of the second test electric drive and the first test electric drive, and repeat all the aforementioned steps.

[0026] In one embodiment, determining whether the cooling oil circuit of the electric drive system meets design requirements based on the temperature of the first rotor assembly, the temperature of the first stator assembly, and the spray image includes:

[0027] If the temperature of the first rotor assembly and the temperature of the first stator assembly are both too high, it is determined that the output value of the oil pump of the electric drive system does not meet the design requirements.

[0028] If the temperature of the first rotor assembly is suitable, but the temperature of the first stator assembly is too high, then a judgment is made based on the spray image: if there is a small amount of cooling oil sprayed onto the first stator assembly, it is determined that the number and diameter of the holes in the oil guide ring of the electric drive system do not meet the design requirements; if there is a large amount of cooling oil sprayed onto the first stator assembly, it is determined that the output value of the oil pump of the electric drive system does not meet the design requirements.

[0029] If the temperature of the first rotor assembly is too high, but the temperature of the first stator assembly is suitable, then a judgment is made based on the spray image: if there is a lot of cooling oil sprayed on the first stator assembly, it is determined that the number and diameter of the holes in the oil guide ring of the electric drive system do not meet the design requirements.

[0030] This application tests the first test electric drive and the second test electric drive on the first test bench and the second test bench respectively. Then, by comprehensively judging the obtained temperature distribution information and cooling oil spray image, when the relevant cooling structure of the cooling oil circuit does not meet the design requirements, the relevant cooling structure can be quickly and accurately located by means of analysis, elimination, comparison, etc., thereby playing a guiding role in the improvement of the cooling oil circuit. Attached Figure Description

[0031] Figure 1 This is a circuit connection diagram of the electric drive system calibration and testing system provided in Embodiment 1 of this application;

[0032] Figure 2 A cross-sectional view of the first test electric drive of the electric drive system calibration test system provided in Embodiment 1 of this application;

[0033] Figure 3 A cross-sectional view of the second test electric drive of the electric drive system calibration test system provided in Embodiment 1 of this application;

[0034] Figure 4 This is a schematic diagram of the cooling oil circuit of the electric drive system;

[0035] Figure 5 This is a schematic diagram of the installation of the wireless temperature sensor in the electric drive system calibration and testing system provided in Embodiment 1 of this application;

[0036] Figure 6 Two schematic diagrams of the wireless temperature sensor for the electric drive system calibration and testing system provided in Embodiment 1 of this application;

[0037] Figure 7 A cross-sectional view of the second rotor assembly of the electric drive system calibration test system provided in Embodiment 1 of this application;

[0038] Figure 8 This is a schematic diagram of the installation of the temperature sensing component of the electric drive system calibration test system provided in Embodiment 2 of this application;

[0039] Figure 9 This is a cross-sectional view of the second rotor assembly of the electric drive system calibration test system provided in Embodiment 3 of this application.

[0040] Reference numerals: 100, First test bench; 110, First controller; 120, Rotor temperature acquisition module; 121, Wireless temperature sensor; 122, Temperature sensing component; 123, Temperature sensing transmitter; 124, Temperature sensing receiver; 130, Stator temperature acquisition module; 200, First test electric drive; 210, First rotor assembly; 211, Rotor oil passage; 220, First stator assembly; 230, First electric drive housing 300. Second test bench; 310. Second controller; 320. Second dynamometer; 330. Image acquisition module; 331. Wired endoscope; 332. Wireless endoscope; 400. Second test electric drive; 410. Second electric drive housing; 411. Motor end cover; 420. Second rotor assembly; 421. Magnet model; 422. Guide bar model; 423. End ring model; 424. Rotor core; 430. Second stator assembly. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0042] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of the present invention.

[0043] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0044] The orientations or positional relationships indicated by terms such as "upper," "lower," "left," "right," "middle," "longitudinal," "lateral," "horizontal," "inner," "outer," "radial," and "circumferential" used in this specification are based on the orientations or positional relationships shown in the accompanying drawings and are only for the purpose of simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "second" and "first" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0045] Example 1

[0046] Embodiment 1 of this application provides an electric drive system calibration and testing system for calibrating and testing electric drive systems, such as... Figures 1 to 9As shown, the electric drive system calibration test system includes:

[0047] The first test bench 100 includes a first controller 110, a plurality of rotor temperature acquisition modules 120 and a plurality of stator temperature acquisition modules 130, wherein the plurality of rotor temperature acquisition modules 120 and the plurality of stator temperature acquisition modules 130 are electrically connected to the first controller 110.

