A power stage hardware-in-the-loop (HIL) test system and test device for motor controllers

Abstract

Embodiments of the present application provide a power stage hardware-in-the-loop (HIL) test system and test device for an executing motor controller. The test system integrates a host computer, a control module and an electronic load module to test the operating conditions of the executing motor controller. During the test, the host computer sends a preset first test operating condition instruction to the motor controller to be tested, and the motor controller generates a voltage signal based on the instruction. The electronic load module collects the voltage signal and simulates a corresponding motor current behavior, and feeds back the simulated current signal to the control module. The control module sends operation parameters including the simulated current signal to the host computer. Finally, the host computer generates a power stage HIL test result of the motor controller under a specific test operating condition according to the operation parameters. The power stage HIL test system provided by the embodiments of the present application is suitable for various power stage HIL tests of executing motor controllers.

Description

Technical Field

[0001] This application relates to the field of motor controller technology, and more specifically, to a power stage hardware-in-the-loop (HIL) test system and test apparatus for executing a motor controller. Background Technology

[0002] In the V-model development process, Hardware-in-the-Loop (HIL) simulation testing is a crucial testing method. HIL systems use real-time processors to run simulation models to model the operating state of the controlled object. Connecting to the motor controller via I / O interfaces, they perform comprehensive and systematic testing of the motor controller, reducing the number and time of real-vehicle road tests, verifying the hardware and software quality of the motor controller, and improving overall vehicle performance and reliability. Motor controller HIL systems are mainly divided into three categories: mechanical-level HIL systems, signal-level HIL systems, and power-level HIL systems.

[0003] In the power-level HIL system, the motor simulator is connected to the physical motor controller. The different load conditions of the motor simulator can test the performance of the motor controller under different operating conditions.

[0004] Among them, the actuator motor drive system structure is widely used in drive-by-wire systems such as drive-by-wire steering and drive-by-wire braking. The actuator motor controller is the core component of the drive-by-wire system. In the early stages of project development, it is of great significance to quickly verify and repeatedly test the control logic and functions of the actuator motor controller in the laboratory, and to test it under dangerous operating conditions.

[0005] However, in related technologies, the HIL system for the power stage of the actuator controller cannot meet the testing needs of some actuator controllers. Therefore, there is an urgent need for a more scalable and comprehensive HIL system for the power stage of the actuator controller. Summary of the Invention

[0006] The purpose of this application is to provide a power stage hardware-in-the-loop (HIL) test system and apparatus for motor controllers, so as to achieve the technical effect of adapting to the HIL test of various motor controllers.

[0007] The first aspect of this application provides a power stage hardware-in-the-loop (HIL) test system for an actuator motor controller. The test system is connected to the motor controller under test and includes a host computer, a control module, and an electronic load module.

[0008] The host computer is used to send a first test command to the motor controller under test according to a preset first test condition.

[0009] The motor controller under test is used to generate a voltage signal according to the first working condition test command;

[0010] The electronic load module is used to simulate the current behavior of the motor based on the voltage signal acquired from the motor controller under test, and send the generated simulated current signal to the control module.

[0011] The control module is used to generate operating parameters and send them to the host computer; the operating parameters include the analog current signal;

[0012] The host computer is also used to generate the power level HIL test results of the motor controller under test under the first test condition based on the operating parameters.

[0013] In the above implementation process, the power stage hardware-in-the-loop (HIL) test system for the motor controller integrates a host computer, a control module, and an electronic load module to perform operating condition tests on the motor controller. During the test, the host computer sends a preset first test condition command to the motor controller under test, which generates a voltage signal accordingly. The electronic load module acquires these voltage signals and simulates the corresponding motor current behavior, feeding back the simulated current signal to the control module. The control module then sends the operating parameters back to the host computer. Finally, the host computer generates the power stage HIL test results of the motor controller under specific test conditions based on the operating parameters.

[0014] Furthermore, the motor controller under test includes a power board;

[0015] The motor controller under test is specifically used to control the power board to turn on the power switch to generate the voltage signal according to the first operating condition test command.

[0016] In the above implementation process, precise control of the power switch's on and off states can ensure that the generated voltage signal highly meets the test requirements in terms of amplitude, waveform, and other parameters, thereby improving the accuracy of the test.

[0017] Furthermore, the host computer is also used to send the first working condition test command to the control module;

[0018] The control module is also used to determine the simulated position signal according to the first working condition test command;

[0019] The electronic load module is specifically used to send the acquired voltage signal to the control module;

[0020] The control module is further configured to determine the analog current parameters based on the analog position signal and the voltage signal, and send the analog current parameters to the electronic load module;

[0021] The electronic load module is specifically used to simulate the current behavior of the motor based on the simulated current parameters.

