An automated testing method, device and system for motor controller

Abstract

The present invention discloses an automated testing method, device and system for motor controllers. The present invention numbers the test torque output instructions of the current batch of motor controllers, and automatically collects and analyzes the temperature and output current of preliminary qualified products under different torque output instructions, thereby reducing human operation errors and improving the consistency and accuracy of the test. Based on the temperature and output current performance of the preliminary qualified products under different torque output instructions, a comprehensive evaluation is performed to obtain the performance evaluation values ​​of the preliminary qualified products under different torque output instructions, thereby accurately evaluating the performance and stability of the preliminary qualified products under different working conditions, solving the problem in the prior art that a single testing process cannot fully cover the performance of the motor controller under various actual working conditions, resulting in the inability to accurately evaluate its performance and stability under different working conditions.

Description

Technical Field

[0001] The present invention relates to the technical field of motor controller testing, and in particular to an automated testing method, equipment and system applied to a motor controller. Background Art

[0002] As a core component in electric vehicles and industrial automation systems, the performance and reliability of motor controllers are crucial to the stability and efficiency of the entire system. With the rapid development of electric vehicles and automation technology, the performance requirements for motor controllers are becoming increasingly higher.

[0003] However, the testing methods used in the prior art for motor controllers still have the following deficiencies:

[0004] Relying on manual operation, the manual testing process is not only time-consuming, but also due to the intervention of human factors, the consistency and accuracy of the test results are difficult to guarantee;

[0005] Secondly, a single testing process cannot fully cover the performance of the motor controller under various actual working conditions, resulting in the inability to accurately evaluate its performance and stability under different working conditions.

[0006] To this end, an automated testing method, device and system for a motor controller are introduced. Summary of the invention

[0007] In view of this, the present invention provides an automated testing method, device and system for a motor controller to solve the problems raised by the above background technology.

[0008] The purpose of the present invention can be achieved by the following technical solution: An automated testing method for a motor controller, comprising:

[0009] Test preparation: Randomly select t motor controllers from the current batch of motor controllers as test items, where t>5;

[0010] Preliminary test: Install the selected test products on the fixed test fixture in sequence; run the TSMaster program to test the control panel function of each test product, and divide the selected test products into preliminary qualified products and faulty and defective products based on the test results;

[0011] Performance test: Test the performance of preliminary qualified products under different working conditions, and analyze the test results to obtain the comprehensive performance value vn of the preliminary qualified products;

[0012] Repeat the test: Based on the results of the performance test, randomly select t motor controllers from the current batch as test items and repeat the test;

[0013] Result evaluation: Based on the test results, an evaluation report for the current batch of motor controllers is generated.

[0014] In some embodiments, the TSMaster program is run to test the control panel functions of each test product, specifically:

[0015] Run the TSMaster program, flash the application layer software to each test product, and check the functions of each test product.

[0016] , determine whether each test product has faults, including whether it can normally collect temperature, DC side high voltage, and control relay closure and disconnection; use TSMaster to simulate the vehicle controller to send operation instructions to each test product, automatically read the level and duty cycle information of the drive signal detected by the oscilloscope, and determine whether the drive signal is normal;

[0017] For the test results of flashing the application layer software and issuing running instructions, if each test product fails, set a label of a different color corresponding to each fault; mark the corresponding test product with a label of the corresponding color based on the corresponding fault type, and after marking, judge the marked test product as a faulty defective product and transport it to the defective workshop; if each test product does not have any fault, then each test product is judged as a preliminarily qualified product.

[0018] In some embodiments, the performance of the preliminary qualified products under different working conditions is tested, specifically:

[0019] S1: Connect the three-phase AC output of the preliminary qualified product to the three-phase AC load, and connect the external temperature sensor and current probe to the preliminary qualified product; preset the data acquisition frequency in the TSMaster program; set the CAN communication protocol to simulate the vehicle controller to send instructions to the preliminary qualified product;

[0020] S2: Based on step S1, the TSMaster program is started to simulate the vehicle controller on the automatic CAN bus to issue a series of preset torque output instructions, and the TSMaster program starts to automatically record the temperature and output current of the preliminary qualified products;

[0021] S3: Under a preset torque output instruction, obtain the temperature value and output current value of the preliminary qualified product at different time points. First, compare the temperature value and output current value of the preliminary qualified product at different time points with the readings of the external temperature sensor and current probe. If they are consistent, execute step S4. If they are inconsistent, trigger a configuration error and send it to the technician who is in working state at the current time point;