[0048] The first test electric drive 200 uses the same cooling oil circuit as the electric drive system and includes a first rotor assembly 210 and a first stator assembly 220. The first rotor assembly 210 is the same as the rotor assembly of the electric drive system, and the first stator assembly 220 is the same as the stator assembly of the electric drive system.

[0049] The first controller 110 is configured to: control the rotor temperature acquisition module 120 to acquire the temperature of the first rotor assembly 210; and control the stator temperature acquisition module 130 to acquire the temperature of the first stator assembly 220.

[0050] The electric drive system calibration test system also includes:

[0051] The second test bench 300 includes a second controller 310, a second dynamometer 320 and several image acquisition modules 330, wherein the second dynamometer 320 and several image acquisition modules 330 are electrically connected to the second controller 310.

[0052] The second test electric drive 400 uses the same cooling oil circuit as the electric drive system and is connected to the second dynamometer 320. The second test electric drive 400 includes a second electric drive housing 410 and a second rotor assembly 420. The second electric drive housing 410 is the same as the electric drive housing of the electric drive system. The second rotor assembly 420 is a model of the rotor assembly of the electric drive system. Several image acquisition modules 330 are disposed on the second electric drive housing 410.

[0053] The second controller 310 is configured to: control the second dynamometer 320 to drive the second test electric drive 400 to operate, the rotational speed of the second test electric drive 400 driven by the second dynamometer 320 is the same as the rotational speed of the first test electric drive 200, and the second test electric drive 400 does not experience electromagnetic induction when it is driven to operate; and control the image acquisition module 330 to acquire the spraying image of the cooling oil inside the housing 410 of the second electric drive.

[0054] like Figure 1As shown in this embodiment, by way of example, both the first test bench 100 and the second test bench 300 can be electric drive test benches. Each electric drive test bench includes at least a controller and a dynamometer. The dynamometer is used to drive the electric drive system, and the controller is used to implement related control functions. The second test bench 300 and the first test bench 100 can also be used to acquire parameters such as the speed, output torque, and output power of the tested electric drive. It is easy to understand that the electric drive system can also operate autonomously on the electric drive test bench.

[0055] like Figure 1 and Figure 2 As shown, the main function of the first test electric drive 200 is to simulate the normal operation of the electric drive system. It adopts the electric drive housing, stator assembly, and rotor assembly of the electric drive system; that is, the first electric drive housing 230, the first stator assembly 220, and the first rotor assembly 210 are identical to the electric drive housing, stator assembly, and rotor assembly of the electric drive system, respectively. The first test electric drive 200 operates automatically on the first test bench 100 using the principle of electromagnetic induction, and it is driven by the first dynamometer on the first test bench 100, i.e., the first test electric drive 200 drives the first dynamometer to facilitate the acquisition of parameters of the first test electric drive 200 by the first test bench 100. Several rotor temperature acquisition modules 120 and several stator temperature acquisition modules 130 are also arranged on the first test bench 100 to acquire the temperature distribution of the first rotor assembly 210 and the first stator assembly 220 of the first test electric drive 200, respectively.

[0056] like Figure 1 and Figure 3As shown, the main function of the second test electric drive 400 is to simulate the circulation of cooling oil in the cooling oil circuit of the electric drive system. The second test electric drive 400 is a simulation model of the electric drive system, which may include a second electric drive housing 410, a second stator assembly 430, and a second rotor assembly 420. The second electric drive housing 410 and the second stator assembly 430 can be configured with the same structure and materials as the electric drive housing and stator assembly of the electric drive system; in other words, the second test electric drive 400 uses the electric drive housing and stator assembly of the electric drive system. However, unlike the second test electric drive, the second rotor assembly 420 is a model of the rotor assembly of the electric drive system. When the second test electric drive 400 is running, it does not experience electromagnetic induction. That is, although the second rotor assembly 420 is running, the second test electric drive 400 cannot function normally. The second rotor assembly 420 is driven and rotated by the second dynamometer 320. The rotational speed of the second test electric drive 400 driven by the second dynamometer 320 is essentially the same as the rotational speed of the first test electric drive 200. It should be noted that the design of the cooling oil circuit in the second rotor assembly 420 is the same as that in the rotor assembly of the electric drive system. The second test bench 300 also houses the second test electric drive 400 and several image acquisition modules 330 for capturing the spraying of cooling oil within the second test electric drive 400.