[0022] In the above implementation process, the control module first determines the simulated position signal based on the working condition test command, and then determines the simulated current parameters based on the simulated position signal and voltage signal and sends them to the electronic load module to simulate the motor current behavior, thereby improving the accuracy of the simulated current.

[0023] Furthermore, the test system is connected to the first power module; the test system also includes a second power module, a third power module, and a fourth power module;

[0024] The first power module is used to supply AC power to the second power module;

[0025] The second power module is used to supply AC power to the third power module, the fourth power module, and the control module;

[0026] The third power module is used to rectify the AC power supplied by the second power module into DC power and then supply power to the electronic load module.

[0027] The fourth power module is used to rectify the AC power supplied by the second power module into DC power and then supply power to the motor controller under test.

[0028] In the above implementation process, the test system uses an external power supply module (first power supply module) and internal power supply modules (second, third, and fourth power supply modules). These power supply modules constitute the system's power supply network. The first power supply module provides AC power to the second power supply module, which then acts as a relay station, further distributing the AC power to the third and fourth power supply modules and the control module. The third power supply module rectifies the AC power into DC power, specifically for powering the electronic load module; while the fourth power supply module also rectifies the AC power into DC power, but is used to power the controller of the motor under test.

[0029] Furthermore, the electronic load module includes a resistive-inductive load network for storing electrical energy;

[0030] The host computer is also used to send energy recovery instructions to the motor controller under test;

[0031] The motor controller under test is also used to generate a recovery signal according to the energy recovery command;

[0032] The electronic load module is further configured to recover the electrical energy stored in the resistive-inductive load network to the second power module through the third power module based on the recovery signal collected from the motor controller under test.

[0033] In the above implementation process, through the energy recovery function, the system can effectively recover and reuse the electrical energy stored in the resistive-inductive load network, avoiding the waste of this energy.

[0034] Furthermore, the testing system also includes a fault injection component;

[0035] The host computer is also used to send fault test commands to the fault injection component through the control module according to preset fault conditions.

[0036] The fault injection component is used to simulate the fault condition of the motor controller under test according to the fault test command.

[0037] The motor controller under test is also used to perform fault diagnosis and send the diagnostic information to the host computer;

[0038] The host computer is also used to generate a fault test report for the motor controller under test based on the diagnostic information.

[0039] In the above implementation process, a fault injection component is used to simulate the fault test of the motor controller under test in order to verify the fault diagnosis capability of the motor controller under test.

[0040] Furthermore, the motor controller under test is a fully redundant motor controller; the electronic load module includes a first electronic load submodule and a second electronic load submodule;

[0041] The fully redundant motor controller is used to generate a first voltage signal and a second voltage signal according to the first operating condition test command.

[0042] The first electronic load submodule is used to simulate the motor current behavior based on the first voltage signal acquired from the fully redundant motor controller, and send the generated first simulated current signal to the control module;

[0043] The second electronic load submodule is used to simulate the motor current behavior based on the second voltage signal acquired from the fully redundant motor controller, and send the generated second simulated current signal to the control module;

[0044] The control module is specifically used to generate a first operating parameter and a second operating parameter and send them to the host computer; the first operating parameter includes the first analog current signal; the second operating parameter includes the second analog current signal.

[0045] The host computer is also used to generate the power level HIL test results of the fully redundant motor controller under the first test condition based on the first operating parameters and the second operating parameters.

[0046] In the above implementation process, by simulating the current behavior of a fully redundant motor using two independent electronic load submodules, the actual current variations of a fully redundant motor in operation can be simulated more accurately. This dual-channel simulation not only improves the accuracy of the test but also increases the flexibility of the test, allowing the performance of each redundant channel to be tested separately.

[0047] Furthermore, the motor controller under test includes an external power board;

[0048] The control module is communicatively connected to the power board;

[0049] The host computer is also used to send a second test command to the control module according to the preset second test condition;

[0050] The control module is also used to send a modulation signal to the power board according to the second operating condition test command;

[0051] The power board is used to generate a third voltage signal based on the modulation signal;

[0052] The electronic load module is also used to simulate the motor current behavior based on the third voltage signal collected from the power board, and to send the third voltage signal and the modulated current signal generated by simulating the motor current behavior to the host computer through the control module;

[0053] The host computer is also used to generate the test results of the power board under the second test condition based on the third voltage signal and the modulation current signal.

[0054] In the above implementation process, separate testing of the power board was achieved.

[0055] Furthermore, the host computer is equipped with an automated testing platform and engineering software;

[0056] The automated testing platform is used to acquire test data input by the user;

[0057] The engineering software is used to generate test instructions based on the test data.

[0058] In the above implementation process, the use of an automated testing platform and engineering software on the host computer can significantly improve testing efficiency, reduce testing costs, improve testing accuracy, and facilitate test management and maintenance.

