A method and system for detecting off-line of a multi-speed electric drive assembly

Abstract

The present invention provides an offline detection method and system for a multi-speed electric drive assembly, the system comprising: a low-voltage power supply for providing power to a controller; a high-voltage power supply for providing power to the multi-speed electric drive assembly; a speed sensor installed on an engine shaft of the multi-speed electric drive assembly for collecting engine speed; a controller for collecting signals from sensors in the multi-speed electric drive assembly, and performing electrical inspection on the multi-speed electric drive assembly according to the sensor signals; calibrating an initial position of a shift hub, and performing shift inspection on the multi-speed electric drive assembly according to the collected engine speed; in this way, a low-voltage power supply is used to provide power to the controller, and a high-voltage power supply is used to drive the multi-speed electric drive assembly for inspection, and only the speed sensor needs to be installed on the engine shaft to implement a shift test, and effectively inspect the shift performance of the multi-speed electric drive assembly, and the structure is simple, and the arrangement of a dynamometer and special test equipment is omitted, thereby reducing the inspection cost.

Description

Technical Field

[0001] The present application relates to the technical field of off-line detection of electric drive assemblies, and in particular to an off-line detection method and system for a multi-speed electric drive assembly. Background Art

[0002] As environmental protection measures in countries around the world become increasingly stringent, hybrid vehicles have been widely developed. The performance of the drive system in hybrid vehicles is directly related to the power, economy and emission performance of the entire vehicle. The key to hybrid vehicles is the electric drive system, and its performance is directly related to the performance of the hybrid vehicle. After more than ten years of development, the hybrid system assembly has developed from the original discrete structure of the engine and motor to the integrated structure of the engine, motor and gearbox, that is, the integrated electric drive assembly system.

[0003] To ensure product quality during the production process of the electric drive assembly, offline testing is usually required. Currently, offline testing of the electric drive assembly is usually carried out by reverse dynamometer, which is mainly completed by special test equipment and multiple dynamometers, and requires the use of professional test software. The test equipment used in this test method has a long manufacturing cycle and a large investment, especially for products in the trial production stage, the number of products is small, but it still requires a high testing cost. Summary of the invention

[0004] In response to the problems existing in the prior art, an embodiment of the present invention provides a method and system for off-line detection of a multi-speed electric drive assembly, so as to solve or partially solve the technical problem in the prior art that when performing off-line detection on an electric drive assembly in the trial production stage, special testing equipment and multiple dynamometers need to be deployed, thereby increasing the detection cost.

[0005] The present invention provides a multi-speed electric drive assembly offline detection system, the system comprising: a low-voltage power supply, a high-voltage power supply, a controller and a speed sensor;

[0006] The low-voltage power supply is used to provide power to the controller;

[0007] The high voltage power supply is used to provide power for the multi-speed electric drive assembly;

[0008] The speed sensor is mounted on the engine shaft of the multi-speed electric drive assembly and is used to collect the engine speed;

[0009] The controller is used to collect signals from sensors in the multi-speed electric drive assembly and perform electrical inspection on the multi-speed electric drive assembly according to the sensor signals;

[0010] The initial position of the shift hub is calibrated, and the shift detection of the multi-speed electric drive assembly is performed according to the collected engine speed.

[0011] In the above scheme, the sensors include: an oil pressure sensor, an oil temperature sensor, a shift motor, an oil pump motor, a resolver connector and a motor temperature sensor.

[0012] In the above solution, the system further includes: a host computer, and the controller performs electrical inspection on the multi-speed electric drive assembly according to the sensor signal, including:

[0013] For any sensor, if it is determined that a signal corresponding to the sensor can be collected, it is determined that the circuit connection corresponding to the sensor is normal;

[0014] If it is determined that the signal corresponding to the sensor cannot be collected, an alarm prompt signal is sent to the host computer.

[0015] In the above solution, the controller specifically calibrates the initial position of the shift hub, including:

[0016] When the shift motor is controlled to drive the shift hub to rotate in the opposite direction to the top dead center, a calibration angle corresponding to the top dead center is received;

[0017] When the shift hub is controlled to rotate forward to the bottom dead center, a corresponding actual shift angle is obtained;

[0018] If it is determined that the difference between the actual shift angle and the theoretical angle of the bottom dead center is greater than a preset angle threshold, adjusting the calibration angle so that the difference is less than or equal to the angle threshold;

[0019] The position corresponding to the adjusted calibration angle is taken as the initial position of the shift hub.

[0020] In the above solution, the controller performs shift detection on the multi-speed electric drive assembly according to the collected engine speed, including:

[0021] Controlling the shift motor to drive the shift hub to rotate to a target gear position, wherein the target gear position is any gear position of the shift hub;

[0022] At a target gear position of the parallel direct drive mode, controlling the generator to rotate to obtain a current speed ratio between the generator and the engine;

[0023] Whether there is a fault in the target gear is detected according to the current speed ratio.

