A Load-carrying Vibration Testing Device and Method for a Main Drive Motor Controller

Abstract

The present invention discloses a load-bearing vibration test device and method for a main drive motor controller. Vibration under set conditions is applied successively in the X, Y, and Z directions of a vibration test bench. According to the different movement modes at both ends of the resolver harness, the lighting conditions of the indicator lights of the resolver signal jump monitoring module are observed respectively, and based on the lighting conditions of the indicator lights, it is determined whether the vibration resistance performance of the main drive motor controller, the resolver harness, the resolver signal interface at the controller end, and the resolver signal interface at the motor end meets the standards. The present invention uses a DC power supply to supply power for the load-bearing vibration test of the main drive motor controller, and at the same time sets up a resolver signal jump monitoring module to monitor whether the vibration resistance performance of the main drive motor controller meets the standards during the vibration test. The test device is simple, easy to implement, has high safety during the test process, and high accuracy of the test results.

Description

Technical Field

[0001] The present invention belongs to the technical field of automobiles, and particularly relates to a load-carrying vibration test device and method for a main drive motor controller. Background Art

[0002] As a high-voltage and high-power component, the main drive motor controller uses weak electrical signals to control strong electrical signals. The reliability of the internal signal connection of the controller directly affects whether the controller can operate normally. Poor contact of some low-voltage signals will cause the three-phase current of the main drive motor controller to get out of control, trigger overcurrent fault shutdown or controller explosion, and thus lead to unexpected driving safety problems. Signals that have a greater impact on the reliable operation of the controller include rotor position sensor (resolver transformer) signals, Hall current sensor signals, PWM wave signals from the main control board to the drive board, and IGBT gate drive signals from the drive circuit board. The reliability of the internal signal connection of the controller needs to check not only the reliability of the connection in the static state, but also the reliability of the signal connection under the vibration caused by vehicle operation.

[0003] For checking the reliability of the signal connection of the main drive motor controller, currently the following two test schemes are mainly adopted:

[0004] Scheme 1: During the vibration test, the main drive motor controller is placed on the vibration table, disconnected from the external high-voltage power supply and the load, and does not operate. After the vibration test is completed, an electrical connection test is carried out on the tested main drive motor controller, and it is powered on and run to see whether the controller can operate normally.

[0005] Scheme 2: During the vibration test, the main drive motor controller is placed on the vibration table, connected to the high-voltage power supply and the load, and runs with a light load. The high-voltage power supply and the load are not on the vibration table. The high-voltage power supply simulates the output characteristics of the vehicle power battery system, and the load is the vehicle main drive motor. During the vibration test, observe the bus voltage / current, three-phase voltage / current to see whether the controller can operate normally with a light load.

[0006] The existing technical schemes have the following disadvantages:

[0007] Scheme 1: Since the main drive motor controller does not run with a load during the vibration test, after the vibration test is completed, the electrical connection is reset, and static inspection and operation are carried out, which cannot truly simulate the influence of vibration on the reliability of the signal connection inside the main drive motor controller during vehicle operation, and it is also impossible to check whether the potential weak points in the electrical signal connection inside the controller are in the position signal or the current signal.

[0008] Scheme 2: During the vibration test, if there are poor contacts of resolver signals, Hall signals, IGBT drive signals, etc. caused by vibration, it will cause the phase current of the main drive motor to get out of control, resulting in a risk of controller explosion. In the lightest case, it will cause damage to the controller, and in the worst case, it will cause damage to the vibration test bench. Summary of the Invention

[0009] The purpose of the present invention is to solve the deficiencies existing in the above-mentioned background technology, and to provide a load-carrying vibration test device and method for a main drive motor controller.

[0010] The technical solution adopted by the present invention is: a load-carrying vibration test device for a main drive motor controller, including a DC power supply, a vibration test bench, a main drive motor controller, a resolver signal jump monitoring module, a three-phase AC motor, and a voltage and current monitoring module. The main drive motor controller is fixed on the vibration test bench. The input end of the main drive motor controller is connected to the DC power supply, and the three-phase output end is connected to the three-phase AC motor. The resolver signal jump monitoring port of the main drive motor controller is connected to the input end of the resolver signal jump monitoring module. A resolver harness is connected between the resolver of the main drive motor controller and the three-phase AC motor. The middle of the resolver harness, the resolver signal interface at the main drive motor controller end connecting the resolver harness, and the resolver signal interface at the three-phase AC motor end are all fixed on the vibration test bench. The voltage and current monitoring module monitors the bus voltage and current and the three-phase voltage and current of the main drive motor controller during the vibration test.