[0057] like Figure 1 As shown, during the calibration test of the electric drive system, the first test electric drive 200 runs automatically. The first controller 110 controls several rotor temperature acquisition modules 120 and several stator temperature acquisition modules 130 to acquire the temperature distribution information of the first rotor assembly 210 and the first stator assembly 220 of the first test electric drive 200, respectively. The second test bench 300 controls the second dynamometer 320 to drive the second test electric drive 400, and controls the first test electric drive 200 and the second test electric drive 400 to maintain basically the same speed. At the same time, it controls several image acquisition modules 330 to acquire the spray image of the cooling oil in the housing 410 of the second electric drive. Subsequently, based on the temperature distribution information of the first rotor assembly 210 and the first stator assembly 220 and the spray image of the cooling oil, it is determined whether the cooling oil circuit of the electric drive system meets the design requirements at this speed.

[0058] like Figure 4 As shown, determining the design requirements for the cooling oil circuit can include assessing whether the output value of the oil pump in the electric drive system meets the requirements, and whether the number and diameter of the holes in the oil guide ring of the electric drive system meet the requirements. Specific assessment steps may include:

[0059] If the temperature of the first rotor assembly 210 and the temperature of the first stator assembly 220 are both too high, it can be determined that the output value of the oil pump of the electric drive system does not meet the design requirements.

[0060] If the temperature of the first rotor assembly 210 is suitable, but the temperature of the first stator assembly 220 is too high, further judgment needs to be made based on the spray image: if there is a small amount of cooling oil sprayed onto the first stator assembly 220, it can be determined that the number and diameter of the holes in the oil guide ring of the electric drive system do not meet the design requirements; if there is a large amount of cooling oil sprayed onto the first stator assembly 220, it can be determined that the output value of the oil pump of the electric drive system does not meet the design requirements.

[0061] If the temperature of the first rotor assembly 210 is too high, but the temperature of the first stator assembly 220 is suitable, it is necessary to make a judgment based on the spray image: if there is a lot of cooling oil sprayed on the first stator assembly 220, it can be determined that the number and diameter of the holes in the oil guide ring of the electric drive system do not meet the design requirements.

[0062] like Figure 4 As shown, in some embodiments, the determination of the design requirements for the cooling oil circuit may also include the determination of other cooling structures. For example, the cooling oil circuit may also include an oil-throwing hole provided on the rotor end ring, which is used to throw the cooling oil of the rotor assembly to the inner side of the stator assembly; and the determination step may also include:

[0063] If the temperature of the first rotor assembly 210 is suitable, but the temperature of the first stator assembly 220 is too high, and if it is observed through the spray image that a small amount of cooling oil is thrown to the inside of the first stator assembly 220, then it can be determined that the number and diameter of the oil throwing holes do not meet the design requirements.

[0064] It is understandable that whether the cooling oil circuit meets the design requirements is a comprehensive judgment, and it is difficult to accurately determine whether a certain structure of the cooling oil circuit meets the design requirements based solely on single temperature distribution information. However, this application tests the first test electric drive 200 and the second test electric drive 400 using the first test bench 100 and the second test bench 300, respectively. Subsequently, by comprehensively judging the obtained temperature distribution information and cooling oil spray images, when the relevant cooling structure of the cooling oil circuit does not meet the design requirements, the relevant cooling structure can be quickly and accurately located through analysis, elimination, comparison, and other methods, thereby providing guidance for the improvement of the cooling oil circuit.