[0024] In the above solution, the controller detects whether there is a fault in the target gear according to the current speed ratio, including:

[0025] For any target gear, if it is determined that the current speed ratio is inconsistent with the preset speed ratio, it is determined that there is a fault in the target gear.

[0026] In the above solution, the controller performs shift detection on the multi-speed electric drive assembly according to the collected engine speed, including:

[0027] Controlling the shift motor to drive the shift hub to rotate to a target gear position, wherein the target gear position is any gear position of the shift hub;

[0028] At the target gear of the parallel direct drive mode, the drive motor is controlled to rotate; the current speed of the engine is determined according to the speed of the drive motor, the wheel side speed ratio and the gear speed ratio corresponding to the target gear;

[0029] Gear shift detection is performed based on the current speed and the reference engine speed corresponding to the target gear.

[0030] In the above solution, the controller is also used for:

[0031] If it is determined that there is a fault in the target gear, the fault prompt information is pushed to the upper computer;

[0032] If it is determined that the target gear is the first gear or the second gear, the fault prompt information is: there is a fault in the first and second gear gears, the ICE intermediate shaft or the differential;

[0033] If it is determined that the target gear is the third gear or the fourth gear, the fault prompt information is: there is a fault in the third and fourth gear gears, the EV intermediate shaft, the drive motor input shaft or the differential;

[0034] If it is determined that the target gear is the second gear or the fourth gear, the fault prompt information is: there is a fault in the planetary gear or the intermediate plate engaging gear;

[0035] If the target gear is determined to be the first gear and the third gear, the fault prompt information is: there is a fault in the ring gear shaft or the ring gear shaft combined gear.

[0036] In the above solution, the controller is also used for:

[0037] If it is determined that the multi-speed electric drive assembly cannot shift gears, the fault prompt information pushed is: there is a fault in the synchronizer, the shift fork or the synchronizer ring.

[0038] A second aspect of the present invention provides a method for detecting an off-line vehicle of a multi-speed electric drive assembly, which is applied to the off-line detection system described in any one of the first aspects above, and the method comprises:

[0039] Use a low voltage power supply to provide power to the controller;

[0040] Using a high voltage power supply to provide power to a multi-speed electric drive assembly;

[0041] Using a controller to collect signals from sensors in the multi-speed electric drive assembly, and performing electrical inspection on the multi-speed electric drive assembly according to the sensor signals;

[0042] The controller is used to calibrate the initial position of the shift hub, and the shift detection of the multi-speed electric drive assembly is performed according to the collected engine speed.

[0043] In the above solution, the calibration of the initial position of the shift hub includes:

[0044] When the shift motor is controlled to drive the shift hub to rotate to the top dead center, a calibration angle corresponding to the top dead center is received;

[0045] When the shift hub is controlled to rotate forward to the bottom dead center, the corresponding actual shift angle is obtained;

[0046] If it is determined that the difference between the actual shift angle and the theoretical angle of the bottom dead center is greater than a preset angle threshold, adjusting the calibration angle so that the difference is less than or equal to the angle threshold;

[0047] The position corresponding to the adjusted calibration angle is taken as the initial position of the shift hub.

[0048] The present invention provides an offline detection method and system for a multi-speed electric drive assembly, the system comprising: a low-voltage power supply, a high-voltage power supply, a controller and a speed sensor; the low-voltage power supply is used to provide power to the controller; the high-voltage power supply is used to provide power to the multi-speed electric drive assembly; the speed sensor is installed on the engine shaft of the multi-speed electric drive assembly and is used to collect the engine speed; the controller is used to collect signals from each sensor in the multi-speed electric drive assembly and perform electrical inspection on the multi-speed electric drive assembly according to the sensor signals; the initial position of the shift hub is calibrated, and the multi-speed electric drive assembly is subjected to shift detection according to the collected engine speed; in this way, the low-voltage power supply is used to provide power to the controller, and the high-voltage power supply is used to drive the multi-speed electric drive assembly for detection. It only needs to install the speed sensor on the engine shaft to realize the shift test, effectively detect the shift performance of the multi-speed electric drive assembly, and the structure is simple, and the arrangement of the dynamometer and special test equipment is omitted, thereby reducing the detection cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0050] Figure 1 A schematic diagram of the structure of an offline detection system for a multi-speed electric drive assembly provided according to an embodiment of the present invention is shown;

[0051] Figure 2A schematic flow chart of an off-line detection method for a multi-speed electric drive assembly provided according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0052] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0053] The embodiment of the present invention provides a multi-speed electric drive assembly offline detection system, such as Figure 1 As shown, the system includes: a low voltage power supply 1, a high voltage power supply 2, a controller 3 and a speed sensor;

[0054] A low voltage power supply 1, connected to the controller 3, for providing power to the controller 3;

[0055] A high voltage power supply 2, connected to the multi-speed electric drive assembly 4, for providing power to the multi-speed electric drive assembly 4;

[0056] A speed sensor, mounted on the engine shaft of the multi-speed electric drive assembly 4, for collecting the engine speed;

[0057] The controller 3 is used to collect signals from various sensors in the multi-speed electric drive assembly 4, and perform electrical inspection on the multi-speed electric drive assembly according to the sensor signals; calibrate the initial position of the shift hub, and perform shift inspection on the multi-speed electric drive assembly according to the collected engine speed.

