A detection system for electric vehicle electronic control assembly

Abstract

The present invention discloses a detection system for an electric vehicle electric control assembly, including a test loop, a workstation cabinet, a pallet, a stereoscopic warehouse, a transfer device, and a control system. The electric control assembly to be detected is supported and installed on the pallet, and the pallet is automatically transported and circulated on the test loop. The workstation cabinet and the stereoscopic warehouse are used for the detection of the electric control assembly. The workstation cabinet and the stereoscopic warehouse are connected to the test loop. The pallet can be automatically transferred between the test loop and the workstation cabinet and between the test loop and the stereoscopic warehouse through the transfer device. The workstation cabinet and the stereoscopic warehouse fix and position the pallet and the test equipment at the workstation cabinet and the stereoscopic warehouse, and automatically connect the electric control assembly and the test equipment. The present invention has a high degree of automation, improves the detection efficiency and detection accuracy, and can automatically complete multiple detections of the electric control assembly. The pallet drives the electric control assembly to circulate on the test loop, which is convenient for the detection of the electric control assembly at different test stations, the management and control of the detection items, and there is no need to repeatedly connect the electric control assembly and the test equipment, thereby reducing the plug-in error rate.

Description

Technical Field

[0001] The invention belongs to the technical field of electric control assembly detection or verification, and in particular relates to a detection system for an electric control assembly of an electric vehicle. Background Art

[0002] The electric control assembly of electric vehicles needs to be tested and verified before leaving the factory, such as testing its safety and calibrating the sensor. However, many current detection systems and methods still rely heavily on manual labor, with poor automation, low detection efficiency, and easy to miss detection. In addition, the three-phase Hall current sensor needs to be calibrated when the electric control assembly of an electric vehicle is tested as a whole machine. The electric control assembly of an electric vehicle usually adopts a three-phase voltage-type bridge inverter circuit and uses IGBT (insulated gate bipolar transistor) as a switching device. The basic working mode of the three-phase voltage-type bridge inverter circuit is a 180° conduction mode, that is, the conduction angle of each bridge arm is 180°, and the upper and lower arms of the same phase (that is, the same half bridge) conduct alternately, and the angles at which each phase starts to conduct differ by 120°. At any moment, three bridge arms are turned on at the same time, and each commutation is carried out between the upper and lower arms of the same phase, which is called longitudinal commutation. Among them, the current sensor is on the output line of each phase. At present, the calibration of the three-phase Hall current sensor of the electric control assembly of an electric vehicle usually adopts a method of directly detecting by simulating actual working conditions. However, due to the characteristics of the three-phase voltage-type bridge circuit, the three-phase output voltage is a PWM (pulse width modulation) rectangular wave, the current waveform varies depending on the load, and a certain dead time needs to be reserved when the IGBT is turned on and off, which makes the output current quality not high, the waveform is not smooth enough, there are large errors and time lags, and the three-phase Hall current sensor of the electronic control assembly cannot be accurately and scientifically calibrated, which may affect the normal operation of the electronic control assembly. In other words, the calibration effect of the three-phase Hall current sensor of the electric control assembly of electric vehicles is greatly affected by IGBT and the accuracy is not high. In addition, there are multiple interfaces on the electric control assembly of electric vehicles. In order to efficiently detect and calibrate the electric control assembly and reduce errors caused by human factors during the detection process, it is required to accurately, efficiently and stably connect the multiple interfaces on the electric control assembly to the test equipment. Summary of the invention

[0003] In view of the above-mentioned problems existing in the prior art, the purpose of the present invention is to provide a detection system for the electronic control assembly of an electric vehicle, which has a high degree of automation, improved detection efficiency, and high detection accuracy, and can automatically complete the detection of multiple items on the product. The tray can support and drive the electronic control assembly to flow on the test line, which is convenient for the connection and detection of the electronic control assembly at different test stations, and is convenient for the management and control of the detection items. There is no need to repeatedly connect the electronic control assembly and the test equipment, which reduces the connection frequency of the electronic control assembly and the test equipment. The interfaces are basically fixed and unchanged, which reduces the plug-in error rate.

[0004] In order to achieve the above object, the technical solution adopted by the present invention is:

[0005] A detection system for an electric vehicle electric control assembly comprises a test loop, a workstation cabinet, a pallet, a stereoscopic warehouse, a transfer device, and a control system. The electric control assembly to be detected is supported and mounted on the pallet, which is automatically transported and circulated on the test loop. The workstation cabinet and the stereoscopic warehouse are used for detecting the electric control assembly. The workstation cabinet and the stereoscopic warehouse are connected to the test loop. The pallet can be automatically transferred between the test loop and the workstation cabinet and between the test loop and the stereoscopic warehouse through the transfer device. The workstation cabinet and the stereoscopic warehouse fix and position the pallet and the test equipment at the workstation cabinet and the stereoscopic warehouse, and automatically connect the electric control assembly and the test equipment to form a test loop.

[0006] As a further improvement of the above technical solution:

[0007] Preferably, there are multiple workstation cabinets and at least one stereoscopic warehouse, different workstation cabinets perform different types of inspections on the electric control assembly, and the workstation cabinets and stereoscopic warehouse are arranged at intervals along the transmission direction of the test loop.

[0008] Preferably, the test loop is provided with a product loading point, a qualified product unloading point and an unqualified product unloading point. The pallet equipped with the electronic control assembly is placed on the test loop from the product loading point of the test loop, and the electronic control assembly that has passed all the inspection items is unloaded from the qualified product unloading point along with the pallet. When the electronic control assembly fails the inspection items at any workstation, the electronic control assembly is moved out of the test loop along with the pallet from the unqualified product unloading point by the transfer equipment.

[0009] Preferably, the detection system further comprises a product tray connection confirmation unit, which is used to confirm whether the electronic control assembly and the tray are correctly and completely connected.

[0010] Preferably, the test loop includes two parts connected in sequence, namely a main body and a lifting part, the lifting part includes a lifting and steering assembly, an overhead conveying line, and a descending steering assembly, one end of the main body, the lifting and steering assembly, the overhead conveying line, the descending steering assembly, and the other end of the main body are connected in sequence, the conveying direction of the pallet on the overhead conveying line is perpendicular to the conveying direction of the pallet at one end of the main body and the conveying direction of the pallet at the other end of the main body, the lifting and steering assembly lifts and changes the conveying direction of the pallet, and the descending steering assembly descends and changes the conveying direction of the pallet, and the space below the overhead conveying line is available for personnel and equipment to enter and exit the test loop.

[0011] Preferably, the workstation includes a supporting part and a second docking part, the second docking part is connected to the test equipment, the supporting part is used to carry and transport the pallet coming from the test loop, the second docking part moves and docks with the pallet on the supporting part to connect the electronic control assembly and the test equipment.

[0012] Preferably, the supporting part includes a supporting and conveying support part, which is connected to the transfer device, and the supporting and conveying support part receives the pallet sent by the transfer device and conveys the pallet to a set position.

[0013] Preferably, the second docking part includes a docking base plate, a docking mounting plate, and a docking cylinder. The docking mounting plate is provided with multiple interfaces, each interface is connected to the test equipment, and the docking mounting plate is reciprocatingly mounted on the docking base plate. The docking cylinder connects and drives the docking mounting plate to reciprocate linearly to the multiple interfaces on the docking mounting plate to respectively dock with multiple joints on the pallet moved to set positions on the workstation. The pallet includes a docking plate, and the docking plate is provided with multiple joints, and the multiple joints are respectively connected to multiple sockets of the electronic control assembly on the pallet.

[0014] More preferably, the docking installation plate also has a first docking member and a second docking member, and the docking plate has a first-level docking member and a second-level docking member. When the docking installation plate and the docking plate are docked, the first docking member and the first-level docking member cooperate to form a first-level floating guide, and the second docking member and the second-level docking member cooperate to form a second-level floating guide. The floating range of the first-level floating guide is greater than the floating range of the second-level floating guide.

[0015] Preferably, the transfer device between the workstation cabinet and the test loop is a lifting and transplanting mechanism, and the transfer device between the stereoscopic warehouse and the test loop includes a stacker.

[0016] The beneficial effects of the present invention are:

[0017] (1) The whole process is automated, with low reliance on manual labor, improved detection efficiency and high detection accuracy.

[0018] (2) The tray can be used for testing the calibration of the three-phase Hall current sensor of the electronic control assembly. The stable current output of the constant current source makes the calibration more accurate, saves the configuration cost of the power supply and load, and improves the calibration efficiency.

[0019] (3) The tray can support and drive the electronic control assembly to flow on the test line, which is convenient for the connection and testing of the electronic control assembly at different test stations, and is convenient for the management and control of the test items. There is no need to repeatedly connect the electronic control assembly and the test equipment, which reduces the connection frequency between the electronic control assembly and the test equipment and improves the test efficiency. The tray is used as a standard tooling, and the interfaces are basically fixed, which reduces the error rate of plugging.