[0065] Specifically, the second electric drive housing 410 is provided with a countersunk hole and a through hole. The countersunk hole is located on the inner side of the second electric drive housing 410, and the through hole is provided on the second electric drive housing 410. The image acquisition module 330 includes a wired endoscope 331 and a wireless endoscope 332. The wired endoscope 331 is provided in the through hole, and the wireless endoscope 332 is embedded in the countersunk hole.

[0066] like Figure 3As shown in this embodiment, it is exemplarily illustrated that the wireless endoscope 332 can transmit image information based on electromagnetic waves. Since the second rotor assembly 420 is a model of the rotor assembly of the electric drive system, and the second electric drive system does not generate electromagnetic induction during operation, both the wired endoscope 331 and the wireless endoscope 332 can operate normally within the second electric drive system without interference. When arranging the wired endoscope 331, a through hole needs to be provided in the second electric drive housing 410 to facilitate wiring. However, when arranging the wireless endoscope 332, only a countersunk hole needs to be provided in the second electric drive housing 410, meaning the second electric drive housing 410 is not penetrated. The choice between wired endoscope 331 and wireless endoscope 332 is based on whether the placement location facilitates wiring. For example, wired endoscope 331 can be placed on the motor end cover 411 of the second electric drive housing 410, while wireless endoscope 332 can be placed on the side of the motor housing of the second electric drive housing 410 near the gearbox housing. These two sets of endoscopes facilitate the observation of the spraying of cooling oil at the two ends of the second rotor assembly 420 and the second stator assembly 430.

[0067] It is understood that by setting the image acquisition module 330 as a wired endoscope 331 and a wireless endoscope 332, this embodiment facilitates the arrangement of the image acquisition module 330 in a predetermined position in the second electric drive housing 410 according to actual needs, thereby accurately acquiring the required cooling oil spray image and improving the guiding role of the spray image.

[0068] Specifically, the cooling oil circuit of the electric drive system includes a rotor oil passage 211. The rotor oil passage 211 of the first test electric drive 200 is axially arranged within the first rotor assembly 210. The rotor temperature acquisition module 120 includes a wireless temperature sensor 121, which is disposed within the rotor oil passage 211. The stator temperature acquisition module 130 includes a wired temperature sensor, which is disposed on the first stator assembly 220.

[0069] like Figure 2 and Figure 5As shown in this embodiment, the rotor assembly of the electric drive system may specifically include a rotor shaft, which may be a hollow shaft to form a rotor oil passage 211 arranged axially. The rotor oil passage 211 is one of the cooling structures of the electric drive system. Cooling oil can enter the rotor assembly from the rotor oil passage 211 to cool the rotor assembly. Similarly, the first rotor assembly 210 is also arranged with a rotor oil passage 211 to maintain the same cooling oil path as the rotor assembly of the electric drive system. The rotor temperature acquisition module 120 may be configured as a wireless temperature sensor 121 arranged in the rotor oil passage 211 of the first rotor assembly 210, which rotates synchronously with the first rotor assembly 210 to acquire the temperature information of the first rotor assembly 210 in real time. The wireless temperature sensor 121 can transmit temperature information based on sound waves, and the first controller 110 is used to directly receive the temperature information, that is, the first controller 110 is equipped with a corresponding receiver. Since the first stator assembly 220 remains fixed when the first test electric drive 200 is running, the stator temperature sensor can be a wired temperature sensor to obtain the temperature information of the first stator assembly 220 in real time.

[0070] It is understood that in this embodiment, by setting the rotor temperature acquisition module 120 as a wireless temperature sensor 121 and the stator temperature acquisition module 130 as a wired temperature sensor, it is convenient to acquire temperature information according to actual needs.

[0071] More specifically, the wireless temperature sensor 121 is configured to be arc-shaped or annular along the cross-section of the first rotor assembly 210.

[0072] like Figure 5 and Figure 6 As shown in this embodiment, by way of example, the cross-section of the first rotor assembly 210 can be understood as a section perpendicular to the axis of the first rotor assembly 210. Along this section, the shape of the wireless temperature sensor 121 is arc-shaped or annular. The outer diameter of the wireless temperature sensor 121 can be equal to the inner diameter of the rotor oil passage 211 of the first rotor assembly 210, and the wireless temperature sensor 121 can be interference-fitted with the first rotor assembly 210. The wireless temperature sensor 121 is in direct contact with the first rotor assembly 210 so that the wireless temperature sensor 121 can obtain the temperature of the first rotor assembly 210.