[0022] S4: Based on a series of preset torque output instructions, set the temperature exceeding threshold value and the current exceeding threshold value of the preliminary qualified product under different torque output instructions, extract the temperature value and the output current value of the preliminary qualified product at different time points under a preset torque output instruction, and compare them with the temperature exceeding threshold value and the current exceeding threshold value set corresponding to the torque output instruction respectively. If the temperature value and the output current value of the preliminary qualified product at a certain time point are greater than the corresponding set temperature exceeding threshold value and the current exceeding threshold value, the preliminary qualified product is marked as a performance defective product; if the temperature value and the output current value of the preliminary qualified product under different torque output instructions are lower than the corresponding set temperature exceeding threshold value and the current exceeding threshold value, execute step S5;

[0023] S5: Comprehensively evaluate the temperature value and output current value of the preliminary qualified product under different torque output instructions, so as to obtain the comprehensive performance value vn of the preliminary qualified product in the current performance test process;

[0024] S6: Based on steps S1-S5, the comprehensive performance value vn of each preliminary qualified product is obtained.

[0025] In some embodiments, the comprehensive performance value vn of the preliminary qualified product in the current performance test process is obtained, specifically:

[0026] S5-501: numbering the test torque output instructions of the current batch of motor controllers, where the number is represented by k, where k=1, 2 or f, and f is the total number of test torque output instructions;

[0027] S5-502: extracting the temperature value and output current value of the preliminary qualified product at each time point under the corresponding torque output instruction, and taking the average of the temperature value and the output current value at each time point as the average temperature value and the average current value of the preliminary qualified product under the corresponding torque output instruction;

[0028] At the same time, the highest temperature value and the highest current value are extracted from the temperature values ​​and output current values ​​at each time point as the temperature peak value and current peak value of the preliminary qualified product under the corresponding torque output instruction; the temperature mean value, current mean value, temperature peak value and current peak value of the preliminary qualified product under the corresponding torque output instruction are marked as wqk, wek, wrk and wtk respectively; the temperature exceeding threshold value and current exceeding threshold value corresponding to the corresponding torque output instruction are marked as and ;

[0029] According to the formula , the temperature mean wqk, current mean wek, temperature peak wrk and current peak wtk of the preliminary qualified product under the corresponding torque output command are weightedly calculated to obtain the performance evaluation value Yk of the preliminary qualified product under the corresponding torque output command; wherein a1, a2, a3 and a4 are the preset influence weight factors corresponding to the temperature mean wqk, current mean wek, temperature peak wrk and current peak wtk respectively.

[0030] In some embodiments, obtaining the comprehensive performance value vn of the preliminary qualified product during the current performance test process further includes:

[0031] S5-503: Similarly to step S5-502, the performance evaluation value Yk of the preliminary qualified product under different torque output instructions is obtained, based on the formula The performance evaluation value Yk of the preliminary qualified product under different torque output instructions is weightedly calculated to obtain the comprehensive performance value vn of the preliminary qualified product in the current performance test process; wherein hk represents the influencing weight factor of the performance evaluation value Yk under different torque output instructions.

[0032] In some embodiments, based on the test results, an evaluation report of the current batch of motor controllers is generated, specifically:

[0033] M1: Count the number of defective products and performance defective products in the sampled test products, add them up, and calculate the ratio of the accumulated value to the total number of sampled test products, that is, the accumulated value / the total number of sampled test products, to obtain the estimated unqualified rate of the current batch of motor controllers;

[0034] M2: Extract the comprehensive performance value vn of each preliminary qualified product from the sampled test products, calculate the mean value, and obtain the estimated performance index of the current batch of motor controllers;

[0035] M3: extracting the performance evaluation value Yk of each preliminary qualified product under different torque output instructions, and performing comprehensive evaluation, thereby obtaining the performance status evaluation result of each preliminary qualified product;

[0036] M4: Fill the analysis results of steps M1-M3 into the pre-built data template to generate an evaluation report for the current batch of motor controllers.

[0037] In some embodiments, the performance evaluation value Yk of each preliminary qualified product under different torque output instructions is extracted and a comprehensive evaluation is performed, specifically:

[0038] M3-301: Calculate the performance evaluation value Yk of the preliminary qualified product under different torque output instructions using the standard deviation formula, thereby obtaining the performance fluctuation value of the preliminary qualified product;

[0039] M3-302: a reference fluctuation threshold of a preset performance fluctuation value. If the performance fluctuation value of the preliminary qualified product is greater than the preset reference fluctuation threshold, the performance state of the preliminary qualified product is determined to be a performance fluctuation state; if the performance fluctuation value of the preliminary qualified product is less than the preset reference fluctuation threshold, the performance state of the preliminary qualified product is determined to be a performance stable state;

[0040] M3-303: Based on M3-301 to M3-302, determine the performance status of each preliminary qualified product.