[0020] (4) A plurality of connectors and wiring harnesses are arranged on the pallet to connect the electronic control assembly and the test equipment. The columns and other components on the pallet can be arranged flexibly, or a movable base can be provided so that the same pallet can be used for the calibration of different electronic control assemblies, thereby increasing the application scope of the pallet and reducing the test cost.

[0021] (5) It ensures that the three-phase output interface on the electronic control assembly and the three-phase adapter on the tray fit closely together, avoiding poor contact caused by the non-parallel tolerance of the copper busbar and preventing the heat and burning of the copper busbar caused by poor contact.

[0022] (6) Each docking module of the pallet and the docking plate as a whole are independently equipped with a floating guide mechanism. In terms of timing, the overall floating guide takes effect before the module floating guide, that is, the first-level floating guide is realized first, and then the second-level floating guide is realized, which improves the accuracy and smoothness of the pallet docking and increases the service life of the pallet docking module.

[0023] (7) Ensures personnel safety in high-voltage testing environments.

[0024] (8) It is compatible with various types of electronic control assembly products commonly found in the market, and can flexibly replace different types of electronic control assemblies to be tested.

[0025] (9) The double-layer section setting can use the calibration parts to automatically detect the function of the workstation without affecting the normal testing of the tested product by the upper line, which greatly saves the space occupied by the detection system. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is an axial schematic diagram of the system layout of an embodiment of the present invention.

[0027] Figure 2 It is a schematic top view of the system layout of an embodiment of the present invention.

[0028] Figure 3 It is a schematic diagram of the structure of a workstation cabinet according to an embodiment of the present invention.

[0029] Figure 4 It is a schematic structural diagram of a workstation cabinet from another perspective of an embodiment of the present invention.

[0030] Figure 5 It is a schematic structural diagram of a tray docked on a workstation according to an embodiment of the present invention.

[0031] Figure 6 It is a schematic structural diagram from another perspective of a tray docked on a workstation according to an embodiment of the present invention.

[0032] Figure 7 It is a schematic structural diagram of a supporting portion of an embodiment of the present invention.

[0033] Figure 8 It is a schematic diagram of the calibration principle of the Hall current sensor of the electronic control assembly of the present invention.

[0034] Fig. 9 It is a schematic diagram of the tray structure of an embodiment of the present invention.

[0035] Fig.10 It is a schematic diagram of the structure of a fixed base and a docking plate of a tray according to an embodiment of the present invention.

[0036] Fig.11 The figure is a schematic diagram of the structure of a three-phase switching device on a tray according to an embodiment of the present invention.

[0037] Fig.12 It is a schematic structural diagram from another perspective of a three-phase switching device on a tray according to an embodiment of the present invention.

[0038] Fig.13 The figure is a schematic diagram of the internal structure of a three-phase switching device on a tray according to an embodiment of the present invention.

[0039] Figure numerals: 1, test loop, 12, main body, 121, double-layer section, 122, single-layer section, 111, transition assembly, 112, lifting and steering assembly, 113, aerial conveyor line, 114, descending and steering assembly, 2, station cabinet, 21, support frame, 22, station, 221, supporting part, 22111, supporting conveying motor, 22112, supporting transmission shaft, 22113, supporting conveying chain, 22114, supporting support plate, 2 212, supporting limit part, 222, positioning part, 223, second docking part, 2231, docking base plate, 2232, docking mounting plate, 2233, docking cylinder, 3, tray, 311, base, 3111, fixed base, 3112, movable base, 3113, rotating buckle, 312, docking plate, 321, column, 331, current input connector, 332, current output connector, 333, three-phase switching device, 3331, switching Connecting base, 3332, transfer fixed seat, 3333, transfer movable seat, 3334, first copper bar, 3335, second copper bar, 3336, connecting pin, 3337, first spring, 3338, cam, 3339, connecting rod, 33310, handle, 33311, limit plate, 33312, beam, 33313, third copper bar, 33314, guide column, 334, current input plug, 335, low voltage connector, 336, rotary Variable connector, 337, low-voltage plug, 338, rotary transformer plug, 339, 16-pin plug module, 3310, first plug, 3311, second plug, 341, first water input connector, 342, second water input connector, 343, first water output connector, 344, second water output connector, 4, three-dimensional warehouse, 81, stacker, 82, lifting and transplanting mechanism, 83, lifting and rotating mechanism, 7, product tray connection confirmation unit, 9, operating table. DETAILED DESCRIPTION

[0040] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0041] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0042] A detection system for an electric vehicle electronic control assembly, such as Figure 1 , Figure 2 As shown, it includes a test loop line 1, a workstation cabinet 2, a pallet 3, a three-dimensional warehouse 4, a product pallet connection confirmation unit 7, a transfer device, and a control system.

[0043] The electric control assembly to be tested is supported and installed on the pallet 3, and the pallet 3 is transported and circulated on the test loop 1. The workstation cabinet 2 and the stereoscopic warehouse 4 are used for the test experiment of the electric control assembly, among which the stereoscopic warehouse 4 is used for the aging experiment of the electric control assembly, and the workstation cabinet 2 is used for the test experiment of other items of the electric control assembly. The specific test items are introduced below. The workstation cabinet 2 and the stereoscopic warehouse 4 are connected to the test loop 1. The pallet 3 can enter the workstation cabinet 2 from the test loop 1, and can also enter the test loop 1 from the workstation cabinet 2. Similarly, the pallet 3 can enter the stereoscopic warehouse 4 from the test loop 1, and can also enter the test loop 1 from the stereoscopic warehouse 4. After the pallet 3 enters the workstation cabinet 2 or the stereoscopic warehouse 4, the workstation cabinet 2 or the stereoscopic warehouse 4 connects the electric control assembly on the pallet 3 with the corresponding test equipment for corresponding testing. There are multiple workstation cabinets 2, and at least one stereoscopic warehouse 4. Each stereoscopic warehouse 4 and the workstation cabinet 2 are arranged at intervals along the conveying direction of the test loop 1. The product tray connection confirmation unit 7 is used to confirm whether the electric control assembly and the tray 3 are correctly and completely connected. The transfer device transfers the tray 3 between the test loop line 1 and the workstation cabinet 2 and between the test loop line 1 and the stereoscopic warehouse 4.

[0044] The control system includes a controller, multiple sensors, multiple motors, cylinders or hydraulic cylinders, an operating table 9, etc. Each sensor, motor, cylinder and other electrical components are electrically connected to the controller. The controller receives information from each electrical component and controls the actions of the motor, transfer equipment, etc.

[0045] like Figure 1 and2 As shown, the test loop line 1 is also provided with a product entry point A, a qualified product exit point B and a failed product exit point C.

[0046] From the above, the overall detection process and principle of the detection system are as follows: manually install the electric control assembly on the tray 3, and connect the interface of the electric control assembly with the corresponding interface on the tray 3, and then put the tray 3 with the electric control assembly installed from the product line A of the test loop 1 into the test loop 1, and the test loop 1 drives the tray 3 to run. The tray 3 first runs to the product tray connection confirmation part 7, and the product tray connection confirmation part 7 checks whether the connection between the interface of the electric control assembly and the corresponding interface on the tray 3 is accurate and complete. If not, the tray 3 is manually removed from the test loop 1, rechecked and connected. If yes, the tray 3 continues to run. When the tray 3 runs to a certain workstation cabinet 2, the tray 3 enters the workstation cabinet 2, and the workstation cabinet 2 electrically connects the electric control assembly on the tray 3 and the detection equipment and performs detection. If the electric control assembly passes the test, the tray 3 drives the electric control assembly to continue running along the test loop 1 to the next workstation cabinet 2 for the next item test; if the electric control assembly fails the test, the tray 3 drives the electric control assembly to run along the test loop 1 to the unqualified product offline point C and moves out of the test loop 1 without entering the next workstation cabinet 2 for testing. If the tray 3 drives the electric control assembly to enter the stereoscopic warehouse 4 and passes the test, the tray 3 returns to the test loop 1 and continues to run to other workstation cabinets 2; if the electric control assembly on the tray 3 fails the test in the stereoscopic warehouse 4, the transfer equipment moves the tray 3 out of the stereoscopic warehouse 4 to the unqualified product storage area and does not return to the test loop 1. All qualified products are transported to the qualified product offline point B by the test loop 1, and the electric control assembly on the tray 3 at the qualified product offline point B is manually removed.

[0047] In this embodiment, the product tray connection confirmation unit 7 is an image monitoring system, which captures the image of the tray 3 entering the monitoring area on the test loop line 1. The control system determines and compares the captured image according to the built-in program to confirm whether the electric control assembly product on the tray 3 is correctly and completely connected. If so, the tray 3 continues to run along the test loop line 1. If not, the control system alarms to remind people to remove the tray 3 passing through the monitoring area at this time. Further, the position sensor can be used to detect and determine whether a tray 3 enters the monitoring area.