[0059] A second aspect of this application provides a testing apparatus, which includes a testing system as described in any of the first aspects. Attached Figure Description

[0060] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0061] Figure 1 A schematic diagram of a power stage hardware-in-the-loop (HIL) test system for an actuator motor controller is provided in an embodiment of this application.

[0062] Figure 2 A schematic diagram of a power supply structure for a test system provided in an embodiment of this application;

[0063] Figure 3 A schematic diagram of energy recovery provided in an embodiment of this application;

[0064] Figure 4 A schematic diagram of a test system structure for a fully redundant motor controller provided in an embodiment of this application;

[0065] Figure 5 This is a schematic diagram of the structure of a standalone test control board provided in an embodiment of this application. Detailed Implementation

[0066] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0067] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0068] Currently, most HIL (High-Intensity Link) systems for motor controller power levels are used for single-phase and three-phase motor controllers, and few can directly recover energy from motor simulators. A typical HIL system for single-phase and three-phase motor controller power levels consists of an AC / DC module, a DC / DC module, a motor simulator, the motor under test (DUT) controller, and a host computer. After AC power is connected to the system, it is rectified by the AC / DC module and converted into a stable primary DC power supply to power the DC / DC module and the motor simulator. The secondary DC power supply, after conversion by the DC / DC module, powers the DUT controller. The host computer issues torque commands to the DUT controller based on the operating conditions. The DUT controller drives the motor simulator, which, like a physical motor, simulates the stator current during motor operation and also simulates resolver and temperature signals, feeding them back to the host computer. The host computer then calculates the motor load for the next moment. This system cannot be used for fully redundant motor controllers, cannot recover power losses from the virtual motor, and can only simulate resolver-type position signals, making it unsuitable for actuator motor controllers with other types of position signal interfaces. It only allows testing of the entire controller, lacking the testing process of disassembling the controller.

[0069] To address any of the aforementioned problems, embodiments of this application provide a power stage hardware-in-the-loop (HIL) test system for an actuator motor controller, referring to... Figure 1 , Figure 1 This is a schematic diagram of a power stage hardware-in-the-loop (HIL) test system for an actuator motor controller, provided as an embodiment of this application.

[0070] In this embodiment, the test system 10 is connected to the motor controller 20 under test. The test system 10 includes a host computer 30, a control module 40, and an electronic load module 50.

[0071] The host computer 30 is used to send a first test command to the motor controller 20 under test according to a preset first test condition.

[0072] The motor controller 20 under test is used to generate a voltage signal according to the first working condition test command;

[0073] The electronic load module 50 is used to simulate the current behavior of the motor based on the voltage signal collected from the motor controller 20 under test, and send the generated simulated current signal to the control module 40;

[0074] The control module 40 is used to generate operating parameters and send them to the host computer 30; the operating parameters include the analog current signal;

[0075] The host computer 30 is also used to generate the power level HIL test result of the motor controller 20 under the first test condition based on the operating parameters.

[0076] It should be understood that power stage hardware-in-the-loop (HIL) testing is a testing technique primarily used to comprehensively verify the performance of complex devices such as motor controllers under high-power conditions. Specifically, power stage HIL testing involves connecting a real controller to a simulated controlled object (in this embodiment, primarily an electronic load module used to simulate the current and other behaviors of a real motor). By simulating the system's operating environment, in-depth testing of the controller can be achieved.

[0077] HIL testing can simulate the current and position behavior of motors under different operating conditions, given the high voltage and high current characteristics of motor controllers, thereby verifying the controller's control algorithm and performance.

[0078] It should be noted that the power stage hardware-in-the-loop (HIL) test system includes hardware devices and software modules. This test system is used to evaluate the performance of the motor under test (MUT) controller. Specifically, this test system tests the response and control capabilities of the MUT controller by simulating real or preset motor operating environments.

[0079] The motor under test (MAD) controller 20 can be an actuator motor controller, specifically used for controlling and driving the operation of the motor. This embodiment uses MAD controller 20 as an example of an actuator motor controller.

[0080] The motor under test controller 20 is the object being tested. It is a hardware device that typically includes a motor control algorithm and necessary hardware interfaces for receiving test commands and generating corresponding motor control signals.

[0081] The host computer 30 is a hardware device on which programs or software for testing run. The host computer 30 is mainly used to manage and control the testing process. Specifically, the host computer 30 is used to send a first test condition command to the motor under test controller according to a preset first test condition, receive operating parameters from the control module, and generate the power level HIL test results of the motor under test controller under the first test condition based on the received operating parameters.

[0082] The control module 40 is a software module used to generate operating parameters and send them to the host computer. The control module 40 is primarily responsible for processing signals and generating necessary control signals or data.

[0083] The electronic load module 50 is a hardware device that tests the performance of the motor controller by simulating the current behavior of an actual motor.