[0058] The controller of this embodiment is: Motor Transmission Control Unit (MTCU); the sensors include: oil pressure sensor, oil temperature sensor, shift motor, oil pump motor, resolver connector and motor temperature sensor in addition to the speed sensor. The oil pressure sensor, oil temperature sensor, shift motor, oil pump motor, resolver connector and motor temperature sensor are all arranged in the multi-speed electric drive assembly 4. When the multi-speed electric drive assembly 4 is running, the signals of the above sensors can be collected.

[0059] Continue to refer Figure 1 The system also includes: a host computer 5, which is mainly used to display the detection results, output warning information, and receive some parameters input by the user, and send the parameters to the control 3. For example, the parameters may include: a calibration angle corresponding to the initial position of the shift hub, a duty cycle of the shift motor, etc.

[0060] The controller 3 can perform electrical inspection on the multi-speed electric drive assembly according to the sensor signal; calibrate the initial position of the shift hub, and perform shift inspection on the multi-speed electric drive assembly according to the engine speed.

[0061] Before conducting the electrical inspection, it is necessary to fill the gearbox of the multi-speed electric drive assembly 4 with oil, connect the coolant pipeline, connect the high-voltage power supply 2, the low-voltage power supply 1, the speed sensor, the controller 3 and the host computer 5 in sequence, and then inspect the multi-speed electric drive assembly 4.

[0062] In one embodiment, the host computer 5 performs electrical inspection on the multi-speed electric drive assembly according to the sensor signal, including:

[0063] For any sensor, if it is determined that the signal corresponding to the sensor can be collected, it is determined that the circuit connection corresponding to the sensor is normal;

[0064] If it is determined that the signal corresponding to the sensor cannot be collected, an alarm signal is sent to prompt the staff to check in time.

[0065] When it is confirmed that the electrical inspection of the multi-speed electric drive assembly 4 is normal, it is necessary to calibrate the initial position of the shift hub of the multi-speed electric drive assembly 4, which specifically includes:

[0066] When the shift motor is controlled to drive the shift hub to rotate in the opposite direction to the top dead center, a calibration angle corresponding to the top dead center is received;

[0067] When the shift hub is controlled to rotate forward to the bottom dead center, the corresponding actual shift angle is obtained;

[0068] If it is determined that the difference between the actual shift angle and the theoretical angle of the bottom dead center is greater than a preset angle threshold, adjusting the calibration angle so that the difference is less than or equal to the angle threshold;

[0069] The position corresponding to the adjusted calibration angle is taken as the initial position of the shift hub.

[0070] Specifically, the shift hub rotates 360 degrees, and each gear corresponds to a different angle. If the initial position calibration is inaccurate, it will cause failures during subsequent gear shifting. Therefore, the initial position of the shift hub needs to be calibrated.

[0071] In this embodiment, the shift hub is controlled to rotate mainly by modifying the duty cycle of the shift motor. For example, the duty cycle input enable is first set to 1, and the duty cycle is adjusted to -25%, thereby driving the shift hub to rotate in the opposite direction to the top dead center and then the duty cycle is adjusted to 0. At this time, the calibration angle is written, and the upper computer 5 can receive the calibration angle corresponding to the top dead center. Here, the duty cycle of the shift motor can be adjusted based on the rotation of the shift hub.

[0072] Secondly, the duty cycle of the shift motor is adjusted to 25%, so that the shift hub rotates forward to the bottom dead center, and the corresponding actual shift angle is obtained. If the difference between the actual shift angle and the theoretical angle of the bottom dead center (generally 339°) is greater than the preset angle threshold, the calibration angle is adjusted so that the difference is less than or equal to the angle threshold; the position corresponding to the adjusted calibration angle is used as the initial position of the shift hub. The preset angle threshold is 3 to 5°.

[0073] After the initial position of the shift hub is calibrated, the controller 3 further tests the shifting performance of the multi-speed electric drive assembly 4 .

[0074] This embodiment mainly detects the gear shift of the multi-speed electric drive assembly by the engine speed. Since the multi-speed electric drive assembly 4 is integrated with a generator and a drive motor, the engine is driven to rotate by the rotation of the generator or the drive motor. Therefore, this embodiment can have two gear shift detection methods. One gear shift detection method is to detect by controlling the operation of the generator alone according to the speed ratio of the generator and the engine, which specifically includes:

[0075] Controlling the shift motor to drive the shift hub to rotate to a target gear position, where the target gear position is any gear position of the shift hub;

[0076] Under the target gear of the parallel direct drive mode, the generator and the engine are controlled to rotate to obtain the current speed ratio between the generator and the engine;

[0077] Check whether there is a fault in the target gear based on the current speed ratio.