[0048] In this embodiment, the test loop line 1 can use a conveyor belt in the prior art, and the conveying direction of the tray 3 is as follows: Figure 2 In the clockwise direction, Figure 2 As shown by arrow F in FIG.

[0049] In this embodiment, the test loop 1 is a closed loop, that is, connected end to end. Figure 1 and 2As shown, in order to save space, a workstation cabinet 2, an operating table 9, etc. are arranged in the space surrounded by the test loop line 1.

[0050] In this embodiment, in order to allow operators and equipment to enter the space surrounded by the test loop 1, the test loop 1 includes two parts connected in sequence, namely a main body 12 and a lifting part. The height of the main body 12 is 900 mm, and the operators and equipment enter the space surrounded by the test loop 1 from below the lifting part.

[0051] The main body 12 includes a double-layer section 121 and a single-layer section 122 . The double-layer section 121 includes upper and lower conveying lines, and the single-layer section 122 has only one conveying line. The upper conveying line of the single-layer section 122 and the double-layer section 121 are connected.

[0052] In this embodiment, the lifting part includes a transition component 111, a lifting and steering component 112, an aerial conveying line 113, and a descending steering component 114. The double-layer section 121, the transition component 111, the lifting and steering component 112, the aerial conveying line 113, the descending steering component 114, the single-layer section 122, and the double-layer section 121 are sequentially connected to form a closed-loop test loop 1. The conveying direction of the aerial conveying line 113 for the pallet 3 is perpendicular to the conveying direction of the double-layer section 121 for the pallet 3, and the conveying direction of the aerial conveying line 113 for the pallet 3 is also perpendicular to the conveying direction of one end of the single-layer section 122 for the pallet 3. The lifting and steering component 112 lifts the pallet 3 and changes the conveying direction, and the descending steering component 114 lowers the pallet 3 and changes the conveying direction.

[0053] The transition assembly 111 and the lifting and steering assembly 112 are essentially the same, and both play the role of lifting and lowering and horizontally conveying the pallet 3. At the same time, the two ends of the transition assembly 111 are also connected to the double-layer section 121 and the lifting and steering assembly 112 respectively. The transition assembly 111 is used to transfer the pallet 3 between the upper and lower conveying lines of the double-layer section 121. Preferably, the transition assembly 111 is provided with a first lifting drive member, a first horizontal conveying member, a position sensor, etc. The first horizontal conveying member is used to support and horizontally convey the pallet 3, and the first lifting drive member is connected to and drives the first horizontal conveying member to rise or fall, thereby driving the pallet 3 to rise and fall. The position sensor is used to detect the position information of the pallet 3.

[0054] In this embodiment, the first lifting drive member is a cylinder, a hydraulic cylinder, etc., and the first horizontal conveying member includes a support plate and a chain sprocket conveying mechanism. The cylinder is connected to and drives the support plate to lift and lower, and the chain sprocket conveying mechanism is installed on the support plate.

[0055] In this embodiment, when the pallet 3 needs to be transferred between the upper and lower conveyor lines of the double-layer section 121, when the transition assembly 111 and one of the layers of the double-layer section 121 are connected, the conveyor line of the double-layer section 121 drives the pallet 3 to run, and sends the pallet 3 to the chain sprocket conveyor mechanism. At the same time, the chain sprocket conveyor mechanism drives the pallet 3 to continue running. When the position sensor detects the pallet 3, the chain sprocket conveyor mechanism stops running. At this time, the pallet 3 stops completely and stably at the set position of the chain sprocket conveyor mechanism. Finally, the first lifting drive member drives the first horizontal conveyor member to rise or fall to connect with the other layer of the double-layer section 121.

[0056] When the pallet 3 only needs to pass through the double-layer section 121, the chain and sprocket conveying mechanism is continuously started without stopping, and when the position sensor detects the pallet 3, the chain and sprocket conveying mechanism does not stop either.

[0057] The lifting and steering assembly 112 is provided with a second lifting drive member, a second horizontal conveying member, a lifting and transplanting mechanism, and a position sensor. The second horizontal conveying member is used to support and horizontally transport the pallet 3, and the lifting and transplanting mechanism is used to support and drive the pallet 3 to be lifted and transported as well as to move horizontally. The direction in which the second horizontal conveying member drives the pallet 3 to be transported and the direction in which the lifting and transplanting mechanism drives the pallet 3 to be transported are perpendicular to each other. The second lifting drive member connects and drives the second horizontal conveying member and the lifting and transplanting mechanism to rise or fall, thereby driving the pallet 3 to rise and fall. The position sensor is used to detect the position information of the pallet 3.

[0058] The lifting and transplanting mechanism can drive the components supported by it to rise and fall and move horizontally. The lifting and transplanting mechanism generally includes a lifting drive component and a horizontal drive component. The lifting drive component is connected to and drives the horizontal drive component to rise and fall, and the horizontal drive component supports and drives the tray 3 to move horizontally. The lifting and transplanting mechanism can adopt products in the prior art, and its specific structure is not repeated here. The lifting drive component of the lifting and transplanting mechanism can be a cylinder, a screw mechanism, etc., and the horizontal drive component is generally a conveyor belt, etc.

[0059] A gap is arranged on the second horizontal conveying member of the lifting and steering assembly 112, and the horizontal driving assembly of the lifting and transplanting mechanism can pass through the second horizontal conveying member of the lifting and steering assembly 112 when lifting and lowering. The initial position of the horizontal driving assembly of the lifting and transplanting mechanism is lower than the second horizontal conveying member.

[0060] The second horizontal conveyor has two setting positions, namely the first setting position and the second setting position. When the second horizontal conveyor is located at the first setting position, the second horizontal conveyor is flush with the upper conveyor line of the double-layer section 121, and the second horizontal conveyor can receive the pallet 3 horizontally coming from the transition component 111; when the second horizontal conveyor is located at the second setting position, the second horizontal conveyor is lower than the aerial conveyor line 113, and the lifting and transplanting mechanism can rise to be flush with and connected to the aerial conveyor line 113, and drive the pallet 3 to rise synchronously.

[0061] In this embodiment, the second lifting drive member can be a screw mechanism, a sprocket chain mechanism, etc. in the prior art.

[0062] The overhead conveying line 113 can adopt a conveyor belt in the prior art.

[0063] From the above, the working process and principle of the pallet 3 entering the lifting and steering assembly 112 from the transition assembly 111 to be lifted and turned, and then sent to the aerial conveyor line 113 are as follows: the upper conveyor line of the double-layer section 121, the first horizontal conveyor of the transition assembly 111, and the second horizontal conveyor of the lifting and steering assembly 112 are aligned, and the pallet 3 is sent from the upper conveyor line of the double-layer section 121 to the first horizontal conveyor of the transition assembly 111, and the first horizontal conveyor of the transition assembly 111 continues to convey, and the pallet 3 is sent to the second horizontal conveyor of the lifting and steering assembly 112. The second horizontal conveyor of the lifting and steering assembly 112 keeps conveying, and the pallet 3 continues to be conveyed. When the pallet 3 is completely located on the second horizontal conveyor of the lifting and steering assembly 112, the position sensor in the lifting and steering assembly 112 detects the pallet 3, and then the control system controls the second horizontal conveyor of the lifting and steering assembly 112 to stop running, and the pallet 3 stops stably on the second horizontal conveyor. Then, the second lifting drive member drives the second horizontal conveyor and the lifting and transplanting mechanism to rise to the second set position and then stop. Next, the lifting drive assembly of the lifting and transplanting mechanism drives the horizontal drive assembly to rise until it passes through the second horizontal conveyor, and the horizontal drive assembly of the lifting and transplanting mechanism contacts and lifts the tray 3. At this time, the horizontal drive assembly is flush with the aerial conveyor line 113. Finally, the horizontal drive assembly drives to drive the tray 3 to continue to run, and the tray 3 is sent to the aerial conveyor line 113.

[0064] The overhead conveyor line 113 transfers the pallet 3 from the lifting and steering assembly 112 to the lowering and steering assembly 114 .

[0065] The structural principle of the descending steering assembly 114 is the same as that of the lifting steering assembly 112. The working process of the descending steering assembly 114 is opposite to that of the lifting steering assembly 112, that is, the horizontal driving assembly of the lifting and transplanting mechanism of the descending steering assembly 114 first rises to be flush with the aerial conveyor line 113 to receive the pallet 3, and then the horizontal driving assembly of the lifting and transplanting mechanism descends until the pallet 3 is supported by the second horizontal conveying member of the descending steering assembly 114. Then, the second lifting driving member of the descending steering assembly 114 drives the lifting and transplanting mechanism and the second horizontal conveying member to descend. Finally, the second horizontal conveying member of the descending steering assembly 114 is started after being flush with the single-layer section 122 to drive the pallet 3 to move onto the single-layer section 122.