[0041] In some embodiments, the performance status evaluation results of each preliminary qualified product are obtained, specifically:

[0042] M3-304: Screen the preliminary qualified products whose performance status is determined to be in a performance fluctuation state as the trend analysis object, and further analyze and extract the performance evaluation value Yk of the trend analysis object under different torque output instructions, and construct a plane rectangular coordinate system, the horizontal axis represents different torque output instructions, and the torque output size of different torque output instructions is sorted from small to large, and the vertical axis represents the performance evaluation value Yk. The corresponding performance evaluation value Yk is drawn in the plane rectangular coordinate system according to the corresponding torque output instruction;

[0043] Calculate the difference between two adjacent groups of performance evaluation values ​​Yk from left to right, by subtracting the value on the left from the value on the right of the two adjacent groups of performance evaluation values ​​Yk; if the difference between two adjacent groups of performance evaluation values ​​Yk is a negative value, mark the negative value as a decreasing value, and if the difference between two adjacent groups of performance evaluation values ​​Yk is a positive value, mark the positive value as an increasing value; take the absolute values ​​of all decreasing values ​​and sum them to obtain the total decreasing value; sum all increasing values ​​to obtain the total increasing value; calculate the ratio between the total decreasing value and the total increasing value, i.e., the total decreasing value / the total increasing value, to obtain the trend ratio;

[0044] If the trend ratio of the preliminary qualified product is greater than 1, the performance fluctuation state of the preliminary qualified product is further marked as a gradually decreasing state; if the trend ratio of the preliminary qualified product is less than 1, the performance fluctuation state of the preliminary qualified product is further marked as a gradually increasing state;

[0045] In some embodiments, an automated testing device for a motor controller includes:

[0046] Three-phase AC load simulation device: receives the three-phase AC output of the motor controller;

[0047] External temperature sensor: collects temperature data from the motor controller;

[0048] Current probe: Collects output current data from the motor controller.

[0049] In some embodiments, an automated testing system for a motor controller includes:

[0050] Test sample extraction module: randomly extract t motor controllers from the current batch as test samples;

[0051] Preliminary test module: Test the control panel functions of each test product, and classify the selected test products into preliminary qualified products and faulty and defective products based on the test results;

[0052] Performance test module: Test the performance of preliminary qualified products under different working conditions, and analyze the test results to obtain the comprehensive performance value vn of the preliminary qualified products;

[0053] Result evaluation module: generates an evaluation report corresponding to the test results of the current batch of motor controllers.

[0054] Compared with the prior art, the present invention has the following beneficial effects:

[0055] The present invention numbers the test torque output instructions of the current batch of motor controllers, and automatically collects and analyzes the temperature and output current of the preliminary qualified products under different torque output instructions, thereby reducing human operation errors and improving the consistency and accuracy of the test. Based on the temperature and output current performance of the preliminary qualified products under different torque output instructions, a comprehensive evaluation is performed to obtain the performance evaluation value of the preliminary qualified products under different torque output instructions, thereby accurately evaluating the performance and stability of the preliminary qualified products under different working conditions, solving the problem that a single test process in the prior art cannot fully cover the performance of the motor controller under various actual working conditions, resulting in the inability to accurately evaluate its performance and stability under different working conditions.

[0056] The present invention generates an evaluation report of the current batch of motor controllers, extracts the performance evaluation values ​​of each preliminary qualified product under different torque output instructions, and performs a comprehensive evaluation, thereby obtaining the performance status evaluation results of each preliminary qualified product. By analyzing the trend of the performance fluctuation value, the performance status of the preliminary qualified product can be determined, providing a basis for further improvement and improving the comprehensiveness of report generation.

[0057] The present invention can more accurately evaluate and control the batch quality of motor controllers by estimating the failure rate and performance index;

[0058] The present invention reduces the need for manual operation through an automated testing process, speeds up the testing process, and improves the overall testing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Further details, features and advantages of the present application are disclosed in the following description of exemplary embodiments in conjunction with the accompanying drawings, in which:

[0060] Figure 1 is a flow chart of the present invention;

[0061] Figure 2 It is a schematic diagram of the present invention. DETAILED DESCRIPTION

[0062] Several embodiments of the present application will be described in more detail below with reference to the accompanying drawings so that those skilled in the art can implement the present application. The present application can be embodied in many different forms and purposes and should not be limited to the embodiments described herein. These embodiments are provided to make the present application comprehensive and complete, and to fully convey the scope of the present application to those skilled in the art. The embodiments do not limit the present application.