[0073] It is understood that by setting the shape of the wireless temperature sensor 121 to an arc or ring, this embodiment can avoid the wireless temperature sensor 121 from clogging the cooling oil and affecting the actual spraying of the cooling oil when the cooling oil flows through the rotor oil passage 211.

[0074] Specifically, the rotor assembly of the electric drive system is a permanent magnet rotor, and the second rotor assembly 420 includes a magnet model 421, which is made of a non-magnetic material.

[0075] like Figure 7 As shown in this embodiment, by way of example, when the rotor assembly of the electric drive system is a permanent magnet rotor, in order to avoid the phenomenon of electromagnetic induction generated by the second test electric drive 400, the second rotor assembly 420 uses a magnet model 421 made of non-magnetic material to replace the magnet. The non-magnetic material can be plastic, rubber, etc.

[0076] It is understandable that in this embodiment, the magnet model 421 of the second rotor assembly 420 is prepared using a non-magnetic material, which makes it easier to achieve the phenomenon of no electromagnetic induction when the second test electric drive 400 is running.

[0077] Example 2

[0078] This application provides a calibration and testing system for an electric drive system in embodiment two. The difference between this embodiment and embodiment one is at least in the structure and installation method of the rotor temperature acquisition module 120.

[0079] Specifically, the rotor temperature acquisition module 120 includes a temperature sensing component 122, which includes a temperature transmitter 123 and a temperature receiver 124. The temperature transmitter 123 is disposed on the first rotor assembly 210. The first test electric drive 200 also includes a first electric drive housing 230. The first stator assembly 220 and the first rotor assembly 210 are disposed inside the first electric drive housing 230. The temperature receiver 124 is disposed on the inner wall of the first electric drive housing 230. When the first rotor assembly 210 rotates, the temperature transmitter 123 and the temperature receiver 124 are positioned opposite each other.

[0080] like Figure 8As shown in this embodiment, the temperature transmitter 123 in the temperature sensing assembly 122 is used to collect the temperature of the first rotor assembly 210. It is arranged on the end of the first rotor assembly 210 and rotates synchronously with the first rotor assembly 210. The temperature receiver 124 is fixedly disposed on the first electric drive housing 230. When the first rotor assembly 210 rotates, it can rotate the temperature transmitter 123 to a position opposite to the temperature receiver 124. At this time, the temperature transmitter 123 can send the collected temperature of the first rotor assembly 210 to the temperature receiver 124. The temperature transmitter 123 and the temperature receiver 124 can transmit temperature information based on sound waves. The temperature receiver 124 can further transmit the received temperature information to the first test bench 100. That is, the temperature receiver 124 is not integrated with the first controller 110, but is electrically connected.

[0081] It is understood that by setting the rotor temperature acquisition module 120 as a temperature sensing component 122 including a temperature sensing transmitter 123 and a temperature sensing receiver 124, this embodiment also facilitates the acquisition of temperature information of the first rotor assembly 210; at the same time, similar to the wireless temperature sensor 121 arranged in the rotor oil passage 211, this embodiment can reduce the impact on the smooth flow of cooling oil in the rotor assembly.

[0082] More specifically, the temperature sensing transmitter 123 is threadedly connected to the first rotor assembly 210, and the temperature sensing receiver 124 is threadedly connected to the first electric drive housing 230. Both the temperature sensing transmitter 123 and the temperature sensing receiver 124 have a screwing groove on the side that is close to each other.

[0083] like Figure 8 As shown in this embodiment, both the temperature-sensing transmitter 123 and the temperature-sensing receiver 124 can be configured as hexagonal bolts, including a threaded rod end for screwing into the first rotor assembly 210 or the first electric drive housing 230, and a screwing head for screwing. The screwing groove is a hexagonal groove on the screwing head. The screwing head can also be embedded in the first electric drive housing 230 so that the end of the first rotor assembly 210 maintains the original distance from the inner wall of the first electric drive housing 230, and also avoids interference between the temperature-sensing transmitter 123 and the temperature-sensing receiver 124 when the transmitter rotates.