[0066] The workstation cabinet 2 includes a support frame 21 and at least one workstation 22. The workstation cabinet 2 is a rectangular parallelepiped as a whole, and is used to install necessary components, such as the workstation 22 is installed inside the support frame 21. The support frame 21 is equipped with lighting, an electrical box, a display control screen and other components. In order to facilitate the smooth progress of the process and protect the components on the workstation cabinet 2, the four sides of the workstation cabinet 2 are adaptively provided with doors or set to an open state. Preferably, the gap between the workstation cabinet 2 and the test loop 1 is 71 to 73 mm.

[0067] In this embodiment, each workstation cabinet 2 is provided with two identical workstations 22, and the same item of the workstation can be inspected on two trays 3 respectively.

[0068] like Figures 2 to 4 As shown, each station 22 can accommodate a tray 3, such as Figures 5 to 7 As shown, the workstation 22 includes a supporting portion 221, a positioning portion 222, and a second docking portion 223. The second docking portion 223 is connected to the test equipment. The supporting portion 221 is used to carry the tray 3 entering the workstation cabinet 2 from the test loop 1, and the second docking portion 223 moves and fixes and positions the electric control assembly on the tray 3 on the supporting portion 221 to achieve docking between the electric control assembly and the corresponding test equipment, and the electric control assembly is tested after connection.

[0069] In this embodiment, the transfer device for transferring the pallet 3 between the workstation 22 and the test loop line 1 is a lifting and transplanting mechanism 82. Each workstation 22 is provided with a corresponding lifting and transplanting mechanism 82. The lifting and transplanting mechanism 82 is located on the test loop line 1. In the initial state, the horizontal drive component of the lifting and transplanting mechanism 82 is located below the conveying surface of the test loop line 1. When the pallet 3 moves along the test loop line 1 to the top of the lifting and transplanting mechanism 82 and the pallet 3 needs to be transferred to the workstation 22, the lifting and driving component of the lifting and transplanting mechanism 82 drives the horizontal driving component to rise to pass through the test loop line 1 and then lift the pallet 3. Then, the horizontal driving component of the lifting and transplanting mechanism 82 drives the pallet 3 to move horizontally to the supporting portion 221 on the workstation 22. Finally, the lifting and transplanting mechanism 82 is reset so as not to block the operation of other pallets 3 on the test loop line 1.

[0070] Preferably, the driving direction of the horizontal driving assembly of the lifting and transferring mechanism 82 on the test loop line 1 is perpendicular to the conveying direction of the test loop line 1 at the location of the lifting and transferring mechanism 82 .

[0071] The supporting part 221 is as follows Figures 5 to 7 As shown, it includes a supporting and conveying support part and a supporting and limiting part 2212, the supporting and conveying support part is connected with the lifting and transplanting mechanism 82, and the supporting and conveying support part is used to support and convey the tray 3. The supporting and limiting part 2212 is used to limit the terminal position of the tray 3.

[0072] like Figure 7 As shown, in this embodiment, the supporting conveying support portion includes a supporting support plate 22114 and a supporting conveying motor 22111, a supporting transmission shaft 22112, and a supporting conveying chain 22113 installed on the supporting support plate 22114. The supporting conveying chain 22113 is drivably installed on the supporting support plate 22114, and is provided with two supporting conveying chains 22113, which are arranged in parallel and spaced apart. The two supporting conveying chains 22113 are connected and synchronously transmitted through the supporting transmission shaft 22112. Specifically, the two ends of the supporting conveying chain 22113 are respectively engaged or tensioned on two transmission wheels, and each end of the supporting transmission shaft 22112 is respectively fixedly connected to a transmission wheel of the two supporting conveying chains 22113, and it is obvious that the transmission wheel is a driving wheel. The supporting conveying motor 22111 is connected and drives the supporting transmission shaft 22112 to rotate.

[0073] Preferably, one end of the supporting conveyor chain 22113 is connected to the jacking and transplanting mechanism 82, and the other end is provided with a supporting limit portion 2212 and a position sensor, and the supporting limit portion 2212 and the position sensor are located between the two supporting conveyor chains 22113. When the tray 3 enters the supporting conveyor support portion from one end of the supporting conveyor chain 22113, the two ends of the tray 3 are respectively supported on the two supporting conveyor chains 22113 and transported by the supporting conveyor chains 22113. When the tray 3 is transported to contact the supporting limit portion 2212, the tray 3 cannot continue to move and is detected by the position sensor. The control system controls the supporting conveyor motor 22111 to stop starting. At this time, the tray 3 is transported into place.

[0074] like Figure 6 , Figure 7 As shown, the positioning part 222 is used to fix the pallet 3 delivered to the position. The positioning part 222 includes two positioning cylinders installed on the supporting support plate 22114, and the two supporting conveying chains 22113 are located between the two positioning cylinders. When the cylinder shafts of the two positioning cylinders are extended, they can be inserted into the positioning holes on the pallet 3 delivered to the position.

[0075] Furthermore, a wire lifting mechanism can be provided, which can be connected to and drive the supporting part 221 to rise and fall: when the supporting part 221 rises to a set position, it can be flush with the lifting and transplanting mechanism 82 to transfer the pallet 3; when the supporting part 221 descends to a set position, the bottom of the pallet 3 delivered to the position can be inserted into the positioning flange below the supporting part 221 to improve the positioning effect of the pallet 3.

[0076] The supporting portion 221 is located between the second docking portion 223 and the corresponding lifting and transplanting mechanism 82. Figure 5 , Figure 6 As shown, it includes a docking base plate 2231, a docking mounting plate 2232, and a docking cylinder 2233. The docking base plate 2231 is fixed in the workstation cabinet 2, and the docking mounting plate 2232 is reciprocatingly mounted on the docking base plate 2231, and the docking cylinder 2233 is connected and drives the docking mounting plate 2232 to reciprocate linearly. In order to make the movement of the docking mounting plate 2232 more stable, two parallel and spaced guide rails are provided on the docking base plate 2231, and the bottoms of both ends of the docking mounting plate 2232 are slidably mounted on the two guide rails. The docking mounting plate 2232 is provided with a first docking member, a second docking member and a plurality of interfaces, and each interface is connected to the test equipment through wires and switches. The docking principle and process of the docking mounting plate 2232 and the tray 3 are shown below.

[0077] There are multiple workstation cabinets 2, and different workstation cabinets 2 are used to detect different test indicators of the electronic control assembly.

[0078] A plurality of workstations 22 are also provided in the stereoscopic warehouse 4. The transfer equipment between the stereoscopic warehouse 4 and the test loop 1 is a lifting and rotating mechanism 83 and a stacker 81. Preferably, each stereoscopic warehouse 4 is equipped with two lifting and rotating mechanisms 83, and two adjacent stereoscopic warehouses 4 can share one stacker 81 and two lifting and rotating mechanisms 83. The pallet 3 on the test loop 1 is transferred to a lifting and rotating mechanism 83 by the lifting and transplanting mechanism, and the stacker 81 transfers the pallet 3 on the lifting and rotating mechanism 83 to the workstation 22 of the stereoscopic warehouse 4. The workstation 22 automatically connects the electric control assembly on the pallet 3 to the second docking part 223, and then performs aging detection. The stacker 81 transfers the pallet 3 that has passed the test to another lifting and rotating mechanism 83, and the lifting and rotating mechanism 83 sends the pallet 3 back to the test loop 1, and the pallet 3 continues to run along the test loop 1. The stacker 81 transfers the pallet 3 that has failed the test to the designated storage area for unqualified products.

[0079] The lifting and rotating mechanism 83 and the stacker 81 both adopt solutions in the prior art, which will not be described in detail here.

[0080] In this embodiment, six workstation cabinets 2 and three stereoscopic warehouses 4 are provided. Figure 1 and 2 As shown, along the transmission direction of the test loop line 1, the product on-line A, the product tray connection confirmation part 7, four workstation cabinets 2, the unqualified product off-line C, two three-dimensional warehouses 4, another two workstation cabinets 2, and the qualified product off-line B are arranged in sequence. The elevated part of the test loop line 1 is located between the unqualified product off-line C and the three-dimensional warehouse 4. Each three-dimensional warehouse 4 is independent of each other. After a pallet 3 enters a three-dimensional warehouse 4 and completes the inspection, it will not enter other three-dimensional warehouses 4.

[0081] In this embodiment, along the transmission direction of the test loop line 1, the six workstation cabinets 2 are respectively a safety test workstation cabinet, a program burning test workstation cabinet, a calibration test workstation cabinet, an EOL test workstation cabinet, an automatic liquid return workstation cabinet and a vehicle program burning workstation cabinet.

[0082] In this embodiment, four workstation cabinets 2 , namely, a safety test workstation cabinet, a program burning test workstation cabinet, a calibration test workstation cabinet, and an EOL test workstation cabinet, are connected to the double-layer section 121 .