[0063] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art to which this application belongs. It will be further understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the relevant art and / or the context of this specification, and will not be interpreted in an idealized or overly formal sense unless explicitly defined as such herein.

[0064] See also Figure 1 As shown, an automated testing method for a motor controller includes:

[0065] Test preparation: Randomly select t motor controllers from the current batch of stacking locations as test items, where t>5, and the specific number is set by the technicians based on the batch size, expected failure rate, and risk tolerance; ensure that the t test items selected cover different areas of the stacking location;

[0066] Preliminary test: The extracted test products are installed on the fixed test fixture in sequence by an automated robot; after installation, the wiring harness is connected to ensure communication and data transmission between the test fixture and the motor controller; the TSMaster program is run to test the control board function of each test product, and the extracted test products are divided into preliminary qualified products and faulty and defective products based on the test results;

[0067] Run the TSMaster program to test the control panel functions of each test product, specifically:

[0068] Run the TSMaster program, flash the application layer software to each test product, and check the functions of each test product.

[0069] , determine whether each test product has a fault, including whether the temperature, DC side high voltage, and control relay closure and disconnection can be normally collected;

[0070] Use TSMaster to simulate the vehicle controller to send running instructions to each test product, automatically read the level and duty cycle information of the drive signal detected by the oscilloscope, and determine whether the drive signal is normal;

[0071] It should be noted that by performing a control board functional test first, the basic functions and hardware status of the circuit controller can be verified before the actual load test; this ensures that the basic functions of the controller are reliable before conducting more complex tests that are closer to actual working conditions.

[0072] For the test results of flashing the application layer software and issuing the running instructions, if any test product fails, such as temperature acquisition failure or abnormal drive signal, different faults are set to correspond to labels of different colors. The corresponding test products are marked with corresponding color labels based on the corresponding fault types. After marking, the marked test products are judged as defective products and transported to the defective workshop.

[0073] If no fault occurs in each test product, each test product is judged as a preliminary qualified product and proceeds to the next performance test;

[0074] Performance test: Test the performance of preliminary qualified products under different working conditions, and analyze the test results to obtain the comprehensive performance value vn of the preliminary qualified products;

[0075] Specifically:

[0076] S1: Connect the three-phase AC output of the preliminary qualified product to the three-phase AC load, and connect the external temperature sensor and current probe to the corresponding parts of the preliminary qualified product; the corresponding parts are such as the power module and the connector;

[0077] Data collected by external sensors and probes can be used as a reference to independently verify the data recorded by the TSMaster program; this helps ensure the accuracy of the data and avoid misjudgments due to program errors or sensor failures;

[0078] Preset the data collection frequency in the TSMaster program; for example, collect data every 2 seconds; set the CAN communication protocol to simulate the vehicle controller sending instructions to the preliminary qualified products;

[0079] S2: Based on step S1, the TSMaster program is started to simulate the vehicle controller on the automatic CAN bus to issue a series of preset torque output instructions, and the TSMaster program starts to automatically record the temperature and output current of the preliminary qualified products;

[0080] The torque output command is directly related to the load condition of the motor controller, allowing the motor controller to work under varying loads;

[0081] S3: Under a preset torque output instruction, obtain the temperature value and output current value of the preliminary qualified product at different time points. First, compare the temperature value and output current value of the preliminary qualified product at different time points with the readings of the external temperature sensor and current probe. If they are consistent, execute step S4. If they are inconsistent, trigger a configuration error and send it to the technician who is in working state at the current time point;

[0082] S4: Based on a series of preset torque output instructions, set the temperature exceeding threshold value and the current exceeding threshold value of the preliminary qualified product under different torque output instructions, extract the temperature value and the output current value of the preliminary qualified product at different time points under a preset torque output instruction, and compare them with the temperature exceeding threshold value and the current exceeding threshold value set corresponding to the torque output instruction respectively. If the temperature value and the output current value of the preliminary qualified product at a certain time point are greater than the corresponding set temperature exceeding threshold value and the current exceeding threshold value, the preliminary qualified product is marked as a performance defective product; if the temperature value and the output current value of the preliminary qualified product under different torque output instructions are lower than the corresponding set temperature exceeding threshold value and the current exceeding threshold value, execute step S5;

[0083] S5: Comprehensively evaluate the temperature value and output current value of the preliminary qualified product under different torque output instructions, so as to obtain the comprehensive performance value vn of the preliminary qualified product in the current performance test process;

[0084] S5-501: numbering the test torque output instructions of the current batch of motor controllers, where the number is represented by k, where k=1, 2 or f, and f is the total number of test torque output instructions;