[0011] Further, the resolver signal jump monitoring module includes a low-voltage power supply, an indicator light, and a switch connected in series in sequence. The control end of the switch is connected to the resolver signal jump monitoring port of the main drive motor controller.

[0012] Further, the voltage and current monitoring module includes a first monitoring module and a second monitoring module. The input end of the first monitoring module is connected to the input end of the main drive motor controller, and is used to monitor the bus voltage and bus current of the main drive motor controller during the vibration test. The input end of the second monitoring module is connected to the three-phase output end of the main drive motor controller, and is used to monitor the three-phase voltage and three-phase current of the main drive motor controller during the vibration test.

[0013] Even further, it further includes a short-circuit protection circuit, and the short-circuit protection circuit is connected between the DC power supply and the input end of the main drive motor controller.

[0014] A test method based on the above-mentioned load-carrying vibration test device for a main drive motor controller applies vibrations under set conditions in the X, Y, and Z directions of the vibration test bench. According to the different movement modes of both ends of the resolver harness, observe the lighting conditions of the indicator light of the resolver signal jump monitoring module respectively, and judge whether the vibration resistance performance of the main drive motor controller, the resolver harness, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end meets the standards based on the lighting conditions of the indicator light.

[0015] Further, the lighting conditions of the indicator light include always on, flashing, and always off.

[0016] Furthermore, when the following conditions are met, it is determined that the vibration resistance performance of the main drive motor controller, resolver harness, resolver signal interface at the main drive motor controller end, and resolver signal interface at the three-phase AC motor end all meet the standards:

[0017] There is relative movement between both ends of the resolver harness and the vibration test bench, and the indicator light remains off throughout the test cycle.

[0018] Furthermore, when the following conditions are simultaneously met, it is determined that the vibration resistance performance of the main drive motor controller meets the standards, while the vibration resistance performance of the resolver harness, resolver signal interface at the main drive motor controller end, and resolver signal interface at the three-phase AC motor end do not meet the standards:

[0019] A. There is relative movement between both ends of the resolver harness and the vibration test bench, and the indicator light is constantly on or flashing during the test cycle;

[0020] B. Both ends of the resolver harness vibrate together with the vibration test bench, and the indicator light remains off throughout the test cycle.

[0021] Furthermore, when the following conditions are simultaneously met, it is determined that the vibration resistance performance of the main drive motor controller, resolver harness, resolver signal interface at the main drive motor controller end, and resolver signal interface at the three-phase AC motor end all do not meet the standards:

[0022] A. There is relative movement between both ends of the resolver harness and the vibration test bench, and the indicator light is constantly on or flashing during the test cycle;

[0023] B. Both ends of the resolver harness vibrate together with the vibration test bench, and the indicator light is constantly on or flashing during the test cycle.

[0024] Even further, during the vibration test process, if any mutation or abnormality occurs in the bus voltage waveform or three-phase voltage waveform of the main drive motor controller, the vibration resistance performance of the voltage signal of the main drive motor controller does not meet the standards; if any mutation or abnormality occurs in the bus current waveform or three-phase current waveform of the main drive motor controller, the vibration resistance performance of the current signal of the main drive motor controller does not meet the standards.

[0025] The beneficial effects of the present invention are as follows:

[0026] The present invention uses a DC power supply to supply power for the load-bearing vibration test of the main drive motor controller, and simultaneously sets a resolver signal jump monitoring module to monitor whether the vibration resistance performance of the main drive motor controller meets the standards during the vibration test. The test device is simple, easy to implement, has high safety during the test process, and high accuracy of the test results.

[0027] The present invention provides a short - circuit protection circuit at the input end of the main drive motor controller, which can avoid the occurrence of loop short - circuit or current out - of - control phenomena during the test of the drive motor controller, thereby preventing the short - circuit of the high - voltage DC bus loop and further ensuring the safety during the load - carrying vibration test. Brief Description of the Drawings

[0028] Figure 1 It is a schematic diagram of the principle of the test device of the present invention.