[0083] The function of the double-layer section 121 is as follows: the upper conveyor line of the double-layer section 121 constitutes a part of the test loop line 1. The lower conveyor line of the double-layer section 121 is used to store the calibration parts for the start of the shift, which are used to detect the workstation 22. Specifically, the calibration parts are placed on the lower conveyor line. The calibration parts are standard products that are qualified or unqualified for the specified test items, and are used to detect whether the functions of the test equipment on each workstation 22 are normal. For example, if a calibration part is a calibration product that is qualified for a safety item, when it is tested in a safety test workstation cabinet, the test result is qualified, indicating that the workstation functions normally, and the test result is unqualified, indicating that the workstation has a fault. For another example, if a calibration part is a calibration product that is unqualified for a safety item, when it is tested in a safety test workstation cabinet, the test result is qualified, indicating that the workstation has a fault, and the test result is unqualified, indicating that the workstation is normal.

[0084] After the calibration parts are used to detect each station 22, each calibration part is returned to the lower conveying line of the double-layer section 121. After the detection of each station 22 is completed, the detection system is turned on again to perform normal detection on the detected product.

[0085] The transfer of the calibration parts between the upper conveyor line and the lower conveyor line of the double-layer section 121 can be achieved through the transition assembly 111. The lower conveyor line delivers the calibration parts to the transition assembly 111, the transition assembly 111 lifts the calibration parts to the upper conveyor line, and the upper conveyor line delivers the calibration parts to the designated workstation 22 and then is delivered into the workstation 22 by the lifting and transplanting mechanism.

[0086] In summary, the detection system can automatically complete the detection of each workstation 22 before the start of the class calibration. The setting of the double-layer section 121 can use the calibration piece to automatically detect the function of the workstation 22, while not affecting the normal testing of the upper line body on the tested product, greatly saving the space occupied by the detection system.

[0087] Safety testing mainly conducts comprehensive inspection on the insulation performance of the electric control assembly. Because high voltage will be passed into the product during use, it is necessary to conduct insulation and withstand voltage test on the product to check the insulation of the product. In this embodiment, during the safety test, the electric control assembly is subjected to insulation resistance test, withstand voltage test, ground resistance test, terminal resistance test, PTC / CMP conduction test, and high-voltage interlock test.

[0088] The program burning test is mainly to meet the needs of the electronic control assembly function test, and to update the program in the electronic control assembly control chip to make it meet the test conditions. The main function of the program burning test is to write the EOL and aging test program for the products transferred from the assembly section. Only after the test program is flashed can the EOL and aging tests be carried out.

[0089] The whole vehicle burning station is the last station in the test loop. After the test, it will be transported to the three-in-one production line. The three-in-one production line needs to use the whole vehicle program. The function of the whole vehicle burning station is to flash the whole vehicle program to the controller for the three-in-one test.

[0090] Hall sensor calibration mainly involves comparing the data of the external high-precision sensor measurement with the internal sensor of the electronic control after assembly, calculating the difference between the two through the equipment, and correcting the sensor measurement of the electronic control assembly product through instructions to achieve the accuracy of the electronic control output.

[0091] The automatic liquid return test includes TM motor temperature, GM motor temperature calibration test, resolver position signal calibration test, low voltage detection test, static current test, output current test, and active discharge test.

[0092] The low-voltage signal inspection mainly determines whether the electronic control assembly is operating normally through some small changes in the low-voltage signal.

[0093] The high-current aging operation test mainly considers that the electronic control assembly works in complex usage scenarios. By running it under high temperature and high current conditions, the newly assembled electronic control assembly is subjected to aging test to achieve the purpose of quality screening.

[0094] It should be noted that the above-mentioned single test principles, methods and test equipment that need to be connected are all existing technologies and will not be repeated here. The second docking portion 223 on each station 22 can be the same or set differently according to different test items. When the second docking portion 223 on the station 22 is connected to the docking plate 312 of the tray 3, only the interfaces and test equipment that need to be used on the docking plate 312 are connected and connected to the test circuit, and the interfaces and test equipment that are not needed are not connected.

[0095] In summary, in this embodiment, the test process is as follows: manually install the electric control assembly on the tray 3, and connect the interface of the electric control assembly with the corresponding interface on the tray 3, and then put the tray 3 with the installed electric control assembly from the product line A of the test loop 1 into the test loop 1, and the test loop 1 drives the tray 3 to run. The tray 3 first runs to the product tray connection confirmation part 7, and the product tray connection confirmation part 7 checks whether the connection between the interface of the electric control assembly and the corresponding interface on the tray 3 is accurate and complete. If not, the tray 3 is manually removed from the test loop 1, rechecked and connected, and if yes, the tray 3 continues to run. Then, the pallet 3 moves to the safety test cabinet, program burning test cabinet, calibration test cabinet, and EOL test cabinet in turn to be tested for the corresponding items. When the test result of a pallet 3 in a cabinet is unqualified, the pallet 3 does not need to enter the subsequent cabinet for testing, but runs along the test loop 1 to the unqualified product offline point C, and is moved out of the test loop 1 through the transfer equipment at the unqualified product offline point C. The pallet 3 that passes the test passes through the transition component 111, the lifting and steering component 112, the aerial conveyor line 113, and the descending and steering component 114 in turn, and then enters a stereoscopic warehouse 4 for aging test. The pallet 3 that fails the test is transferred to the unqualified product storage area by the stacker 81, and the pallet 3 that passes the test is sent back to the test loop 1 by the stacker 81 and the lifting and rotating mechanism 83. The pallet 3 that passes the inspection continues to run, passes through and enters the automatic liquid return work cabinet and the vehicle program burning work cabinet for inspection in turn. The electronic control assembly products that fail the inspection are moved out of the test loop 1 along with the pallet 3 by the transfer equipment, and the pallet 3 that passes the inspection continues to run to the qualified product offline point B, and the electronic control assembly on the pallet 3 at the qualified product offline point B is manually removed.

[0096] The tray 3 is used to support and fix the electric control assembly, and drive the electric control assembly to flow on the test loop line 1 to each workstation cabinet 2 and the three-dimensional warehouse 4.

[0097] The tray 3 is as Figures 9 to 13 As shown, it includes a supporting portion, a positioning and fixing portion, a connecting portion, a cooling portion and a first docking portion. The supporting portion is used to support and install other components of the tray 3. The positioning and fixing portion is used to position the electric control assembly and fix it on the supporting portion. The connecting portion is used to connect the electric control assembly with the components on the docking mounting plate 2232. The cooling portion is used to cool the electric control assembly. The first docking portion is used to automatically and accurately dock the tray 3 with the docking mounting plate 2232 to ensure that the electric control assembly and the components on the docking mounting plate 2232 are accurately connected.

[0098] The support part includes a base 311 and a docking plate 312. Both the base 311 and the docking plate 312 are plate-shaped structures. The base 311 is supported on the test loop 1, and the base 311 is parallel to the horizontal plane. One side of the base 311 is a support surface that contacts and supports the test loop 1, and the other side is a mounting surface for mounting other components of the tray 3. The docking plate 312 and the base 311 are vertically connected to form an L shape, and the docking plate 312 is located on one side of the mounting surface.

[0099] Further, the base 311 includes a fixed base 3111 and a movable base 3112, the fixed base 3111 and the docking plate 312 are fixedly connected to form an L shape, and the movable base 3112 is detachably mounted on the fixed base 3111. The fixed base 3111 and the movable base 3112 are both plate-like structures, and the fixed base 3111 and the movable base 3112 are both provided with connecting holes, and the connecting holes on the fixed base 3111 and the connecting holes on the movable base 3112 are aligned and locked and fixed by a rotating buckle 3113 passing through the aligned connecting holes. The rotating buckle 3113 can be connected to the connecting hole by threaded connection or clamping. Preferably, the fixed base 3111 is provided with two connecting holes, which are respectively located near the two diagonal corners of the quadrilateral-like fixed base 3111. Similarly, the movable base 3112 is also provided with two corresponding connecting holes.

[0100] The positioning and fixing part includes a column 321 and a clamp, both of which are located on one side of the mounting surface of the base 311. The column 321 is used to support the electric control assembly, and the column 321 is a column structure, and the column 321 is detachably mounted on the base 311. The clamp is used to clamp and fix the electric control assembly, that is, when the electric control assembly is supported on the column 321, the clamp presses the electric control assembly and fixes the electric control assembly with the cooperation of the column 321.

[0101] Furthermore, different models or types of electric control assemblies have different appearances, and the parts that the column 321 can contact and the required heights of the column 321 are different. For this reason, the tray 3 is designed to be suitable for a variety of different models of electric control assemblies. Specifically, a plurality of groups of column assemblies are provided on the base 311, each group of the column assemblies is used to support one or a type of electric control assembly, and the plurality of groups of column assemblies are respectively used to support a plurality of different models of electric control assemblies, and each group of column assemblies includes a plurality of columns 321. When supporting one electric control assembly, other columns 321 that interfere with the electric control assembly can be removed, and columns 321 that do not interfere with the electric control assembly can be removed or not removed.