[0085] S5-502: extracting the temperature value and output current value of the preliminary qualified product at each time point under the corresponding torque output instruction, and taking the average of the temperature value and the output current value at each time point as the average temperature value and the average current value of the preliminary qualified product under the corresponding torque output instruction;

[0086] At the same time, the highest temperature value and the highest current value are extracted from the temperature values ​​and output current values ​​at each time point as the temperature peak value and current peak value of the preliminary qualified product under the corresponding torque output instruction; the temperature mean value, current mean value, temperature peak value and current peak value of the preliminary qualified product under the corresponding torque output instruction are marked as wqk, wek, wrk and wtk respectively; the temperature exceeding threshold value and current exceeding threshold value corresponding to the corresponding torque output instruction are marked as and ;

[0087] According to the formula , weighted calculation is performed on the temperature mean wqk, current mean wek, temperature peak wrk and current peak wtk of the preliminary qualified product under the corresponding torque output command, so as to obtain the performance evaluation value Yk of the preliminary qualified product under the corresponding torque output command; wherein a1, a2, a3 and a4 are respectively the preset influence weight factors corresponding to the temperature mean wqk, current mean wek, temperature peak wrk and current peak wtk;

[0088] It should be noted that, based on the above steps, for each preset torque output instruction, the actual temperature and current value of the motor controller are compared with the set threshold value to determine whether they exceed the corresponding threshold value. When the comparison shows that they do not exceed the corresponding threshold value, the performance data of the motor controller under different torque output instructions is comprehensively evaluated, and the performance evaluation value is calculated. The performance of the motor controller under different working conditions is comprehensively evaluated, which provides a more comprehensive evaluation result and helps the continuous improvement and quality control of the product.

[0089] S5-503: Similarly to step S5-502, the performance evaluation value Yk of the preliminary qualified product under different torque output instructions is obtained, based on the formula The performance evaluation value Yk of the preliminary qualified product under different torque output instructions is weightedly calculated to obtain the comprehensive performance value vn of the preliminary qualified product in the current performance test process; wherein hk represents the influencing weight factor of the performance evaluation value Yk under different torque output instructions;

[0090] S6: Based on steps S1-S5, the comprehensive performance value vn of each preliminary qualified product is obtained;

[0091] Repeat the test: Based on the results of the performance test, randomly select t motor controllers from the current batch as test items and repeat the test;

[0092] The technicians can actively repeat the test and set the trigger conditions for the repeated test, that is, the number of faulty defective products and performance defective products is accumulated, and the proportion of the accumulated value in the number of test products t is calculated, which is recorded as the trigger proportion. A reference threshold of the trigger proportion is preset. If the calculated trigger proportion is greater than the preset reference threshold, the test products are sampled again for repeated testing.

[0093] Result evaluation: Generate an evaluation report for the current batch of motor controllers based on the test results;

[0094] Specifically:

[0095] M1: Count the number of defective products and performance defective products in the sampled test products, add them up, and calculate the ratio of the accumulated value to the total number of sampled test products, that is, the accumulated value / the total number of sampled test products, to obtain the estimated unqualified rate of the current batch of motor controllers;

[0096] M2: Extract the comprehensive performance value vn of each preliminary qualified product from the sampled test products, calculate the mean value, and obtain the estimated performance index of the current batch of motor controllers;

[0097] M3: extracting the performance evaluation value Yk of each preliminary qualified product under different torque output instructions, and performing comprehensive evaluation, thereby obtaining the performance status evaluation result of each preliminary qualified product;

[0098] M3-301: Calculate the performance evaluation value Yk of the preliminary qualified product under different torque output instructions using the standard deviation formula, thereby obtaining the performance fluctuation value of the preliminary qualified product;

[0099] M3-302: a reference fluctuation threshold of a preset performance fluctuation value. If the performance fluctuation value of the preliminary qualified product is greater than the preset reference fluctuation threshold, the performance state of the preliminary qualified product is determined to be a performance fluctuation state; that is, the performance evaluation value Yk of the preliminary qualified product under different torque output instructions has a large difference; if the performance fluctuation value of the preliminary qualified product is less than the preset reference fluctuation threshold, the performance state of the preliminary qualified product is determined to be a stable performance state;

[0100] M3-303: Based on M3-301 to M3-302, determine the performance status of each preliminary qualified product;

[0101] M3-304: Screen the preliminary qualified products whose performance status is determined to be in a performance fluctuation state as the trend analysis object, and further analyze and extract the performance evaluation value Yk of the trend analysis object under different torque output instructions, and construct a plane rectangular coordinate system, the horizontal axis represents different torque output instructions, and the torque output size of different torque output instructions is sorted from small to large, and the vertical axis represents the performance evaluation value Yk. The corresponding performance evaluation value Yk is drawn in the plane rectangular coordinate system according to the corresponding torque output instruction;