[0084] Understandably, the first test condition was:

[0085] Definition: A pre-set set of specific conditions or parameters used to simulate a working scenario that a motor controller may encounter in actual applications. These conditions may include the motor's speed range, load size, temperature conditions, etc. For example, a test condition table is pre-stored in the host computer. This table contains multiple sets of specific conditions, covering all working scenarios that the motor controller may encounter in actual applications. Tests are performed sequentially based on the conditions included in this table. Specifically, after completing a set of test conditions, the host computer issues the motor torque command for the next moment according to the test condition table, and all test conditions are completed sequentially.

[0086] Purpose: The purpose of the first test condition is to evaluate the performance, stability, and reliability of the motor controller under test (MTBD) under specific operating conditions. By simulating these conditions, it is possible to verify whether the controller meets the design requirements and to identify any potential problems or defects.

[0087] First operating condition test command:

[0088] Definition: Used to specify the specific operating condition for the test. The content of the first operating condition test instruction may include, but is not limited to: Target speed: Specifies the target speed that the motor should reach; Load simulation: Indicates how to simulate the motor load, which may be through external load devices or software simulation; Duration: Specifies the duration that the test condition should last.

[0089] The first operating condition test command can be a torque command.

[0090] One of its functions is to guide the controller of the motor under test on how to operate during the test.

[0091] Voltage signal:

[0092] Definition: An electrical signal generated by the motor controller under test (MTBD) to control the operation of the motor (electronic load module in the HIL environment).

[0093] Function: To drive the electronic load module to simulate the current behavior of a motor.

[0094] Analog current signal:

[0095] Definition: The signal generated by the electronic load module simulating the current response of the motor under different operating conditions.

[0096] Function: To serve as the basis for the control module to generate operating parameters.

[0097] Operating parameters:

[0098] Definition: During the test, the data generated by the control module and sent to the host computer includes analog current signals. Of course, the operating parameters can be configured to include specific content according to test requirements; for example, in addition to analog current signals, the operating parameters may also include voltage signals generated by the controller of the motor under test.

[0099] Function: To serve as the basis for generating the power level HIL test results of the motor controller under test under specific test conditions.

[0100] Test results:

[0101] Definition: The conclusions drawn by the host computer from the analysis of the received operating parameters are used to evaluate the performance of the motor controller under test.

[0102] Purpose: To provide important reference for the design, optimization and verification of motor controllers.

[0103] In this embodiment, on the one hand, the host computer can send instructions to the motor controller under test according to the preset first test conditions. These conditions can be flexibly configured according to the characteristics of different actuators, and the system can simulate the motor operation behavior under various conditions, including normal and extreme conditions, to comprehensively evaluate the performance of the actuators. On the other hand, by adjusting the simulation parameters, the system can simulate different types of motors (such as permanent magnet synchronous motors, AC asynchronous motors, etc.), thereby adapting to the testing requirements of different actuators.

[0104] Based on any of the above embodiments, the motor controller under test includes a power board;

[0105] The motor controller under test is specifically used to control the power board to turn on the power switch to generate the voltage signal according to the first operating condition test command.

[0106] It should be noted that the positional relationship between the power board and the motor controller can vary depending on the design and application requirements of different motor control systems. Their positional relationship can be that the power board is directly integrated inside the controller, or the power board is external to the motor controller, connected to the main body of the controller as an independent module. In this embodiment, the power board is integrated inside the controller.

[0107] The power board is a crucial component of a motor controller, typically containing multiple power switches (such as IGBTs and MOSFETs) used to control the magnitude and direction of the motor drive current. The high-frequency switching action of these power switches enables efficient motor control. During motor control, the power board, based on control signals from the controller, regulates the current flowing to the motor by turning the power switches on or off, thereby controlling the motor's speed and torque.

[0108] In practical implementation, when the controller of the motor under test receives the first operating condition test command, it first parses the various parameters in these commands, such as the target speed, load simulation, duration, transition conditions, and parameters to be monitored. Then, based on these parameters, the controller calculates the corresponding control strategy and generates control signals to send to the power board. After receiving the control signals, the power board opens or closes the corresponding power switches according to the signal's indication. The switching states of these power switches determine the current path in the motor drive circuit, thereby generating the required voltage signals. These voltage signals are then applied to the simulated motor, driving it to operate according to the predetermined operating conditions.

[0109] In this embodiment, by precisely controlling the power switch of the power board, the controller of the motor under test can generate a voltage signal that meets the test conditions.

[0110] Based on any of the above embodiments, the host computer is further configured to send the first working condition test command to the control module;

[0111] The control module is also used to determine the simulated position signal according to the first working condition test command;

[0112] The electronic load module is specifically used to send the acquired voltage signal to the control module;

[0113] The control module is further configured to determine the analog current parameters based on the analog position signal and the voltage signal, and send the analog current parameters to the electronic load module;

[0114] The electronic load module is specifically used to simulate the current behavior of the motor based on the simulated current parameters.