[0078] The controller 3 detects whether there is a fault in the target gear according to the current speed ratio, including:

[0079] For any target gear, if it is determined that the current speed ratio is inconsistent with the preset speed ratio, it is determined that there is a fault in the target gear.

[0080] Specifically, for the first gear, the calibration angle of the first gear of the shift hub input by the user is received, and the shift motor is controlled by the controller 3 to drive the shift hub to rotate to the first gear of the parallel direct drive mode. The power-on current is set to control the rotation of the drive motor and the engine respectively, and the engine speed is collected using the speed sensor.

[0081] Since the generator and engine input shaft are directly driven in the first and third gears in parallel direct drive mode, the preset speed ratio should be 1:1. For example, in the first gear, the generator speed is 2000r / min and the engine speed is also 2000r / min, then the current speed ratio (generator speed divided by engine speed) is 1:1. At this time, the current speed ratio is consistent with the preset speed ratio, indicating that there is no fault in the first gear.

[0082] In the second and fourth gears, the engine input shaft and the generator are disconnected, and the engine input shaft will rotate slightly against the planetary carrier at a relatively low speed; therefore, if the current speed ratio is very large, it means that there is no fault.

[0083] Another detection method is to control the operation of the drive motor separately and detect the gear shift according to the gear ratio, drive motor speed and wheel side speed ratio, including:

[0084] Controlling the shift motor to drive the shift hub to rotate to a target gear position, where the target gear position is any gear position of the shift hub;

[0085] At the target gear of the parallel direct drive mode, the drive motor is controlled to rotate; the current speed of the engine is determined according to the speed of the drive motor, the wheel side speed ratio and the gear ratio corresponding to the target gear;

[0086] The gear shift detection is performed based on the current speed and the reference engine speed corresponding to the target gear.

[0087] Specifically, for any target gear, the product value of the drive motor speed and the gear ratio is obtained, and the product value is divided by the wheel side speed ratio to obtain the reference engine speed.

[0088] If the current engine speed acquired by the speed sensor is consistent with the reference engine speed, it is determined that there is no fault in the gear shift;

[0089] If the current speed is inconsistent with the reference engine speed, it is determined that a shift failure has occurred.

[0090] For example, since each gear corresponds to a gear ratio and the wheel speed ratio is also fixed, if the drive motor speed is a known value, the reference engine speed corresponding to each gear can be calculated.

[0091] Assuming that the drive motor speed is 2000r / min, in the first gear, the gear ratio is 7.19, and the wheel side speed ratio is 11.659, then the reference engine speed is: 2000rpm*7.19 / 11.659=1233rpm;

[0092] In the second gear, the gear ratio is 5.193, the wheel speed ratio is 11.659, then the reference engine speed is: 2000rpm*5.193 / 11.659=890rpm;

[0093] In the third gear, the gear ratio is 3.516, the wheel speed ratio is 11.659, then the reference engine speed is: 2000rpm*3.516 / 11.659=603rpm;

[0094] In the fourth gear, the gear ratio is 2.54 and the wheel speed ratio is 11.659, so the reference engine speed is: 2000rpm*2.54 / 11.659=435rpm.

[0095] Taking the first gear as an example, if the current engine speed is not 1233rpm, it means that there is a fault in the first gear.

[0096] In one embodiment, if it is determined that there is a fault in the target gear, the controller 3 is also used to push fault prompt information to the upper computer 5 to facilitate R&D personnel to eliminate it in time.

[0097] Specifically, if the target gear is determined to be the first or second gear, the fault prompt information is: there is a fault in the first or second gear gear, the ICE (Internal Combustion Engine) intermediate shaft or the differential;

[0098] If the target gear is determined to be the third or fourth gear, the fault prompt information is: there is a fault in the first and second gears, the EV (Electric Vehicle) intermediate shaft, the drive motor input shaft or the differential;

[0099] If the target gear is determined to be the second gear or the fourth gear, the fault prompt information is: there is a fault in the planetary gear or the intermediate plate engaging gear;

[0100] If the target gear is determined to be the first gear and the third gear, the fault prompt information is: there is a fault in the ring gear shaft or the ring gear shaft combined gear.

[0101] When it is determined that the multi-speed electric drive assembly cannot shift gears, the fault prompt information pushed by the controller 3 is: a fault exists in the synchronizer, the shift fork or the synchronizer ring.

[0102] In this embodiment, the synchronizer includes: a first synchronizer and a second synchronizer; the shift fork includes: a first shift fork and a second shift fork; the first synchronizer and the first shift fork are installed on the gearbox side of the multi-speed electric drive assembly 4, and the second synchronizer and the second shift fork are installed on the generator side of the multi-speed electric drive assembly 4.

[0103] When it is determined that a fault exists, the R&D personnel need to check the multi-speed electric drive assembly 4 according to the fault prompt information.