[0102] Calculate the difference between two adjacent groups of performance evaluation values ​​Yk from left to right, by subtracting the value on the left from the value on the right of the two adjacent groups of performance evaluation values ​​Yk; if the difference between two adjacent groups of performance evaluation values ​​Yk is a negative value, mark the negative value as a decreasing value, and if the difference between two adjacent groups of performance evaluation values ​​Yk is a positive value, mark the positive value as an increasing value;

[0103] Take the absolute values ​​of all the decreasing values ​​and sum them up to get the total decreasing value; sum all the increasing values ​​to get the total increasing value;

[0104] Calculate the ratio between the total value of decrease and the total value of increase, that is, the total value of decrease / the total value of increase, to get the trend ratio;

[0105] If the trend ratio of the preliminary qualified product is greater than 1, the performance fluctuation state of the preliminary qualified product is further marked as a gradually decreasing state;

[0106] It means that when the preliminary qualified products are being tested for performance, different torque output instructions will cause the performance of the preliminary qualified products to gradually decline;

[0107] If the trend ratio of the preliminary qualified product is less than 1, the performance fluctuation state of the preliminary qualified product is further marked as a gradually rising state;

[0108] It means that when the preliminary qualified products are being tested for performance, different torque output instructions will cause the performance of the preliminary qualified products to gradually increase;

[0109] M4: Fill the analysis results of steps M1-M3 into the pre-built data template to generate an evaluation report for the current batch of motor controllers.

[0110] The evaluation report includes, for example:

[0111] The production date of the current batch of motor controllers is: XX year XX month;

[0112] Total number of test items extracted: t;

[0113] Qualification: estimated failure rate;

[0114] Batch performance: estimated performance index;

[0115] Test performance status changes: the number of stable performance states is XX; the number of performance fluctuation states is XX, of which the number of gradually decreasing states accounts for XX, and the number of gradually increasing states accounts for XX;

[0116] Automatic test equipment for motor controllers, including:

[0117] Test fixture: used to fix the motor controller test product; specifically, it is a bench with a clamp that can firmly clamp the motor controller and ensure that all connections are in the correct position;

[0118] Automated robots: used to install the test product on the test fixture; specifically, industrial robotic arms can be programmed to grab the motor controller and place it in a specific location on the test fixture;

[0119] Wiring harness: ensures communication and data transmission between the test fixture and the motor controller; contains power cables for power supply and CAN bus cables for communication;

[0120] Three-phase AC load simulation device: used to receive the three-phase AC output of the motor controller; a device that simulates the actual motor load, used to test the output of the motor controller, specifically a three-phase AC motor, used to simulate the load conditions of the motor controller in actual applications;

[0121] External temperature sensor: used to collect temperature data from the motor controller; specifically, a K-type thermocouple can be installed at the hot spot of the motor controller to measure its operating temperature;

[0122] Current probe: used to collect output current data from the motor controller; specifically, a current clamp that can be clamped onto the power cord to measure the current flowing through the wire without disconnecting it;

[0123] CAN communication protocol equipment: used to simulate the vehicle controller sending instructions to the motor controller; the CAN analyzer can simulate sending torque request signals to the motor controller;

[0124] Example 2

[0125] See also Figure 2 As shown, based on an automated testing method for a motor controller provided in Example 1 of the present application, Example 2 of the present application proposes an automated testing system for a motor controller. Example 2 is only a preferred method of Example 1, and the implementation of Example 2 will not affect the independent implementation of Example 1.

[0126] Specifically, the difference of an automated test system applied to a motor controller provided in Embodiment 2 of the present application is that it includes a test product extraction module, a preliminary test module, a performance test module, and a result evaluation module;

[0127] The test sample extraction module is used to randomly extract t motor controllers from the current batch as test samples;

[0128] The preliminary test module is used to test the control board functions of each test product, and classify the extracted test products into preliminary qualified products and faulty and defective products based on the test results;

[0129] The performance test module is used to test the performance of preliminary qualified products under different working conditions, and analyze the test results to obtain the comprehensive performance value vn of the preliminary qualified products;

[0130] The result evaluation module is used to generate an evaluation report corresponding to the test results of the current batch of motor controllers.