[0115] It should be noted that the control module includes a motor model algorithm and a position signal simulation interface. For example, the motor model algorithm can be a three-phase motor model algorithm; when the motor controller under test is a fully redundant motor controller, the motor model algorithm can be a dual three-phase motor model algorithm. The position signal simulation interface can include incremental encoder (ABZ) type / PWM type / Hall switch type / sine / cosine type / resolver type position signal simulation interfaces. The appropriate position signal simulation interface should be selected according to the type of motor controller under test.

[0116] The motor model algorithm is used to simulate the dynamic behavior of the motor and calculate motor parameters under various operating conditions. Based on the motor's physical characteristics and electrical parameters, this algorithm simulates the motor's actual operation using mathematical formulas and numerical methods. The position signal simulation interface can be a standalone hardware device, such as a position signal generator, or it can be part of a software module, where signal generation and output are implemented through programming. Specifically, the position signal simulation interface is a hardware or software interface used to generate and output simulated position signals. This interface generates corresponding types of position signals based on the calculation results of the motor model algorithm or external input to simulate the actual position of the motor.

[0117] Specifically, after receiving the first operating condition test command, the control module uses the position signal simulation interface to determine the simulated position signal, and calculates the simulated current parameters corresponding to the voltage signal and the simulated position signal through the motor model algorithm. The simulated current parameters include the amplitude, phase, and waveform of the current, which are used to guide the electronic load module to simulate the current behavior of the motor under specific operating conditions.

[0118] In this embodiment, the operating parameters may further include the simulated position signal calculated by the control module. The control module sends the operating parameters, which include the simulated position signal and the simulated current signal, to the host computer. The position signal and the current signal represent different aspects of the motor system. By comprehensively analyzing the position signal and the current signal, the host computer can more accurately evaluate the performance and stability of the motor controller, thereby generating more accurate power stage HIL test results.

[0119] It should be understood that, based on the received analog current parameters, the electronic load module simulates the current behavior of the motor. This is typically achieved by adjusting the internal circuitry or software algorithms of the electronic load module so that it can output a current value that matches the analog current parameters.

[0120] In this embodiment, based on simulated position and voltage signals, the control module calculates simulated current parameters and sends these parameters to the electronic load module. The electronic load module then uses these parameters to simulate the current behavior of the motor under different operating conditions. This method accurately simulates the current characteristics of the motor during actual operation, providing reliable data support for the performance evaluation of the motor under test controller.

[0121] Based on any of the above embodiments, the test system is connected to the first power module; the test system further includes a second power module, a third power module, and a fourth power module;

[0122] The first power module is used to supply AC power to the second power module;

[0123] The second power module is used to supply AC power to the third power module, the fourth power module, and the control module;

[0124] The third power module is used to rectify the AC power supplied by the second power module into DC power and then supply power to the electronic load module.

[0125] The fourth power module is used to rectify the AC power supplied by the second power module into DC power and then supply power to the motor controller under test.

[0126] It should be noted that this embodiment uses a three-phase power supply as the first power supply module, an uninterruptible power supply as the second power supply module, a bidirectional DC power supply as the third power supply module, and a programmable DC power supply module as the fourth power supply module for illustration.

[0127] Converting three-phase alternating current to direct current is a common requirement in power systems and various electronic devices because:

[0128] Improved efficiency and stability: Since direct current (DC) does not exhibit phase and frequency changes like alternating current (AC) during transmission and distribution, it reduces energy loss caused by factors such as resistance and inductance, thereby improving the efficiency of power transmission. Furthermore, the stable voltage and current waveforms of DC are beneficial for the stable operation and precise control of electronic equipment.

[0129] Adapting to specific equipment needs: Many electronic devices, especially modern ones such as computers, communication equipment, and motor controllers, require direct current (DC) as their power source. The internal circuits and components of these devices are often designed for DC, therefore converting alternating current (AC) to DC is a necessary step to meet their operational requirements.

[0130] Simplified Circuit Design: In some cases, using direct current (DC) can simplify circuit design. For example, in motor control systems, using a DC motor eliminates the need for the complex commutation devices and control systems required for AC motors. Furthermore, DC facilitates precise voltage and current regulation, thus meeting the demands of different operating conditions.

[0131] Reducing electromagnetic interference: Alternating current (AC) generates electromagnetic fields during transmission, which can lead to electromagnetic interference (EMI) and affect the normal operation of surrounding electronic equipment. Direct current (DC), on the other hand, does not generate such electromagnetic fields, thus reducing the problem of EMI.

[0132] Facilitates energy storage and distribution: DC power is easy to connect to and charge energy storage devices because the energy storage devices themselves are a type of DC power source.

[0133] Understandably, the three-phase power supply (first power module) serves as the main power source for the entire test system, providing three-phase AC power. The three-phase power supply then supplies AC power to the uninterruptible power supply (second power module), serving as the power source for subsequent power modules. Three-phase power supplies typically offer higher power and stability, making them suitable as the main power source for large-scale test systems.