[0084] It is understood that this embodiment makes it easy to arrange and install the temperature transmitter 123 and the temperature receiver 124 by setting them to a rotatable structure.

[0085] Example 3

[0086] This application provides an electric drive system calibration test system in embodiment three. The difference between this embodiment and embodiment one is at least in the structure of the second rotor assembly 420.

[0087] Specifically, the rotor assembly of the electric drive system is an induction rotor. The second rotor assembly 420 includes a rotor core 424, a rotor shaft, a guide bar model 422, and an end ring model 423. The rotor core 424 is sleeved on the rotor shaft. There are two end ring models 423, which are respectively located at both ends of the rotor core 424. The guide bar model 422 passes through the rotor core 424 and connects the two end ring models 423. Several guide bar models 422 are arranged along the circumference of the rotor core 424. Both the guide bar model 422 and the end ring model 423 are made of non-conductive material.

[0088] like Figure 9 As shown in this embodiment, by way of example, when the rotor assembly of the electric drive system is an induction rotor, in order to avoid electromagnetic induction when the second rotor assembly 420 rotates, the guide bars and end rings of the induction rotor of the electric drive system can be made into guide bar model 422 and end ring model 423 by using a non-conductive material (e.g., plastic material). The guide bar model 422 and end ring model 423 can be integrally formed to fix the rotor core 424.

[0089] It is understood that in this embodiment, the guide bar model 422 and end ring model 423 of the second rotor assembly 420 are made of plastic material, which can also achieve the phenomenon of no electromagnetic induction when the second test electric drive 400 is running.

[0090] Example 4

[0091] Embodiment 4 of this application provides a calibration test method for an electric drive system. The method uses any of the electric drive system calibration test systems provided in this application to calibrate and test the electric drive system. The electric drive system calibration test method includes the following steps:

[0092] S1. The first test electric drive 200 operates by itself using the principle of electromagnetic induction, controls the rotor temperature acquisition module 120 to acquire the temperature of the first rotor assembly 210, and controls the stator temperature acquisition module 130 to acquire the temperature of the first stator assembly 220.

[0093] S2. The second controller 310 controls the second dynamometer 320 to drive the second test electric drive 400 to operate. The rotational speed of the second dynamometer 320 driving the second test electric drive 400 is the same as that of the first test electric drive 200. The control image acquisition module 330 obtains the spraying image of the cooling oil inside the housing 410 of the second electric drive.

[0094] S3. Determine whether the cooling oil circuit of the current electric drive system meets the design requirements based on the temperature of the first rotor assembly 210, the temperature of the first stator assembly 220 and the spray image.

[0095] S4. If the current cooling oil circuit of the electric drive system does not meet the design requirements, improve the cooling oil circuit of the electric drive system.

[0096] S5. Adjust the rotation speed of the second test electric drive 400 and the first test electric drive 200, and repeat steps S1 to S4.

[0097] like Figure 1 As shown in this embodiment, the rotor temperature acquisition module 120 can be a wireless temperature sensor 121 or a temperature sensing component 122, the stator temperature acquisition module 130 can be a wired temperature sensor, and the image acquisition module 330 can be a wired endoscope 331 or a wireless endoscope. Determining the design requirements of the cooling oil circuit can include judging whether the output value of the oil pump in the electric drive system meets the requirements, and judging whether the number and diameter of the holes in the oil guide ring of the electric drive system meet the requirements, etc.

[0098] It is understood that this application tests the first test electric drive 200 and the second test electric drive 400 on the first test bench 100 and the second test bench 300 respectively. Then, by comprehensively judging the obtained temperature distribution information and cooling oil spray image, when the relevant cooling structure of the cooling oil circuit does not meet the design requirements, the relevant cooling structure can be quickly and accurately located through analysis, elimination, comparison and other methods, thereby playing a guiding role in the improvement of the cooling oil circuit.

[0099] Specifically, step S3 involves determining whether the cooling oil circuit of the electric drive system meets the design requirements based on the temperature of the first rotor assembly 210, the temperature of the first stator assembly 220, and the spray image, and includes the following steps:

[0100] S31. If the temperature of the first rotor assembly 210 and the temperature of the first stator assembly 220 are both too high, it is determined that the output value of the oil pump of the electric drive system does not meet the design requirements.