[0029] Figure 2 It is a schematic diagram of a normal three - phase current waveform. Detailed Embodiments

[0030] The following further describes the detailed embodiments of the present invention in conjunction with the drawings. It should be noted here that the description of these embodiments is used to help understand the present invention, but does not constitute a limitation to the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0031] As Figure 1 shown, the present invention provides a load - carrying vibration test device for a main drive motor controller, including a DC power supply 101, a vibration test bench 103, a main drive motor controller 106, a resolver signal jump monitoring module 105, a three - phase AC motor 112, and a voltage - current monitoring module. The vibration test bench meets the sweep - frequency vibration excitation requirements of GB / T18488.1. The resolver signal jump monitoring module is used to determine whether the resolver signal is in good contact during the vibration test. The main drive motor controller 106 is fixed on the vibration test bench 103. The input end of the main drive motor controller 106 is connected to the DC power supply, and the three - phase output end is connected to the three - phase AC motor 112. The resolver signal jump monitoring port 107 of the main drive motor controller is connected to the input end of the resolver signal jump monitoring module 105. Whether the resolver signal jumps determines the high or low level of the DO output of the resolver signal jump monitoring port, thereby controlling the on or off of the indicator light in the resolver signal jump monitoring module. The resolver between the main drive motor controller and the three - phase AC motor is connected through a resolver harness 109. Plug connectors are respectively provided at both ends of the resolver harness, which are respectively plugged and connected to the resolver signal interface 108 at the main drive motor controller end and the resolver signal interface 110 at the three - phase AC motor end to realize the connection between the resolver of the main drive motor controller. The voltage - current monitoring module monitors the bus voltage and current and three - phase voltage and current of the main drive motor controller during the vibration test.

[0032] In the above solution, the main drive motor controller 106, the resolver harness 109, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end are all installed and fixed on the vibration test bench together. The installation and layout direction is consistent with the actual vehicle layout. The Z direction of the main drive motor controller is parallel to the vertical direction of the vehicle, and the rest of the components are placed outside the vibration test bench.

[0033] There are two different fixing methods for both ends of the resolver harness according to the test requirements: ① Only place 1 - 2 fixing points at the middle position of the resolver harness 109, so that the connectors at both ends of 109 have relative movement with the main drive motor controller and the vibration table; ② In addition to placing fixing points at the middle part of 109, place one or more fixing points at positions within 150 mm from the resolver signal interface 108 at the main drive motor controller end and the resolver signal interface 110 at the three-phase AC motor end of the resolver harness 109 respectively, so that the connectors at both ends of the resolver harness 109 vibrate together with the main drive motor controller and the vibration table, minimizing relative movement as much as possible.

[0034] In the above solution, the DC power supply is a DC power supply with adjustable voltage. To ensure safety, the output voltage should not be too high or too low. Therefore, it is preferably set at 200 - 220 VDC.

[0035] In the above solution, to ensure the effectiveness of current signal monitoring, considering the range of the three-phase Hall current sensor of the main drive motor controller, the rated current of the load three-phase motor 112 should be not less than 15 - 20 A, and the rated power is 8 - 10 kW.

[0036] In the above solution, the resolver signal jump monitoring module 105 includes a low-voltage power supply, an indicator light, and a switch connected in series in sequence. The control end of the switch is connected to the resolver signal jump monitoring port of the main drive motor controller, and the switch is generally a relay.

[0037] In the above solution, the voltage and current monitoring module includes a first monitoring module 104 and a second monitoring module 111. The input end of the first monitoring module is connected to the input end of the main drive motor controller, and is used to monitor the bus voltage and bus current of the main drive motor controller during the vibration test; the input end of the second monitoring module is connected to the three-phase output end of the main drive motor controller, and is used to monitor the three-phase voltage and three-phase current of the main drive motor controller during the vibration test. Both the first monitoring module and the second monitoring module are oscilloscopes.

[0038] In the above solution, to ensure safety during the load-bearing vibration test and avoid short circuits or current out-of-control phenomena in the high-voltage circuit caused by vibration, necessary protection measures need to be adopted. The present invention sets up a short-circuit protection circuit 102, which is connected between the DC power supply and the input end of the main drive motor controller. The short-circuit protection circuit selects two 1000W / 48.4Ω quartz lamps in parallel. When a short-circuit fault occurs during the vibration test, the DC voltage is applied to the 24Ω resistor, and there will be no risk of power supply short circuit.

[0039] Based on the above load-bearing vibration test device for the main drive motor controller, the present invention also provides a load-bearing vibration test method for the main drive motor controller. Vibrations under set conditions are applied sequentially in the X, Y, and Z directions of the vibration test bench. According to the different fixed / moving modes at both ends of the resolver harness, the lighting conditions of the indicator lights of the resolver signal jump monitoring module are observed respectively, and based on the lighting conditions of the indicator lights, it is judged whether the vibration resistance performance of the main drive motor controller, the resolver harness, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end meets the standards.