[0102] From the above, the column 321 to be selected for each column area and the mounting hole to be installed for the column 321 can be determined according to the type of the electric control assembly to be supported and fixed by the tray. Further, the column 321 can be marked for quick matching and rotation.

[0103] The clamp applies pressure to the upper surface of the electric control assembly, and the electric control assembly is stably fixed with the cooperation of the column 321. The clamp can be a quick clamp in the prior art, which will not be described in detail here.

[0104] The connecting part includes multiple plugs and multiple connectors. The multiple plugs include a three-phase switching device 333, a current input plug 334, a low-voltage plug 337, a resolver plug 338, a first plug 3310 and a second plug 3311. The multiple connectors include a current input connector 331, a current output connector 332, a low-voltage connector 335, a resolver connector 336, and a 16-pin plug module 339.

[0105] The current input connector 331, the current output connector 332, the low voltage connector 335, the resolver connector 336, and the 16-pin plug module 339 are all installed on the docking board 312. The three-phase switching device 333, the current input plug 334, the low voltage plug 337, the resolver plug 338, the first plug 3310, and the second plug 3311 are all installed on the base 311. Each plug on the base 311 can be connected to the socket on the electric control assembly.

[0106] In this embodiment, the connectors on the docking plate 312 are arranged in two rows as a whole, and the low-voltage connector 335, the rotary connector 336 and the 16-pin plug module 339 are basically located in the same plane parallel to the base 311, which is set as the first plane. The current input connector 331 and the two current output connectors 332 are also basically located in the same plane parallel to the base 311, which is set as the second plane. The first plane, the second plane and the plane where the base 311 is located are arranged in sequence from top to bottom.

[0107] The three-phase switching device 333 is pressed against the three-phase output interface 62 on the electric control assembly. Figures 11 to 13 As shown, it includes a transfer base 3331, a transfer fixed seat 3332, a transfer movable seat 3333, a first copper bar 3334, a second copper bar 3335, a connecting pin 3336, a first spring 3337, a cam 3338, a connecting rod 3339, a handle 33310, a limit plate 33311, a crossbeam 33312, a third copper bar 33313, a guide column 33314, and a second spring.

[0108] The transfer base 3331 is fixedly mounted on the movable base 3112, and the transfer fixed base 3332 is fixedly mounted on the transfer base 3331. The transfer movable base 3333 is movably mounted on the transfer base 3331. Specifically, the transfer movable base 3333 can move back and forth linearly, moving in a direction close to or away from the transfer fixed base 3332. Three first copper bars 3334 are provided, which are installed in parallel and at intervals on a side of the transfer fixed base 3332 close to the transfer movable base 3333. Three second copper bars 3335 are also provided, which are installed in parallel and at intervals on a side of the transfer movable base 3333 close to the transfer fixed base 3332. The cam 3338 can rotate and contact a side of the transfer movable base 3333 away from the second copper bar 3335, and the cam 3338 can push the transfer movable base 3333 when it rotates.

[0109] In order to make the transfer movable seat 3333 move more smoothly, the lower end of the transfer fixed seat 3332 and the lower end of the transfer movable seat 3333 are connected through the guide column 33314, and the transfer movable seat 3333 moves along the guide column 33314, and the outer cover of the guide column 33314 is connected with a second spring, and the second spring is located between the transfer fixed seat 3332 and the transfer movable seat 3333. In this embodiment, the lower end of the transfer fixed seat 3332 is provided with a guide column 33314, and the lower end of the transfer movable seat 3333 is provided with a guide hole, one end of the guide column 33314 is fixedly connected to the transfer fixed seat 3332, and the other end extends into the guide hole, and the transfer movable seat 3333 moves along the length direction of the guide column 33314 when moving.

[0110] Based on the above structure, the three-phase output interface 62 on the electric control assembly is inserted between the first copper bar 3334 and the second copper bar 3335. When the cam 3338 rotates, the transfer movable seat 3333 is pushed to move toward the transfer fixed seat 3332, so that the three second copper bars 3335 move toward the three first copper bars 3334 respectively, and the three-phase output interface 62 is pressed between the second copper bar 3335 and the first copper bar 3334. The three interfaces of the three-phase output interface 62, the three first copper bars 3334 and the three second copper bars 3335 are respectively in contact to form a three-phase output copper bar. After the cam 3338 is rotated in the opposite direction, the transfer movable seat 3333 is reset under the pressure of each second spring. The three-phase output interface 62 is three copper sheets.

[0111] The first copper bar 3334 is mounted on the transfer fixing seat 3332 through the connecting pin 3336 and the first spring 3337. Fig.13As shown, a connecting hole is provided on the transfer fixing seat 3332, and the connecting pin 3336 is fixedly connected to the first copper bar 3334 after passing through the connecting hole. Preferably, the connecting pin 3336 can move along the connecting hole, and the connecting pin 3336 and the first copper bar 3334 are interference fit. The connecting pin 3336 includes a head and a body, the outer diameter of the head is larger than the outer diameter of the body, a limiting protrusion is provided in the connecting hole, the head of the connecting pin 3336 is blocked by the limiting protrusion and cannot pass through the connecting hole, and the body of the connecting pin 3336 is fixedly connected to the first copper bar 3334 after passing through the connecting hole. The connecting pin 3336 is outer-mounted with a first spring 3337, and the first spring 3337 is located between the first copper bar 3334 and the limiting protrusion in the connecting hole on the transfer fixing seat 3332, that is, the first spring 3337 and the head of the connecting pin 3336 are respectively located on both sides of the limiting protrusion. The second copper busbar 3335 is also installed on the transfer movable seat 3333 through the connecting pin 3336 and the first spring 3337. The connection method between the second copper busbar 3335 and the transfer movable seat 3333 is the same as the connection method between the first copper busbar 3334 and the transfer fixed seat 3332, which will not be repeated here.

[0112] Further, the first copper bar 3334 is perpendicular to the moving direction of the movable base 3112 and the transfer movable seat 3333. The first copper bar 3334 is rod-shaped as a whole. In order to make the movement of the transfer movable seat 3333 more stable and the connection of the first copper bar 3334 and the second copper bar 3335 more accurate and the wiring harness connection of the three-phase switching device 333, the second copper bar 3335 is set to L shape, that is, the second copper bar 3335 includes a vertical bar and a cross bar connected as one body, the vertical bar and the cross bar are connected into an L shape, the vertical bar is installed on the transfer movable seat 3333 by a connecting pin 3336 and a first spring 3337, the vertical bar is parallel to the first copper bar 3334, the cross bar passes through the transfer fixed seat 3332, so that the cross bar plays a guiding role, and in the process, the cross bar does not break away from the transfer fixed seat 3332. At the same time, the cross bar of the second copper bar 3335 is convenient to be connected to other interfaces by a wiring harness after extending the transfer fixed seat 3332.

[0113] In this embodiment, each first copper bar 3334 is connected to the transfer fixed seat 3332 through two connecting pins 3336 and two first springs 3337, and the vertical rod of each second copper bar 3335 is connected to the transfer movable seat 3333 through two connecting pins 3336 and two first springs 3337.

[0114] Based on the above structure, when the two sides of the copper sheet of the three-phase output interface 62 contact the vertical rod of the second copper bar 3335 and the first copper bar 3334 respectively, due to the pressure of the first spring 3337 on the connecting pin 3336, the second copper bar 3335 and the first copper bar 3334 clamp the three-phase output interface 62.

[0115] There are two limit plates 33311 , which are arranged in parallel and spaced apart, and the transfer fixed seat 3332 and the transfer movable seat 3333 are located between the two limit plates 33311 . The crossbeam 33312 is straddled on the two limit plates 33311 .

[0116] The cam 3338 is hinged on the crossbeam 33312, one end of the connecting rod 3339 is fixedly connected to the cam 3338, and the other end is connected to the handle 33310. The cam 3338 is driven to rotate by operating the handle 33310, and the cam 3338 pushes the transfer movable seat 3333. Due to the pressure of the second spring, when the cam 3338 rotates in the opposite direction, the second spring pushes the transfer movable seat 3333 to reset.

[0117] In this embodiment, the cam 3338 is shaped like a cuboid.

[0118] The third copper bar 33313 is movably located on the crossbar of the second copper bar 3335, and the third copper bar 33313 and the second copper bar 3335 are connected by a connecting pin 3336 and a first spring 3337. The connecting pin 3336 is fixedly connected to the third copper bar 33313 after passing through the vertical bar of the second copper bar 3335, and the connecting pin 3336 can move relative to the vertical bar of the second copper bar 3335. The connecting pin 3336 is also sleeved with a first spring 3337, and the first spring 3337 is located between the third copper bar 33313 and the vertical bar of the second copper bar 3335. The arrangement of the third copper bar 33313 makes the three-phase switching device 333 and the three-phase output interface 62 more stable when connected, and the contact area between the copper bars is larger.