[0101] S32. If the temperature of the first rotor assembly 210 is suitable, but the temperature of the first stator assembly 220 is too high, then make a judgment based on the spray image: if there is a small amount of cooling oil sprayed on the first stator assembly 220, it is determined that the number and diameter of the holes in the oil guide ring of the electric drive system do not meet the design requirements; if there is a large amount of cooling oil sprayed on the first stator assembly 220, it is determined that the output value of the oil pump of the electric drive system does not meet the design requirements.

[0102] S33. If the temperature of the first rotor assembly 210 is too high, but the temperature of the first stator assembly 220 is suitable, then make a judgment based on the spray image: if there is a lot of cooling oil sprayed on the first stator assembly 220, it is determined that the number and diameter of the oil guide ring of the electric drive system do not meet the design requirements.

[0103] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0104] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. An electric drive system calibration and testing system, used for calibrating and testing electric drive systems, characterized in that, The electric drive system calibration and testing system includes: The first test bench (100) includes a first controller (110), a plurality of rotor temperature acquisition modules (120) and a plurality of stator temperature acquisition modules (130), wherein the plurality of rotor temperature acquisition modules (120) and the plurality of stator temperature acquisition modules (130) are electrically connected to the first controller (110). The first test electric drive (200) uses the same cooling oil circuit as the electric drive system and includes a first rotor assembly (210) and a first stator assembly (220). The first rotor assembly (210) is the same as the rotor assembly of the electric drive system, and the first stator assembly (220) is the same as the stator assembly of the electric drive system. The first controller (110) is configured to: control the rotor temperature acquisition module (120) to acquire the temperature of the first rotor assembly (210); and control the stator temperature acquisition module (130) to acquire the temperature of the first stator assembly (220); The electric drive system calibration and testing system also includes: The second test bench (300) includes a second controller (310), a second dynamometer (320) and a plurality of image acquisition modules (330), wherein the second dynamometer (320) and the plurality of image acquisition modules (330) are electrically connected to the second controller (310); The second test electric drive (400) uses the same cooling oil circuit as the electric drive system and is connected to the second dynamometer (320) in a transmission. The second test electric drive (400) includes a second electric drive housing (410) and a second rotor assembly (420). The second electric drive housing (410) is the same as the electric drive housing of the electric drive system. The second rotor assembly (420) is a model of the rotor assembly of the electric drive system. Several of the image acquisition modules (330) are disposed on the second electric drive housing (410). The second controller (310) is configured to: control the second dynamometer (320) to drive the second test electric drive (400) to operate, wherein the rotational speed of the second dynamometer (320) driving the second test electric drive (400) is the same as the rotational speed of the first test electric drive (200), and the second test electric drive (400) does not experience electromagnetic induction when it is driven to operate; and control the image acquisition module (330) to acquire the spraying image of the cooling oil inside the housing (410) of the second electric drive.

2. The electric drive system calibration and testing system according to claim 1, characterized in that, The second electric drive housing (410) is provided with a countersunk hole and a through hole. The countersunk hole is located on the inner side of the second electric drive housing (410), and the through hole is located on the second electric drive housing (410). The image acquisition module (330) includes a wired endoscope (331) and a wireless endoscope (332). The wired endoscope (331) is located in the through hole, and the wireless endoscope (332) is embedded in the countersunk hole.

3. The electric drive system calibration and testing system according to claim 1, characterized in that, The cooling oil circuit of the electric drive system includes a rotor oil passage (211). The rotor oil passage (211) of the first test electric drive (200) is axially disposed in the first rotor assembly (210). The rotor temperature acquisition module (120) includes a wireless temperature sensor (121) disposed in the rotor oil passage (211). The stator temperature acquisition module (130) includes a wired temperature sensor disposed on the first stator assembly (220).

4. The electric drive system calibration and testing system according to claim 3, characterized in that, The wireless temperature sensor (121) is configured to be arc-shaped or ring-shaped along the cross-section of the first rotor assembly (210).