[0104] The detection system provided in this embodiment utilizes a low-voltage power supply to provide power to the controller, and utilizes a high-voltage power supply to drive the multi-speed electric drive assembly for detection. It only needs to install a speed sensor on the engine shaft to implement the gear shift test, and effectively detect the gear shift performance of the multi-speed electric drive assembly. The structure is simple, and the arrangement of a dynamometer and special test equipment is eliminated, thereby reducing the detection cost.

[0105] Based on the same inventive concept as the above-mentioned embodiment, this embodiment also provides a method for detecting an off-line of a multi-speed electric drive assembly, such as Figure 2 As shown, the method comprises the following steps:

[0106] S210, using a low voltage power supply to provide power to the controller;

[0107] The controller of this embodiment is a motor transmission control unit MTCU, and a low-voltage power supply is connected to the controller to provide power for the controller; wherein the low-voltage power supply can provide a 12V voltage.

[0108] S211, using a high voltage power supply to provide power to a multi-speed electric drive assembly;

[0109] The multi-speed electric drive assembly integrates a drive motor, a gearbox and an engine; a high-voltage power supply is required to power the multi-speed electric drive assembly; the high-voltage power supply can provide a voltage of 350V.

[0110] The multi-speed electric drive assembly integrates an oil pressure sensor, an oil temperature sensor, a shift motor, an oil pump motor, a resolver connector, and a motor temperature sensor, and a speed sensor is also installed on the engine shaft. When the multi-speed electric drive assembly is running, the signals of the above sensors can be collected, and various tests can be performed using the signals of each sensor.

[0111] S212, using a controller to collect signals from sensors in the multi-speed electric drive assembly, and performing an electrical inspection on the multi-speed electric drive assembly according to the sensor signals;

[0112] Before conducting an electrical inspection, it is necessary to fill the gearbox of the multi-speed electric drive assembly with oil, connect the coolant pipeline, connect the high-voltage power supply, low-voltage power supply, speed sensor, controller and host computer in sequence, and then inspect the multi-speed electric drive assembly.

[0113] In one implementation, the host computer performs an electrical inspection on the multi-speed electric drive assembly according to the sensor signal, including:

[0114] For any sensor, if it is determined that the signal corresponding to the sensor can be collected, it is determined that the circuit connection corresponding to the sensor is normal;

[0115] If it is determined that the signal corresponding to the sensor cannot be collected, an alarm signal is sent to prompt the staff to check in time.

[0116] S213, calibrating the initial position of the shift hub, and performing a shift detection on the multi-speed electric drive assembly according to the collected engine speed.

[0117] When the electrical inspection of the multi-speed electric drive assembly is confirmed to be normal, the initial position of the shift hub of the multi-speed electric drive assembly needs to be calibrated, including:

[0118] When the controller is used to control the shift motor to drive the shift hub to rotate in the opposite direction to the top dead center, a calibration angle corresponding to the top dead center is received;

[0119] When the shift hub is controlled to rotate forward to the bottom dead center, the corresponding actual shift angle is obtained;

[0120] If it is determined that the difference between the actual shift angle and the theoretical angle of the bottom dead center is greater than a preset angle threshold, adjusting the calibration angle so that the difference is less than or equal to the angle threshold;

[0121] The position corresponding to the adjusted calibration angle is taken as the initial position of the shift hub.

[0122] Specifically, the shift hub rotates 360 degrees, and each gear corresponds to a different angle. If the initial position calibration is inaccurate, it will cause failures during subsequent gear shifting. Therefore, the initial position of the shift hub needs to be calibrated.

[0123] In this embodiment, the shift hub is controlled to rotate mainly by modifying the duty cycle of the shift motor. For example, the duty cycle input enable is first set to 1, and the duty cycle is adjusted to -25%, thereby driving the shift hub to rotate in the opposite direction to the top dead center and then the duty cycle is adjusted to 0. At this time, the calibration angle is written, and the upper computer can receive the calibration angle corresponding to the top dead center. Here, the duty cycle of the shift motor can be adjusted based on the rotation of the shift hub.

[0124] Secondly, the duty cycle of the shift motor is adjusted to 25%, so that the shift hub rotates forward to the bottom dead center, and the corresponding actual shift angle is obtained. If the difference between the actual shift angle and the theoretical angle of the bottom dead center (generally 339°) is greater than the preset angle threshold, the calibration angle is adjusted so that the difference is less than or equal to the angle threshold; the position corresponding to the adjusted calibration angle is used as the initial position of the shift hub. The preset angle threshold is 3 to 5°.

[0125] After the initial position of the shift hub is calibrated, the controller further tests the shifting performance of the multi-speed electric drive assembly.

[0126] This embodiment mainly detects the gear shift of the multi-speed electric drive assembly by the engine speed. Since the multi-speed electric drive assembly integrates a generator and a drive motor, this embodiment can have two gear shift detection methods. One gear shift detection method is to control the operation of the generator alone and detect according to the speed ratio of the generator and the engine, which specifically includes:

[0127] Controlling the shift motor to drive the shift hub to rotate to a target gear position, where the target gear position is any gear position of the shift hub;

[0128] Under the target gear of the parallel direct drive mode, the generator and the engine are controlled to rotate to obtain the current speed ratio between the generator and the engine;

[0129] Check whether there is a fault in the target gear based on the current speed ratio.