[0119] It should be noted that the first copper bar 3334, the second copper bar 3335 and the third copper bar 33313 are all provided with grooves, so that after the first spring 3337 is compressed, the transfer fixed seat 3332 and the first copper bar 3334 fit together without gaps, and one end of the first spring 3337 on the first copper bar 3334 is located in the connection hole of the transfer fixed seat 3332, and the other end is located in the groove of the first copper bar 3334. Similarly, when the transfer movable seat 3333 and the second copper bar 3335 fit together without gaps, one end of the first spring 3337 on the second copper bar 3335 is located in the connection hole of the transfer movable seat 3333, and the other end is located in the groove of the second copper bar 3335.

[0120] Furthermore, a temperature sensor for detecting the temperature of the second copper bar 3335 is installed on the three-phase switching device 333. The temperature sensor is installed on one end of the cross bar of the second copper bar 3335 extending out of the switching fixing seat 3332, as shown in FIG. Fig.12 The temperature sensor monitors the temperature of the copper busbar and issues an early warning for overheating.

[0121] The three-phase switching device 333 is also equipped with a proximity sensor. Specifically, a contact piece is installed on the side of the switching fixed seat 3332 and the side of the switching movable seat 3333, and the proximity sensor is installed on one of the contact pieces. Fig.12 The proximity sensor detects the position information of another contact piece, thereby determining the relative position information of the transfer fixed seat 3332 and the transfer movable seat 3333, and detecting whether the three-phase output interface 62 is pressed by the first copper bar 3334 and the second copper bar 3335.

[0122] The cooling unit includes a first water input connector 341, a second water input connector 342, a first water output connector 343, and a second water output connector 344. The first water input connector 341 and the first water output connector 343 are respectively arranged at both ends of the docking plate 312, and the second water input connector 342 and the second water output connector 344 are arranged on the base 311. The current input connector 331 and the 16-pin plug module 339 are located between the first water input connector 341 and the first water output connector 343, and the second water input connector 342 and the second water output connector 344 are located on the end of the base 311 away from the docking plate 312. The first water input connector 341 and the second water input connector 342 are connected by a water pipe, and the first water output connector 343 and the second water output connector 344 are connected by a water pipe. The second water input connector 342 can be connected to the upper water inlet of the electric control assembly, and the second water output connector 344 can be connected to the upper water inlet of the electric control assembly.

[0123] It should be noted that the above-mentioned components installed on the base 311 are actually installed on the movable base 3112. Therefore, multiple movable bases 3112 can be set, and the arrangement and position relationship of the positioning and fixing parts, the connecting parts and the cooling parts on each movable base 3112 are different, which is equivalent to setting up multiple movable bases 3112 matching different electric control assemblies. The relative positions, shapes and sizes of the connecting holes on different movable bases 3112 are the same so that they can be connected to the same fixed base 3111. In other words, the same fixed base 3111 and docking plate 312 can be adapted to different movable bases 3112, and different electric control assemblies can be supported and connected by replacing different movable bases 3112.

[0124] The first docking portion is disposed on the docking plate 312, and is used to realize automatic connection between the tray and the test equipment. The first docking portion is disposed on a side of the docking plate 312 away from the base 311, and includes a primary docking member 371 and a secondary docking member 372. Fig.10As shown, two primary docking members 371 are provided, which are respectively installed at both ends of the docking plate 312. The outer diameter of the secondary docking member 372 is smaller than the inner diameter of the primary docking member 371. The center line of the primary docking member 371 is parallel to the center line of the secondary docking member 372. The first docking member on the docking installation plate 2232 can cooperate with the primary docking member 371 to form a primary floating guide, and the second docking member on the docking installation plate 2232 can cooperate with the secondary docking member 372 to form a secondary floating guide.

[0125] In this embodiment, the first-level docking member 371 is a guide cylinder, the second-level docking member 372 is a guide column, the first docking member is a guide column, and the second docking member is a guide cylinder. The first docking member can be inserted into the first-level docking member 371, and the second-level docking member 372 can be inserted into the second docking member. The outer diameter of the first docking member is smaller than the inner diameter of the first-level docking member 371, and the outer diameter of the second-level docking member 372 is not larger than the inner diameter of the second docking member. When the docking installation plate 2232 moves toward the docking plate 312, the first-level docking member 371 first contacts and docks with the first docking member, and then the second-level docking member 372 contacts and docks with the second docking member.

[0126] Based on the above structure, the docking principle of the first docking part and the second docking part 223 is as follows: the first docking part can first contact and cooperate with the first-level docking part 371, that is, first form a first-level floating guide to ensure that the entire large docking plate 312 plane guide docking is accurate; the second-level docking part 372 then contacts and docks with the second docking part to form a second-level guide to ensure that each wiring harness connector module on the docking plate 312 is accurately docked. After accurate docking, each interface on the docking installation plate 2232 is respectively connected to each plug on the docking plate 312, so that the electric control assembly and the test equipment are connected, so that different docking modules can be used later to perform various functional tests.

[0127] Obviously, the floating range of the first-level floating guide is greater than that of the second-level floating guide, which ensures that the guide is rough first and then fine, making the docking more accurate and precise, reducing the wear of the module and increasing its service life.

[0128] In this embodiment, six groups of secondary docking parts 372 are provided, each group has two secondary docking parts 372, and the six groups of secondary docking parts 372 are respectively arranged on the current input connector 331, the low voltage connector 335, the rotary connector 336, the 16-pin plug module 339, and the two current output connectors 332.

[0129] Based on the above structure, the electric control assembly is placed on the tray 3, and the plug on the tray 3 is manually inserted into the corresponding socket on the electric control assembly. The first docking portion and the docking mounting plate 2232 are automatically docked, and the tray 3 and the test equipment are automatically connected.

[0130] Now take the calibration test cabinet work as an example to explain as follows.

[0131] In this embodiment, the calibration test station cabinet calibrates the three-phase Hall current sensor of the electric control assembly.

[0132] The principle of the three-phase voltage bridge inverter circuit of the electronic control assembly is as follows: Figure 8 As shown in the dotted box A, a three-phase circuit is included, and each phase includes an upper arm and a lower arm. An IGBT and a diode connected in parallel with the IGBT are provided on the upper arm of each phase, and an IGBT and a feedback freewheeling diode connected in parallel with the IGBT are also provided on the lower arm of each phase. One end of the three lower arms of the three-phase circuit is commonly connected to the negative electrode interface 61, and one end of the three upper arms of the three-phase circuit is commonly connected to the positive electrode interface 61', and the upper arm and the lower arm of each phase are commonly connected to a Hall current sensor 60. In other words, the three-phase circuit is connected to three Hall current sensors 60 respectively.

[0133] like Figure 8 As shown, Q1 and D1 are respectively the IGBT on the upper arm of the U phase and the feedback freewheeling diode connected in parallel with the IGBT, Q2 and D2 are respectively the IGBT on the lower arm of the U phase and the feedback freewheeling diode connected in parallel with the IGBT; Q3 and D3 are respectively the IGBT on the upper arm of the V phase and the feedback freewheeling diode connected in parallel with the IGBT, Q4 and D4 are respectively the IGBT on the lower arm of the V phase and the feedback freewheeling diode connected in parallel with the IGBT; Q5 and D5 are respectively the IGBT on the upper arm of the W phase and the feedback freewheeling diode connected in parallel with the IGBT, Q6 and D6 are respectively the IGBT on the lower arm of the W phase and the feedback freewheeling diode connected in parallel with the IGBT.

[0134] The electric control assembly is also provided with a control board, a drive board, a water pipe, etc., wherein the water pipe is used to pass cooling water to cool the electric control assembly.

[0135] The test equipment includes a DC power supply 51, an output current sensor 52, a DC current contactor 53, an input current sensor 54, a rotary transformer, and the like.

[0136] The connection between the inverter circuit in the electric control assembly and the components on the tray 3 is as follows: when the electric control assembly is supported and fixed on the tray, one end of the current input connector 331 can be connected to the positive terminal of the DC power supply 51 through a wiring harness, and the other end can be connected to the current input plug 334 through a wiring harness, and the current input plug 334 can be inserted into the negative electrode interface 61 on the electric control assembly. The three-phase switching device 333 can be reliably connected to the three-phase output interface 62 on the electric control assembly, and connected to the current output connector 332 through a wiring harness. Obviously, the current output connector 332 is a three-phase connector, and the current output connector 332 is connected to a three-phase connector through a wiring harness, and the DC current contactor 53 can be controllably switched to connect to one phase of the three-phase connector.

[0137] It should be noted that the electric control assembly can be a dual-motor controller, which has two sets of inverter bridges, i.e., inverter circuits, inside. Therefore, the tray 3 in this embodiment has two current output connectors 332. The two sets of inverter bridges share a DC bus, so there is only one current input connector 331 and one current input plug 334. The tray is obviously also suitable for the electric control assembly of a single motor.