[0040] Vibration excitation requirements: Apply the amplitudes and vibration accelerations specified in Table 1 in the X, Y, and Z directions, and one test cycle for each direction is 2h.

[0041] Table 1 Vibration excitation requirements for the sweep-frequency vibration test

[0042]

[0043] Test requirements: After one test cycle is completed, if there is no signal contact failure, continue to the next test cycle until a signal contact failure and its corresponding vibration frequency are detected, or no contact failure occurs in 4 consecutive test cycles. It is considered that the tested main drive motor controller passes the vibration test. Separate tests need to be carried out for the two fixed modes at both ends of the resolver harness.

[0044] Vibration resistance test and monitoring of current / voltage signal lines: The three-phase current output by the main drive motor controller is as Figure 2 shown. A stepped constant-current controller is adopted, and the current output frequency is not less than 50Hz, and the current amplitude I0 is 10A. Voltage and current detection points are set at P0, P1, P2, P3, and P4 to detect the bus voltage U d , bus current I d , three-phase voltage U A / U B / U C , three-phase current I A / I B / I C . Among them:

[0045] U d =UP1 -U P0

[0046] U A = U P2 -U P0

[0047] U B = U P3 -U P0

[0048] U C = U P4 -U P0

[0049] I d = I P1

[0050] I A = I P2

[0051] I B = I P3

[0052] I C = I P4

[0053] Current / Voltage Signal Line Vibration Resistance Judgment: If during the vibration test, there are sudden changes or abnormalities in the bus voltage / current waveform and the three-phase voltage waveform (i.e., inconsistent with the set waveform), and the three-phase current signal is inconsistent with Figure 2 the waveform, then the vibration resistance performance of the current / voltage signal does not meet the standard.

[0054] Resolver Signal Line Vibration Resistance Test and Monitoring: After the resolver signal of the drive motor is analyzed, it is a continuously cycling and jumping digital signal. To monitor whether the resolver signal is instantaneously interrupted or has poor contact during vibration, the resolver needs to be fixed at a certain angle. After analysis, the resolver signal is a fixed value. When there is an instantaneous interruption or poor contact in the resolver signal, the value of the analyzed resolver signal will jump. Monitor the value jump through a triggering method, that is, when detecting the value jump corresponding to the resolver angle, output a high level through the DO pin to light up the external monitoring lamp; when the monitoring lamp is lit after detecting the resolver position jump, and the resolver position does not jump for 1 s, then reset the DO pin.

[0055] Resolver signal line vibration resistance determination: If the indicator light of 105 flashes during the vibration test, it indicates that there is an instantaneous break in the resolver signal during vibration; if the indicator light of 105 remains on during the vibration test, it indicates that there is a poor contact with a duration exceeding 1 s in the resolver signal during vibration. The above two situations indicate that the vibration resistance performance of the resolver signal line does not meet the standard. According to whether the resolver wire harness within 150 mm from the resolver interface 108 at the main drive motor controller end and the resolver signal interface 110 at the three-phase AC motor end is fixed, there are several determination conclusions listed in Table 2.

[0056] Table 2 Resolver Signal Vibration Resistance Determination

[0057]

[0058] The present invention can be applied to the load-bearing vibration test of the motor controller of medium-sized sanitation vehicles, and is used to investigate the triggering reasons for the "phase current overcurrent hardware protection" fault of the drive motor controller of customer vehicles in the market. By testing, it is possible to check whether there is an instantaneous break or poor contact in the resolver signal line during the vehicle operation, thereby causing the main drive motor controller to report the "phase current overcurrent hardware protection" fault.

[0059] The present invention is also applied to the load-bearing vibration test of the motor controller of heavy-duty tractors and heavy-duty engineering vehicles, and is used for the connection reliability test and verification of signals such as the rotor position sensor (resolver transformer) signal, Hall current sensor signal, PWM wave signal from the main control board to the drive board, and drive circuit board to IGBT gate drive signal of the motor controller, so as to eliminate potential risks.

[0060] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered by the protection scope of the present invention. The content not detailedly described in this specification belongs to the prior art well-known to those skilled in the art.