[0130] The controller detects whether there is a fault in the target gear according to the current speed ratio, including:

[0131] For any target gear, if it is determined that the current speed ratio is inconsistent with the preset speed ratio, it is determined that there is a fault in the target gear.

[0132] Specifically, for the first gear, the calibration angle of the first gear of the shift hub input by the user is received, and the shift motor is controlled by the controller to drive the shift hub to rotate to the first gear of the parallel direct drive mode. The power-on current is set to control the rotation of the drive motor and the engine respectively, and the engine speed is collected using the speed sensor.

[0133] Since the generator and engine input shaft are directly driven in the first and third gears in parallel direct drive mode, the preset speed ratio should be 1:1. For example, in the first gear, the generator speed is 2000r / min and the engine speed is also 2000r / min, then the current speed ratio is 1:1. At this time, the current speed ratio is consistent with the preset speed ratio, indicating that there is no fault in the first gear.

[0134] In the second and fourth gears, the engine input shaft and the generator are disconnected, and the engine input shaft will rotate slightly against the planetary carrier at a relatively low speed; therefore, if the current speed ratio is very large, it means that there is no fault.

[0135] Another detection method is to control the operation of the drive motor separately and detect the gear shift according to the gear ratio, drive motor speed and wheel side speed ratio, including:

[0136] For any gear, obtain the product of the drive motor speed and the gear ratio, and divide the product by the wheel speed ratio to obtain the reference engine speed.

[0137] If the current engine speed collected by the speed sensor is consistent with the reference engine speed, it is determined that there is no fault in the gear shift;

[0138] If the current engine speed is inconsistent with the reference engine speed, it is determined that a shift failure occurs.

[0139] For example, since the gear ratio of each gear is fixed and the wheel speed ratio is also fixed, if the drive motor speed is a known value, the reference engine speed corresponding to each gear can be calculated.

[0140] Assuming that the drive motor speed is 2000r / min, in the first gear, the gear ratio is 7.19, and the wheel side speed ratio is 11.659, then the reference engine speed is: 2000rpm*7.19 / 11.659=1233rpm;

[0141] In the second gear, the gear ratio is 5.193, the wheel speed ratio is 11.659, then the reference engine speed is: 2000rpm*5.193 / 11.659=890rpm;

[0142] In the third gear, the gear ratio is 3.516, the wheel speed ratio is 11.659, then the reference engine speed is: 2000rpm*3.516 / 11.659=603rpm

[0143] In the fourth gear, the gear ratio is 2.54, the wheel speed ratio is 11.659, then the reference engine speed is: 2000rpm*2.54 / 11.659=435rpm.

[0144] Taking the first gear as an example, if the current engine speed is not 1233rpm, it means that there is a fault in the first gear.

[0145] In one implementation, if it is determined that a fault exists in the target gear, fault prompt information is pushed to a host computer to facilitate R&D personnel to eliminate it in a timely manner.

[0146] Specifically, if the target gear is determined to be the first or second gear, the fault prompt information is: there is a fault in the first or second gear gear, the ICE intermediate shaft or the differential;

[0147] If the target gear is determined to be the third or fourth gear, the fault prompt information is: there is a fault in the third or fourth gear gear, the EV intermediate shaft, the drive motor input shaft or the differential;

[0148] If the target gear is determined to be the second gear or the fourth gear, the fault prompt information is: there is a fault in the planetary gear or the intermediate plate engaging gear;

[0149] If the target gear is determined to be the first gear and the third gear, the fault prompt information is: there is a fault in the ring gear shaft or the ring gear shaft combined gear.

[0150] When it is determined that the multi-speed electric drive assembly cannot shift gears, the fault prompt information pushed by the controller 3 is: a fault exists in the synchronizer, the shift fork or the synchronizer ring.

[0151] In this embodiment, the synchronizer includes: a first synchronizer and a second synchronizer; the shift fork includes: a first shift fork and a second shift fork; the first synchronizer and the first shift fork are installed on the gearbox side of the multi-speed electric drive assembly, and the second synchronizer and the second shift fork are installed on the generator side of the multi-speed electric drive assembly.

[0152] When a fault is determined, R&D personnel need to troubleshoot the multi-speed electric drive assembly based on the fault prompt information.