[0138] The current input connector 331 includes two terminals, one of which is a positive terminal and the other is a negative terminal. In this solution, the negative terminal is used for Hall calibration, and the negative terminal is connected to the positive electrode of the DC power supply 51. The other positive terminal is also led out to the test equipment, but it is not used for the Hall calibration test, that is, the Hall calibration current loop does not flow through the positive terminal, which is used for other tests.

[0139] The connection between the low-voltage electrical components in the electric control assembly and the components on the tray is as follows: the low-voltage connector 335 and the low-voltage plug 337 on the tray are connected through a wiring harness, and the low-voltage plug 337 is inserted into the low-voltage socket on the product and connected to the low-voltage electrical components on the product. There is only one low-voltage socket on the electric control assembly, and the low-voltage plug contains many wires, including CAN communication lines, low-voltage power supply lines, and some I / O buses with other functions. The Hall calibration uses low-voltage power supply lines and CAN lines, among which the low-voltage power supply line is connected to a low-voltage DC power supply to power the controller control board, and the CAN line is connected to the CAN box to communicate with the controller and send and receive messages.

[0140] The connection between the resolver socket of the electric control assembly and the components on the tray is as follows: one end of the resolver connector 336 is connected to the resolver through a wiring harness, and the other end is connected to the resolver plug 338 through a wiring harness. The resolver plug 338 can be inserted into the resolver socket on the electric control assembly. The resolver plug 338 also concentrates a variety of lines or wiring harnesses, including positive and negative excitation, positive and negative sine, positive and negative cosine, and motor temperature lines. The function of the resolver is to simulate the resolver on the motor and provide the motor controller with the motor rotation angle and rotation speed.

[0141] The connection between the electric control assembly and other components on the tray is as follows: one end of the 16-pin plug module 339 is connected to the power supply through a wiring harness, and the other end is connected to the first plug 3310 and the second plug 3311 through a wiring harness. The first plug 3310 and the second plug 3311 are respectively inserted into the corresponding sockets on the electric control assembly. The connected circuit is a power supply circuit. Specifically, one end of the power input line is connected to the power supply, and the other end is connected to the negative electrode interface 61 to share the bus bar, that is, the power input line is integrated in the current input plug 334 and input into the electric control assembly. After passing through the electric control assembly, it returns to the 16-pin plug module 339 through the first plug 3310 or the second plug 3311, and finally returns to the power supply to form a loop. The current passing through the first plug 3310 or the second plug 3311 supplies power to different components, such as the air conditioner on the vehicle, other electrical equipment, etc. The power supply circuit passes through the electric control assembly, which is convenient for monitoring and controlling the power supply information.

[0142] In this embodiment, the first plug 3310 is a PTC plug, and the second plug 3311 is a CMP plug.

[0143] Based on the above connection relationship, the verification principle of the three-phase Hall current sensor of the electronic control assembly is as follows: Figure 8 As shown, the arrow direction is the current direction. An output current sensor 52 is installed between the positive output terminal of the DC power supply 51 and the current input connector 331, and an input current sensor 54 is installed between the DC current contactor 53 and the negative output terminal of the DC power supply 51. When the DC current contactor 53 is controlled to switch to one of the phases connected to the three-phase connector (U phase is connected in the figure), the current in the DC power supply 51 enters the electric control assembly through the output current sensor 52, the current input connector 331 and the negative electrode interface 61 in sequence, and then flows through the feedback freewheeling diode on the lower arm of one of the phases and flows through the Hall current sensor 60 on the phase, and finally enters the negative electrode of the DC power supply 51 through the three-phase output interface 62, the three-phase switching device 333, the current output connector 332, the DC current contactor 53, and the input current sensor 54 in sequence. Assume that the current value measured by the output current sensor 52 is V1, the current value measured by the input current sensor 54 is V2, and the current value measured by the Hall current sensor 60 is V. By calculating (V1+V2) / 2-V, the error curve of the Hall sensor 60 under test is obtained. After simple data processing, the calibration of the Hall sensor 60 can be completed.

[0144] In this embodiment, the voltage of the DC power supply 51 is 10V.

[0145] Finally, it is necessary to explain here that the above embodiments are only used to further illustrate the technical solution of the present invention in detail and cannot be understood as limiting the scope of protection of the present invention. Some non-essential improvements and adjustments made by technicians in this field based on the above content of the present invention all fall within the scope of protection of the present invention.

Claims

1. A detection system for an electric vehicle electronic control assembly, characterized in that: The invention comprises a test loop (1), a workstation cabinet (2), a tray (3), a three-dimensional warehouse (4), a transfer device, and a control system. The electric control assembly to be tested is supported and installed on the tray (3). The tray (3) is automatically transported and circulated on the test loop (1). The workstation cabinet (2) and the three-dimensional warehouse (4) are used for testing the electric control assembly. The workstation cabinet (2) and the three-dimensional warehouse (4) are connected to the test loop (1). The tray (3) can be automatically transferred between the test loop (1) and the workstation cabinet (2) and between the test loop (1) and the three-dimensional warehouse (4) through the transfer device. After the tray (3) and the test equipment are fixed and positioned at the workstation cabinet (2) and the three-dimensional warehouse (4), the electric control assembly and the test equipment are automatically connected to form a test loop. The workstation (22) comprises a supporting portion (221) and a second docking portion (223), the second docking portion (223) being connected to the test equipment, the supporting portion (221) being used to carry and transport the tray (3) coming from the test loop (1), the second docking portion (223) moving and docking with the tray (3) on the supporting portion (221), connecting the electric control assembly and the test equipment; The supporting part (221) comprises a supporting and conveying support part, which is connected to the transfer device, and the supporting and conveying support part receives the tray (3) sent by the transfer device and conveys the tray (3) to a set position; The second docking part (223) includes a docking base plate (2231), a docking mounting plate (2232), and a docking cylinder (2233). The docking mounting plate (2232) is provided with a plurality of interfaces, each of which is connected to a test device. The docking mounting plate (2232) is reciprocatably mounted on the docking base plate (2231). The docking cylinder (2233) connects and drives the docking mounting plate (2232) to reciprocate linearly to the plurality of interfaces on the docking mounting plate (2232) to respectively dock with a plurality of joints on a tray (3) moved to a set position on the workstation (22). The tray (3) includes a docking plate (312). The docking plate (312) is provided with a plurality of joints, and the plurality of joints are respectively connected to a plurality of sockets of an electric control assembly on the tray (3).

2. The detection system according to claim 1, characterized in that: A plurality of workstation cabinets (2) are provided, and at least one stereoscopic warehouse (4) is provided. Different workstation cabinets (2) perform different types of inspections on the electric control assembly. The workstation cabinets (2) and the stereoscopic warehouse (4) are arranged at intervals along the transmission direction of the test loop (1).

3. The detection system according to claim 1, characterized in that: The test loop (1) is provided with a product loading point (A), a qualified product unloading point (B) and a failed product unloading point (C). A tray (3) loaded with an electric control assembly is placed on the test loop (1) from the product loading point (A) of the test loop (1). The electric control assembly that has passed all the inspection items is unloaded from the qualified product unloading point (B) along with the tray (3). When the electric control assembly fails the inspection items at any workstation (22), the electric control assembly is moved out of the test loop (1) along with the tray (3) from the failed product unloading point (C) by a transfer device.

4. The detection system according to claim 1, characterized in that: The detection system further comprises a product tray connection confirmation unit (7), which is used to confirm whether the electric control assembly and the tray (3) are correctly and completely connected.

5. The detection system according to claim 1, characterized in that: The test loop (1) comprises two parts connected in sequence, namely a main body (12) and a lifting part, wherein the lifting part comprises a lifting and steering assembly (112), an overhead conveying line (113), and a descending and steering assembly (114); one end of the main body (12), the lifting and steering assembly (112), the overhead conveying line (113), the descending and steering assembly (114), and the other end of the main body (12) are connected in sequence; the conveying direction of the pallet (3) on the overhead conveying line (113) is perpendicular to the conveying direction of the pallet (3) at one end of the main body (12) and the conveying direction of the pallet (3) at the other end of the main body (12); the lifting and steering assembly (112) lifts the pallet (3) and changes the conveying direction; the descending and steering assembly (114) lowers the pallet (3) and changes the conveying direction; and a space surrounded by the test loop (1) is provided below the overhead conveying line (113) for personnel and equipment to enter and exit.

6. The detection system according to claim 1, characterized in that: The docking installation plate (2232) also has a first docking member and a second docking member, and the docking plate (312) has a first docking member (371) and a second docking member (372). When the docking installation plate (2232) and the docking plate (312) are docked, the first docking member and the first docking member (371) cooperate to dock to form a first-level floating guide, and the second docking member and the second docking member (372) cooperate to dock to form a second-level floating guide. The floating range of the first-level floating guide is greater than the floating range of the second-level floating guide.

7. The detection system according to claim 1, characterized in that: The transfer equipment between the workstation cabinet (2) and the test loop (1) is a lifting and transplanting mechanism, and the transfer equipment between the stereoscopic warehouse (4) and the test loop (1) includes a stacker (81).

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