[0131] The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to only specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. An automated testing method for a motor controller, characterized in that: include: Test preparation: Randomly select t motor controllers from the current batch of motor controllers as test items, where t>5; Preliminary test: Install the selected test products on the fixed test fixture in sequence; run the TSMaster program to test the control panel function of each test product, and divide the selected test products into preliminary qualified products and faulty and defective products based on the test results; Performance test: Test the performance of preliminary qualified products under different working conditions, and analyze the test results to obtain the comprehensive performance value vn of the preliminary qualified products; The performance of the preliminary qualified products under different working conditions is tested, specifically: S1: Connect the three-phase AC output of the preliminary qualified product to the three-phase AC load, and connect the external temperature sensor and current probe to the preliminary qualified product; preset the data acquisition frequency in the TSMaster program; set the CAN communication protocol to simulate the vehicle controller to send instructions to the preliminary qualified product; S2: Based on step S1, the TSMaster program is started to simulate the vehicle controller on the automatic CAN bus to issue a series of preset torque output instructions, and the TSMaster program starts to automatically record the temperature and output current of the preliminary qualified products; S3: Under a preset torque output instruction, obtain the temperature value and output current value of the preliminary qualified product at different time points. First, compare the temperature value and output current value of the preliminary qualified product at different time points with the readings of the external temperature sensor and current probe. If they are consistent, execute step S4. If they are inconsistent, trigger a configuration error and send it to the technician who is in working state at the current time point; S4: Based on a series of preset torque output instructions, set the temperature exceeding threshold value and the current exceeding threshold value of the preliminary qualified product under different torque output instructions, extract the temperature value and the output current value of the preliminary qualified product at different time points under a preset torque output instruction, and compare them with the temperature exceeding threshold value and the current exceeding threshold value set corresponding to the torque output instruction respectively. If the temperature value and the output current value of the preliminary qualified product at a certain time point are greater than the corresponding set temperature exceeding threshold value and the current exceeding threshold value, the preliminary qualified product is marked as a performance defective product; if the temperature value and the output current value of the preliminary qualified product under different torque output instructions are lower than the corresponding set temperature exceeding threshold value and the current exceeding threshold value, execute step S5; S5: Comprehensively evaluate the temperature value and output current value of the preliminary qualified product under different torque output instructions, so as to obtain the comprehensive performance value vn of the preliminary qualified product in the current performance test process; The comprehensive performance value vn of the preliminary qualified product in the current performance test process is obtained, specifically: S5-501: numbering the test torque output instructions of the current batch of motor controllers, where the number is represented by k, where k=1, 2 or f, and f is the total number of the test torque output instructions; S5-502: extracting the temperature value and output current value of the preliminary qualified product at each time point under the corresponding torque output instruction, and taking the average of the temperature value and the output current value at each time point as the average temperature value and the average current value of the preliminary qualified product under the corresponding torque output instruction; At the same time, the highest temperature value and the highest current value are extracted from the temperature values ​​and the output current values ​​at each time point, respectively, as the temperature peak value and the current peak value of the preliminary qualified product under the corresponding torque output instruction; The temperature mean, current mean, temperature peak and current peak of the preliminary qualified product under the corresponding torque output command are marked as wqk, wek, wrk and wtk respectively; the temperature exceeding threshold and current exceeding threshold set under the corresponding torque output command are marked as and ; According to the formula , weighted calculation is performed on the temperature mean wqk, current mean wek, temperature peak wrk and current peak wtk of the preliminary qualified product under the corresponding torque output command, so as to obtain the performance evaluation value Yk of the preliminary qualified product under the corresponding torque output command; wherein a1, a2, a3 and a4 are respectively the preset influence weight factors corresponding to the temperature mean wqk, current mean wek, temperature peak wrk and current peak wtk; S5-503: Similarly to step S5-502, the performance evaluation value Yk of the preliminary qualified product under different torque output instructions is obtained based on the formula The performance evaluation value Yk of the preliminary qualified product under different torque output instructions is weightedly calculated to obtain the comprehensive performance value vn of the preliminary qualified product in the current performance test process; wherein hk represents the influencing weight factor of the performance evaluation value Yk under different torque output instructions; S6: Based on steps S1-S5, the comprehensive performance value vn of each preliminary qualified product is obtained; Repeat the test: Based on the results of the performance test, randomly select t motor controllers from the current batch as test items and repeat the test; Result evaluation: Based on the test results, an evaluation report for the current batch of motor controllers is generated.

2. The automated testing method for a motor controller according to claim 1, characterized in that: Run the TSMaster program to test the control panel functions of each test product, specifically: Run the TSMaster program, write the application layer software to each test product, check the function of each test product, and determine whether each test product has any faults, including whether it can normally collect temperature, DC side high voltage, and control relay closure and disconnection; Use TSMaster to simulate the vehicle controller to send running instructions to each test product, automatically read the level and duty cycle information of the drive signal detected by the oscilloscope, and determine whether the drive signal is normal; For the test results of flashing the application layer software and issuing the running command, if each test product fails, set a label of a different color corresponding to each failure; Based on the corresponding fault type, the corresponding test product is marked with a corresponding color label. After marking, the marked test product is determined as a faulty defective product and transported to the defective workshop; If no failure occurs in each test product, each test product is judged as a preliminary qualified product.