[0153] Through one or more embodiments of the present invention, the present invention has the following beneficial effects or advantages:

[0154] The present invention provides a method and system for detecting an off-line device of a multi-speed electric drive assembly. The system comprises: a low-voltage power supply, a high-voltage power supply, a controller and a speed sensor; the low-voltage power supply is used to provide power to the controller; the high-voltage power supply is used to provide power to the multi-speed electric drive assembly; the speed sensor is installed on the engine shaft of the multi-speed electric drive assembly and is used to collect the engine speed; the controller is used to collect signals from various sensors in the multi-speed electric drive assembly and perform electrical inspection on the multi-speed electric drive assembly according to the sensor signals; the initial position of the shift hub is calibrated and the speed sensor is used to collect the signals from various sensors in the multi-speed electric drive assembly and perform electrical inspection on the multi-speed electric drive assembly according to the sensor signals; the initial position of the shift hub is calibrated and the speed sensor is used to collect the signals from various sensors in the multi-speed electric drive assembly and perform electrical inspection on the multi-speed electric drive assembly according to the collected signals; ... The engine speed is collected to perform gear shift detection on the multi-speed electric drive assembly; in this way, a low-voltage power supply is used to provide power to the controller, and a high-voltage power supply is used to drive the multi-speed electric drive assembly for detection. It is only necessary to install a speed sensor on the engine shaft to realize the gear shift test, and the shift performance of the multi-speed electric drive assembly can be effectively detected. The structure is simple, and the arrangement of a dynamometer and special test equipment is omitted, thereby reducing the detection cost. Compared with the method of installing various test equipment in bench tests, the present application only needs to install a speed sensor on the engine shaft, and the detection process is also relatively convenient, and the detection efficiency can be effectively improved.

[0155] The algorithm and display provided herein are not inherently related to any particular computer, virtual system or other device. Various general purpose systems can also be used together with the teachings based on this. According to the above description, it is obvious that the structure required for constructing such systems. In addition, the present invention is not directed to any specific programming language either. It should be understood that various programming languages ​​can be utilized to realize the content of the present invention described herein, and the description of the above specific languages ​​is for disclosing the best mode of the present invention.

[0156] In the description provided herein, a large number of specific details are described. However, it is understood that embodiments of the present invention can be practiced without these specific details. In some instances, well-known methods, structures and techniques are not shown in detail so as not to obscure the understanding of this description.

[0157] Similarly, it should be understood that in order to streamline the present disclosure and aid in understanding one or more of the various inventive aspects, in the above description of exemplary embodiments of the present invention, various features of the present invention are sometimes grouped together into a single embodiment, figure, or description thereof. However, this disclosed method should not be interpreted as reflecting the intention that the claimed invention requires more features than those explicitly recited in each claim. More specifically, as reflected in the claims below, inventive aspects lie in less than all the features of the individual embodiments disclosed above. Therefore, the claims that follow the specific embodiment are hereby expressly incorporated into the specific embodiment, with each claim itself serving as a separate embodiment of the present invention.

[0158] Those skilled in the art will appreciate that the modules in the devices in the embodiments may be adaptively changed and arranged in one or more devices different from the embodiments. The modules or units or components in the embodiments may be combined into one module or unit or component, and in addition they may be divided into a plurality of submodules or subunits or subcomponents. Except that at least some of such features and / or processes or units are mutually exclusive, all features disclosed in this specification (including the accompanying claims, abstracts and drawings) and all processes or units of any method or device disclosed in this manner may be combined in any combination. Unless otherwise expressly stated, each feature disclosed in this specification (including the accompanying claims, abstracts and drawings) may be replaced by an alternative feature providing the same, equivalent or similar purpose.

[0159] In addition, those skilled in the art will appreciate that, although some embodiments herein include certain features included in other embodiments but not other features, the combination of features of different embodiments is meant to be within the scope of the present invention and form different embodiments. For example, in the claims below, any one of the claimed embodiments may be used in any combination.

[0160] The various component embodiments of the present invention can be implemented in hardware, or in software modules running on one or more processors, or in a combination thereof. It should be understood by those skilled in the art that a microprocessor or digital signal processor (DSP) can be used in practice to implement some or all functions of some or all components in a gateway, proxy server, or system according to an embodiment of the present invention. The present invention can also be implemented as a device or apparatus program (e.g., a computer program and a computer program product) for executing part or all of the methods described herein. Such a program implementing the present invention can be stored on a computer-readable medium, or can have the form of one or more signals. Such a signal can be downloaded from an Internet website, or provided on a carrier signal, or provided in any other form.

[0161] It should be noted that the above embodiments illustrate the present invention rather than limit it, and that those skilled in the art may devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference symbol between brackets shall not be construed as a limitation on the claims. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "one" or "an" preceding an element does not exclude the presence of a plurality of such elements. The present invention may be implemented by means of hardware comprising a number of different elements and by means of a suitably programmed computer. In a unit claim enumerating a number of devices, several of these devices may be embodied by the same hardware item. The use of the words first, second, and third, etc., does not indicate any order. These words may be interpreted as names.

[0162] Although the preferred embodiments of the present application have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the present application.