Claims

1. A load-carrying vibration test device for a main drive motor controller, characterized in that: It includes a DC power supply, a vibration test bench, a main drive motor controller, a resolver signal jump monitoring module, a three-phase AC motor, and a voltage and current monitoring module. The main drive motor controller is fixed on the vibration test bench. The input end of the main drive motor controller is connected to the DC power supply, and the three-phase output end is connected to the three-phase AC motor. The resolver signal jump monitoring port of the main drive motor controller is connected to the input end of the resolver signal jump monitoring module. A resolver harness is connected between the resolver of the main drive motor controller and the three-phase AC motor. The middle of the resolver harness, the resolver signal interface at the main drive motor controller end connecting the resolver harness, and the resolver signal interface at the three-phase AC motor end are all fixed on the vibration test bench. The voltage and current monitoring module monitors the bus voltage and current and the three-phase voltage and current of the main drive motor controller during the vibration test; There are two different fixing methods for both ends of the resolver harness according to the experimental test requirements: ① Only 1 to 2 fixing points are placed in the middle position of the resolver harness, and the connectors at both ends of the resolver harness have relative movement with the main drive motor controller and the vibration table; ② Fixing points are placed in the middle part of the resolver harness, and one or more fixing points are placed within 150 mm from the resolver signal interface at the main drive motor controller end and the resolver signal interface at the three-phase AC motor end at both ends of the resolver harness respectively. The connectors at both ends of the resolver harness vibrate together with the main drive motor controller and the vibration table.

2. The load-carrying vibration test device for the main drive motor controller according to claim 1, wherein: The resolver signal jump monitoring module includes a low-voltage power supply, an indicator light, and a switch connected in series in sequence. The control end of the switch is connected to the resolver signal jump monitoring port of the main drive motor controller.

3. The on-load vibration test device for the main drive motor controller according to claim 1, wherein: The voltage and current monitoring module includes a first monitoring module and a second monitoring module. The input end of the first monitoring module is connected to the input end of the main drive motor controller and is used to monitor the bus voltage and bus current of the main drive motor controller during the vibration test; the input end of the second monitoring module is connected to the three-phase output end of the main drive motor controller and is used to monitor the three-phase voltage and three-phase current of the main drive motor controller during the vibration test.

4. The load-carrying vibration test device for the main drive motor controller according to claim 1, characterized in that: It also includes a short-circuit protection circuit, and the short-circuit protection circuit is connected between the DC power supply and the input end of the main drive motor controller.

5. A test method for the on-load vibration test device of the main drive motor controller according to claim 1, characterized in that: Vibrations under set conditions are applied in the X, Y, and Z directions of the vibration test bench. According to the different movement modes of both ends of the resolver harness, the lighting conditions of the indicator light of the resolver signal jump monitoring module are observed respectively, and based on the lighting conditions of the indicator light, it is judged whether the vibration resistance performance of the main drive motor controller, the resolver harness, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end meets the standards.

6. The test method according to claim 5, characterized in that: The lighting conditions of the indicator light include being constantly on, flashing, and being constantly off.

7. The testing method according to claim 5, characterized in that: When the following conditions are met, it is judged that the vibration resistance performance of the main drive motor controller, the resolver harness, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end all meet the standards: Both ends of the resolver harness have relative movement with the vibration test bench and the indicator light is constantly off during the test cycle.

8. The test method according to claim 5, characterized in that: When the following conditions are met simultaneously, it is determined that the vibration resistance performance of the main drive motor controller meets the standard, while the vibration resistance performance of the resolver harness, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end does not meet the standard: A. There is relative movement between both ends of the resolver harness and the vibration test bench, and the indicator light remains on or flashes during the test cycle; B. Both ends of the resolver harness vibrate together with the vibration test bench, and the indicator light is always off during the test cycle.

9. The test method according to claim 5, characterized in that: When the following conditions are met simultaneously, it is determined that the vibration resistance performance of the main drive motor controller, the resolver harness, the resolver signal interface at the main drive motor controller end, and the resolver signal interface at the three-phase AC motor end all do not meet the standard: A. There is relative movement between both ends of the resolver harness and the vibration test bench, and the indicator light remains on or flashes during the test cycle; B. Both ends of the resolver harness vibrate together with the vibration test bench, and the indicator light remains on or flashes during the test cycle.

10. The testing method according to claim 5, wherein: During the vibration test process, if any one of the bus voltage waveform and three-phase voltage waveform of the main drive motor controller shows a sudden change or abnormality, the vibration resistance performance of the voltage signal of the main drive motor controller does not meet the standard; if any one of the bus current waveform and three-phase current waveform of the main drive motor controller shows a sudden change or abnormality, the vibration resistance performance of the current signal of the main drive motor controller does not meet the standard.

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