[0134] An uninterruptible power supply (UPS) receives three-phase AC power from a three-phase power source (first power module) and provides a stable AC output. As an intermediary, the UPS not only supplies AC power to the bidirectional DC power source (third power module) and the programmable DC power source module (fourth power module), but also supplies power to the control module. The main function of the UPS is to ensure continuous power supply to the HIL system during external power outages or fluctuations, providing power assurance for the continued stable operation of the test system.

[0135] A bidirectional DC power supply rectifies AC power from an uninterruptible power supply (UPS) into DC power. It is used to power electronic load modules, which simulate motor loads under real-world operating conditions to test motor controller performance. The bidirectional DC power supply also has the capability to invert DC power back to AC power. A bidirectional DC power supply can be a power supply device that includes hardware components such as rectifiers and filters.

[0136] The programmable DC power supply module also rectifies the AC power provided by the uninterruptible power supply (second power supply module) into DC power. It provides two KL15 and KL30 interfaces to supply power to the motor controller under test. The programmable DC power supply module offers greater flexibility and precision, allowing for programmable control of output voltage and current to meet the needs of different testing scenarios. This is crucial for accurately testing the performance of motor controllers. The programmable DC power supply module typically includes high-precision power management circuitry and communication interfaces, and its programming functions are implemented through a built-in microprocessor or controller and corresponding hardware circuitry.

[0137] like Figure 2 As shown, Figure 2 This diagram illustrates a power supply structure for a test system provided in an embodiment of this application. The diagram shows that after a three-phase power supply is connected to the test system, it first powers an uninterruptible power supply (UPS). The UPS powers a bidirectional DC power supply, a programmable DC power supply module, and a control module. The bidirectional DC power supply, after AC / DC rectification, powers the electronic load module. The programmable power supply module, after AC / DC rectification, powers the controller of the motor under test (MUT) via a DC power line. Multiple power supply modules work together to power the entire test system.

[0138] In this embodiment, the entire test system achieves the conversion and distribution from three-phase AC to DC power through the coordinated operation of multiple power modules, providing stable and reliable power support for the HIL test of the motor controller.

[0139] Based on any of the above embodiments, the electronic load module includes a resistive-inductive load network for storing electrical energy;

[0140] The host computer is also used to send energy recovery instructions to the motor controller under test;

[0141] The motor controller under test is also used to generate a recovery signal according to the energy recovery command;

[0142] The electronic load module is further configured to recover the electrical energy stored in the resistive-inductive load network to the second power module through the third power module based on the recovery signal collected from the motor controller under test.

[0143] It should be noted that electronic load modules, in addition to inductive load networks, may also include components such as current tracking and three-phase inverter bridges. Current tracking is a core function of electronic load modules, referring to the ability of the electronic load to precisely control its input or output current to track (i.e., match) a set reference current value or a dynamically changing current signal. This function allows the electronic load to simulate the current characteristics of a real load, including steady-state and dynamic changes. The three-phase inverter bridge is a key component in electronic load modules used to convert direct current (DC) to alternating current (AC). It typically consists of six power devices (such as MOSFETs or IGBTs) connected in a specific manner to form three arms. By controlling the switching states of these power devices, DC power can be inverted into three-phase AC power, thus simulating the operating conditions of a three-phase load. An inductive load network is a load circuit composed of resistive and inductive elements, used to simulate the resistive and inductive characteristics of a real load. In electronic load modules, inductive load networks are typically used to absorb and dissipate energy to simulate power consumption under different load conditions.

[0144] The recovery signal can be a voltage signal.

[0145] It should be understood that the triggering of energy recovery commands can be based on various conditions, such as the motor being in braking mode, low grid load, or the need for charging of energy storage devices. Energy recovery commands can be transmitted to the motor controller via digital communication interfaces (such as CAN bus, Ethernet, serial port, etc.). The command content may include parameters such as the voltage range for energy recovery, current limits, recovery mode (such as fast charging, constant current charging, etc.), and recovery time. After receiving the energy recovery command, the motor controller controls the power board to generate a corresponding voltage signal. This signal is then detected by the electronic load module, which adjusts its operating state and begins recovering the energy stored in the resistive-inductive load network. The termination of energy recovery commands may be based on various conditions, such as the energy storage device being full, a sudden increase in grid load, or the need to restart the motor.

[0146] like Figure 3 As shown, Figure 3 This is a schematic diagram of energy recovery provided in an embodiment of this application. It can be seen that in drive mode, the power module supplies electrical energy to the motor controller, which converts the electrical energy into current and voltage signals and outputs them to the motor (equivalent to the electronic load module in this embodiment), thereby generating torque to drive the vehicle. In energy recovery mode, such as when the vehicle decelerates or goes downhill, the motor (equivalent to the electronic load module in this embodiment) operates as an engine, converting mechanical energy into electrical energy and recovering it to the power module through the motor controller.