[0163] The above description is only a preferred embodiment of the present invention and is not intended to limit the protection scope of the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A multi-speed electric drive assembly offline detection system, characterized in that: The system comprises: Low voltage power supply, high voltage power supply, controller and speed sensor; The low-voltage power supply is used to provide power to the controller; The high voltage power supply is used to provide power for the multi-speed electric drive assembly; The speed sensor is mounted on the engine shaft of the multi-speed electric drive assembly and is used to collect the engine speed; The controller is used to collect signals from sensors in the multi-speed electric drive assembly, and perform electrical inspection on the multi-speed electric drive assembly according to the sensor signals; calibrate the initial position of the shift hub, and perform shift inspection on the multi-speed electric drive assembly according to the collected engine speed; wherein, The controller performs shift detection on the multi-speed electric drive assembly according to the collected engine speed, including: Controlling the shift motor to drive the shift hub to rotate to a target gear position, wherein the target gear position is any gear position of the shift hub; At a target gear position of the parallel direct drive mode, controlling the generator to rotate to obtain a current speed ratio between the generator and the engine; detecting whether there is a fault in the target gear according to the current speed ratio; The controller is also used for: When performing the gear shift detection, for any target gear, if it is determined that the current speed ratio is inconsistent with the preset speed ratio, it is determined that there is a fault in the target gear; If it is determined that there is a fault in the target gear, the fault prompt information is pushed to the upper computer; If it is determined that the target gear is the first gear or the second gear, the fault prompt information is: there is a fault in the first and second gear gears, the ICE intermediate shaft or the differential; If it is determined that the target gear is the third gear or the fourth gear, the fault prompt information is: there is a fault in the third and fourth gear gears, the EV intermediate shaft, the drive motor input shaft or the differential; If it is determined that the target gear is the second gear or the fourth gear, the fault prompt information is: there is a fault in the planetary gear or the intermediate plate engaging gear; If the target gear is determined to be the first gear and the third gear, the fault prompt information is: there is a fault in the ring gear shaft or the ring gear shaft combined gear.

2. The system according to claim 1, characterized in that The sensors include: an oil pressure sensor, an oil temperature sensor, a shift motor, an oil pump motor, a resolver connector and a motor temperature sensor.

3. The system according to claim 1, characterized in that The system further includes: a host computer, wherein the controller performs electrical inspection on the multi-speed electric drive assembly according to the sensor signal, including: For any sensor, if it is determined that a signal corresponding to the sensor can be collected, it is determined that the circuit connection corresponding to the sensor is normal; If it is determined that the signal corresponding to the sensor cannot be collected, an alarm prompt signal is sent to the host computer.

4. The system according to claim 1, characterized in that The controller calibrates the initial position of the shift hub, including: When the shift motor is controlled to drive the shift hub to rotate in the opposite direction to the top dead center, a calibration angle corresponding to the top dead center is received; When the shift hub is controlled to rotate forward to the bottom dead center, a corresponding actual shift angle is obtained; If it is determined that the difference between the actual shift angle and the theoretical angle of the bottom dead center is greater than a preset angle threshold, adjusting the calibration angle so that the difference is less than or equal to the angle threshold; The position corresponding to the adjusted calibration angle is taken as the initial position of the shift hub.

5. The system according to claim 1, wherein: The controller is also used for: If it is determined that the multi-speed electric drive assembly cannot shift gears, the fault prompt information pushed is: there is a fault in the synchronizer, the shift fork or the synchronizer ring.

6. A method for detecting the off-line of a multi-speed electric drive assembly, characterized in that: Applied in the offline detection system according to any one of claims 1 to 5 above, the method comprises: Use a low voltage power supply to provide power to the controller; Using a high voltage power supply to provide power to a multi-speed electric drive assembly; Using a controller to collect signals from sensors in the multi-speed electric drive assembly, and performing electrical inspection on the multi-speed electric drive assembly according to the sensor signals; The controller is used to calibrate the initial position of the shift hub, and the multi-speed electric drive assembly is tested for shifting according to the collected engine speed; wherein, The gear shift detection of the multi-speed electric drive assembly is performed according to the collected engine speed, including: Controlling the shift motor to drive the shift hub to rotate to a target gear position, wherein the target gear position is any gear position of the shift hub; At a target gear position of the parallel direct drive mode, controlling the generator to rotate to obtain a current speed ratio between the generator and the engine; detecting whether there is a fault in the target gear according to the current speed ratio; When performing the gear shift detection, for any target gear, if it is determined that the current speed ratio is inconsistent with the preset speed ratio, it is determined that there is a fault in the target gear; If it is determined that there is a fault in the target gear, the fault prompt information is pushed to the upper computer; If it is determined that the target gear is the first gear or the second gear, the fault prompt information is: there is a fault in the first and second gear gears, the ICE intermediate shaft or the differential; If it is determined that the target gear is the third gear or the fourth gear, the fault prompt information is: there is a fault in the third and fourth gear gears, the EV intermediate shaft, the drive motor input shaft or the differential; If it is determined that the target gear is the second gear or the fourth gear, the fault prompt information is: there is a fault in the planetary gear or the intermediate plate engaging gear; If the target gear is determined to be the first gear and the third gear, the fault prompt information is: there is a fault in the ring gear shaft or the ring gear shaft combined gear.

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