3. The automated testing method for a motor controller according to claim 1, characterized in that: Based on the test results, an evaluation report for the current batch of motor controllers is generated, specifically: M1: Count the number of defective products and performance defective products in the sampled test products, add them up, and calculate the ratio of the accumulated value to the total number of sampled test products, that is, the accumulated value / the total number of sampled test products, to obtain the estimated unqualified rate of the current batch of motor controllers; M2: Extract the comprehensive performance value vn of each preliminary qualified product from the sampled test products, calculate the mean value, and obtain the estimated performance index of the current batch of motor controllers; M3: extracting the performance evaluation value Yk of each preliminary qualified product under different torque output instructions, and performing comprehensive evaluation, thereby obtaining the performance status evaluation result of each preliminary qualified product; M4: Fill the analysis results of steps M1-M3 into the pre-built data template to generate an evaluation report for the current batch of motor controllers.

4. The automated testing method for a motor controller according to claim 3, characterized in that: The performance evaluation value Yk of each preliminary qualified product under different torque output instructions is extracted and a comprehensive evaluation is performed, specifically: M3-301: Calculate the performance evaluation value Yk of the preliminary qualified product under different torque output instructions using the standard deviation formula, thereby obtaining the performance fluctuation value of the preliminary qualified product; M3-302: a reference fluctuation threshold of a preset performance fluctuation value. If the performance fluctuation value of the preliminary qualified product is greater than the preset reference fluctuation threshold, the performance state of the preliminary qualified product is determined to be a performance fluctuation state; If the performance fluctuation value of the preliminary qualified product is less than the preset reference fluctuation threshold, the performance state of the preliminary qualified product is determined to be a stable performance state; M3-303: Based on M3-301 to M3-302, determine the performance status of each preliminary qualified product.

5. The automated testing method for a motor controller according to claim 4, characterized in that: The performance status evaluation results of each preliminary qualified product are obtained, specifically: M3-304: Screen the preliminary qualified products whose performance status is determined to be in a performance fluctuation state as the trend analysis object, and further analyze and extract the performance evaluation value Yk of the trend analysis object under different torque output instructions, and construct a plane rectangular coordinate system, the horizontal axis represents different torque output instructions, and the torque output size of different torque output instructions is sorted from small to large, and the vertical axis represents the performance evaluation value Yk. The corresponding performance evaluation value Yk is drawn in the plane rectangular coordinate system according to the corresponding torque output instruction; Calculate the difference between two adjacent groups of performance evaluation values ​​Yk from left to right, by subtracting the value on the left from the value on the right of the two adjacent groups of performance evaluation values ​​Yk; if the difference between two adjacent groups of performance evaluation values ​​Yk is a negative value, mark the negative value as a decreasing value; if the difference between two adjacent groups of performance evaluation values ​​Yk is a positive value, mark the positive value as an increasing value; take the absolute values ​​of all decreasing values ​​and sum them to obtain the total decreasing value; sum all increasing values ​​to obtain the total increasing value; Calculate the ratio between the total value of decrease and the total value of increase, that is, the total value of decrease / the total value of increase, to get the trend ratio; If the trend ratio of the preliminary qualified product is greater than 1, the performance fluctuation state of the preliminary qualified product is further marked as a gradually decreasing state; If the trend ratio of the preliminary qualified product is less than 1, the performance fluctuation state of the preliminary qualified product is further marked as a gradually rising state.

6. An automated testing device for a motor controller, applying an automated testing method for a motor controller according to any one of claims 1 to 5, comprising: Three-phase AC load simulation device: receives the three-phase AC output of the motor controller; External temperature sensor: collects temperature data from the motor controller; Current probe: Collects output current data from the motor controller.

7. An automated testing system for a motor controller, applying an automated testing method for a motor controller according to any one of claims 1 to 5, comprising: Test sample extraction module: randomly extract t motor controllers from the current batch as test samples; Preliminary test module: Test the control panel functions of each test product, and classify the selected test products into preliminary qualified products and faulty and defective products based on the test results; Performance test module: Test the performance of preliminary qualified products under different working conditions, and analyze the test results to obtain the comprehensive performance value vn of the preliminary qualified products; Result evaluation module: generates an evaluation report corresponding to the test results of the current batch of motor controllers.

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