[0147] This embodiment provides an energy recovery mechanism in a hardware-in-the-loop (HIL) test system for motor controllers. In this mechanism, the various components work together to achieve effective recovery and reuse of lost power, greatly reducing energy waste.

[0148] Based on any of the above embodiments, the test system further includes a fault injection component;

[0149] The host computer is also used to send fault test commands to the fault injection component through the control module according to preset fault conditions.

[0150] The fault injection component is used to simulate the fault condition of the motor controller under test according to the fault test command.

[0151] The motor controller under test is also used to perform fault diagnosis and send the diagnostic information to the host computer;

[0152] The host computer is also used to generate a fault test report for the motor controller under test based on the diagnostic information.

[0153] It should be noted that the fault injection component may include a signal conditioning module and a fault injection module. Specifically, when injecting faults into the motor controller under test, small-current fault injection and large-current fault injection can be performed through the host computer via the control module, signal conditioning module, and fault injection module to realize ground short-circuit faults, electrical short-circuit faults, open-circuit faults, and signal short-circuit faults in the motor controller under test.

[0154] Understandably, the main function of the signal conditioning module is to preprocess the input signal to ensure it is suitable for subsequent fault injection operations. This includes signal amplification, attenuation, filtering, isolation, and other processing to ensure that fault injection does not cause unnecessary damage to the test system, while also more accurately simulating signal changes in the actual working environment.

[0155] The fault injection module is the unit that actually performs the fault injection operation. It injects different types of faults into the motor controller under test by changing circuit connections, simulating short circuits or open circuits, etc. These faults include, but are not limited to, short circuits to ground, short circuits to electrical circuits, open circuits, and short circuits between signals.

[0156] In practice, testers issue fault injection commands via a host computer, specifying parameters such as the type of fault to be injected and its duration. The control module receives the commands from the host computer, parses them, and sends them to the signal conditioning module and the fault injection module. The control module may also be responsible for monitoring various parameters during the test to ensure safe testing. The signal conditioning module performs necessary preprocessing on the input signal according to the commands from the control module to match the requirements of the fault injection module. The fault injection module executes specific fault injection operations based on the commands from the control module and the output of the signal conditioning module. For example, it may simulate a short circuit to ground or an open circuit fault by changing the circuit connection, or simulate a high-current fault by injecting additional current. During the fault simulation process, the motor under test (MUT) controller monitors the system's operating status in real time and identifies and diagnoses potential faults using a built-in fault diagnosis algorithm. Once a fault is detected, the MUT controller promptly sends the diagnostic information to the host computer for evaluation of the controller's fault diagnosis capabilities. If the fault diagnosis capability of the motor controller under test fails, preventing it from feeding fault information back to the host computer, the host computer needs to adopt other strategies to indirectly assess or confirm whether the fault diagnosis capability of the motor controller has failed. For example, the following methods can be used for assessment:

[0157] Regular self-checks and heartbeat signals:

[0158] The motor controller is designed to periodically send a "heartbeat" signal or a self-test report to the host computer. This signal or report does not need to contain specific fault information, but it serves as an indication that the controller is functioning normally. If the host computer does not receive the heartbeat signal or self-test report within a predetermined time, it can be assumed that the controller's fault diagnosis capability (or at least its communication capability) may be problematic.

[0159] Monitor key parameters:

[0160] The host computer can continuously monitor key operating parameters (such as current, voltage, temperature, and speed) received from the motor controller. If these parameters fluctuate abnormally or exceed the normal range, and the host computer does not receive a corresponding fault report, this may indicate a problem with the controller's fault diagnosis capabilities.

[0161] Redundancy detection mechanism:

[0162] If system conditions permit, redundant sensors or detection elements can be introduced to monitor the status of the motor controller. These redundant elements can communicate directly with the host computer or transmit information to the host computer through an independent path. When the primary detection path (i.e., the motor controller's own fault diagnosis system) fails, the redundant detection mechanism can serve as a backup solution to identify the fault.

[0163] Human intervention and regular inspections:

[0164] Regular manual inspections and maintenance are performed, including checking the physical condition of the motor controller, its connections, and software updates. While this is not an automated method, it can help identify potential faults or problems and serves as one aspect of evaluating the controller's fault diagnosis capabilities.

[0165] Log analysis and comparison with historical data:

[0166] The host computer can record and analyze historical data from the motor controller. By comparing current data with past data, any abnormal patterns or trends can be identified, which may indicate problems with the controller's fault diagnosis capabilities.

[0167] In this embodiment, the test system introduces a fault injection component to achieve comprehensive testing and evaluation of the motor controller under test under fault conditions.