5. The electric drive system calibration and testing system according to claim 1, characterized in that, The rotor temperature acquisition module (120) includes a temperature sensing component (122), which includes a temperature transmitter (123) and a temperature receiver (124). The temperature transmitter (123) is disposed on the first rotor assembly (210). The first test electric drive (200) also includes a first electric drive housing (230). The first stator assembly (220) and the first rotor assembly (210) are disposed inside the first electric drive housing (230). The temperature receiver (124) is disposed on the inner wall of the first electric drive housing (230). When the first rotor assembly (210) rotates, the temperature transmitter (123) and the temperature receiver (124) are positioned opposite each other.

6. The electric drive system calibration and testing system according to claim 5, characterized in that, The temperature sensing transmitter (123) is threadedly connected to the first rotor assembly (210), and the temperature sensing receiver (124) is threadedly connected to the first electric drive housing (230). Both the temperature sensing transmitter (123) and the temperature sensing receiver (124) have a screwing groove on their sides that are close to each other.

7. The electric drive system calibration and testing system according to claim 1, characterized in that, The rotor assembly of the electric drive system is a permanent magnet rotor, and the second rotor assembly (420) includes a magnet model (421) made of a non-magnetic material.

8. The electric drive system calibration and testing system according to claim 1, characterized in that, The rotor assembly of the electric drive system is an induction rotor. The second rotor assembly (420) includes a rotor core (424), a rotor shaft, a guide bar model (422), and an end ring model (423). The rotor core (424) is sleeved on the rotor shaft. There are two end ring models (423), which are respectively located at both ends of the rotor core (424). The guide bar model (422) passes through the rotor core (424) and connects the two end ring models (423). There are several guide bar models (422) arranged along the circumference of the rotor core (424). Both the guide bar model (422) and the end ring model (423) are made of non-conductive material.

9. A calibration test method for an electric drive system, characterized in that, The electric drive system calibration test method uses the electric drive system calibration test system as described in any one of claims 1 to 8 to perform calibration tests on the electric drive system, and the electric drive system calibration test method includes: The first test electric drive (200) operates by itself using the principle of electromagnetic induction, controls the rotor temperature acquisition module (120) to acquire the temperature of the first rotor assembly (210), and controls the stator temperature acquisition module (130) to acquire the temperature of the first stator assembly (220). The second controller (310) controls the second dynamometer (320) to drive the second test electric drive (400) to operate. The rotational speed of the second dynamometer (320) driving the second test electric drive (400) is the same as that of the first test electric drive (200). The control image acquisition module (330) acquires the spray image of the cooling oil inside the housing (410) of the second electric drive. Based on the temperature of the first rotor assembly (210), the temperature of the first stator assembly (220), and the spray image, determine whether the cooling oil circuit of the electric drive system meets the design requirements. If the cooling oil circuit of the current electric drive system does not meet the design requirements, the cooling oil circuit of the electric drive system shall be improved. Adjust the rotational speeds of the second test electric drive (400) and the first test electric drive (200), and repeat all the aforementioned steps.

10. The calibration and testing method for an electric drive system according to claim 9, characterized in that, Based on the temperature of the first rotor assembly (210), the temperature of the first stator assembly (220), and the spray image, it is determined whether the cooling oil circuit of the current electric drive system meets the design requirements, including: If the temperature of the first rotor assembly (210) and the temperature of the first stator assembly (220) are both too high, it is determined that the output value of the oil pump of the electric drive system does not meet the design requirements. If the temperature of the first rotor assembly (210) is suitable, but the temperature of the first stator assembly (220) is too high, then a judgment is made based on the spray image: if there is a small amount of cooling oil sprayed onto the first stator assembly (220), it is determined that the number and diameter of the holes in the oil guide ring of the electric drive system do not meet the design requirements; if there is a large amount of cooling oil sprayed onto the first stator assembly (220), it is determined that the output value of the oil pump of the electric drive system does not meet the design requirements. If the temperature of the first rotor assembly (210) is too high, but the temperature of the first stator assembly (220) is suitable, then a judgment is made based on the spray image: if there is a lot of cooling oil sprayed on the first stator assembly (220), it is determined that the number of holes and the diameter of the oil guide ring of the electric drive system do not meet the design requirements.

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