[0168] Based on any of the above embodiments, the motor controller under test is a fully redundant motor controller; the electronic load module includes a first electronic load submodule and a second electronic load submodule;

[0169] The fully redundant motor controller is used to generate a first voltage signal and a second voltage signal according to the first operating condition test command.

[0170] The first electronic load submodule is used to simulate the motor current behavior based on the first voltage signal acquired from the fully redundant motor controller, and send the generated first simulated current signal to the control module;

[0171] The second electronic load submodule is used to simulate the motor current behavior based on the second voltage signal acquired from the fully redundant motor controller, and send the generated second simulated current signal to the control module;

[0172] The control module is specifically used to generate a first operating parameter and a second operating parameter and send them to the host computer; the first operating parameter includes the first analog current signal; the second operating parameter includes the second analog current signal.

[0173] The host computer is also used to generate the power level HIL test results of the fully redundant motor controller under the first test condition based on the first operating parameters and the second operating parameters.

[0174] It should be noted that a fully redundant motor controller is an actuator motor controller with redundant design. Redundancy means adding extra hardware or software components to the system so that these backup components can take over control tasks when the primary component fails, thereby ensuring the continuity and reliability of the system. This embodiment describes the operation flow of a hardware-in-the-loop (HIL) test system for a fully redundant motor controller. Considering the characteristics of the two sets of components in the redundant system, the electronic load module and the motor model in the control module used to determine the analog position signal based on the analog current signal are both configured as two.

[0175] In its implementation, the fully redundant motor controller generates two independent voltage signals—a first voltage signal and a second voltage signal—based on a given first operating condition test command. These two signals represent the possible outputs of the controller under redundant configuration. The first electronic load submodule is responsible for acquiring the first voltage signal and simulating the motor's current behavior based on this signal. The simulated current signal (i.e., the first simulated current signal) reflects the possible current response of the motor when it receives this voltage signal. This signal is then sent to the control module. The second electronic load submodule is responsible for acquiring the second voltage signal and simulating the corresponding current behavior, generating a second simulated current signal and sending it to the control module. The control module receives the first and second simulated current signals from the two electronic load submodules and sends them to the host computer. Each set of operating parameters includes the simulated current signal, providing a data basis for subsequent testing and evaluation.

[0176] For fully redundant motor controllers, testing whether the redundant system can seamlessly switch over in the event of a fault to ensure continuous system operation is also crucial. As an example of testing the seamless switching capability of a redundant system in the event of a fault, during the test, a fault injection module can simulate a fault in the main control unit (such as power disconnection, sending error signals, etc.); the host computer monitors the operating parameters in real time, and immediately records the current state upon detecting a fault in the main control unit; then, the redundancy mechanism of the fully redundant motor controller is automatically activated, and the backup control unit takes over the control tasks; the backup control unit continues to generate voltage signals according to the first operating condition test command and simulates motor current behavior through an electronic load module; the host computer continues to receive operating parameters from the control module and verifies whether the backup control unit has successfully taken over and whether the system is operating smoothly. This includes checking whether the system operating parameters are stable and whether they meet expected values.

[0177] like Figure 4 As shown, Figure 4This is a schematic diagram of a test system structure for a fully redundant motor controller provided in an embodiment of this application. It includes a three-phase power supply, an uninterruptible power supply (UPS), a bidirectional DC power supply, a programmable DC power supply module, a real-time control system (i.e., the aforementioned control module), an electronic load module, the fully redundant motor controller under test, a signal conditioning module, a fault injection module, and a host computer. When the three-phase AC power is connected to the HIL test system, the UPS is powered first. The UPS powers the bidirectional DC power supply, the programmable DC power supply module, and the real-time control system. The UPS can continue to power the HIL system even after power is cut off externally to the cabinet. The bidirectional DC power supply can power the electronic load module and also receive feedback power from the electronic load module. The programmable DC power supply module provides two KL15 interfaces and a KL30 interface to power the fully redundant motor controller. The real-time control system includes a motor model algorithm and incremental encoder (ABZ) type / PWM type / Hall switch type / sine / cosine type / The system includes a resolver-type position signal simulation interface (allowing for switching between common motor position signal interface modules, eliminating the need for redeveloping position signal interface modules when testing different controllers; furthermore, the real-time control system provides a signal interface, enabling separate testing of the motor controller's control board and power board); electronic load modules (electronic load module 1 and electronic load module 2), each comprising an inductive load network, a three-phase inverter bridge, and a current follower); and a fault injection module (including low-current and high-current fault injection, capable of handling ground short-circuit faults, electrical short-circuit faults, open-circuit faults, and signal-to-signal short-circuit faults). During testing of the fully redundant motor controller, the host computer sends torque commands to the fully redundant motor controller and the real-time control system based on the operating conditions. Upon receiving the torque command, the fully redundant motor controller calculates the torque using its motor control algorithm and sequentially activates the switching transistors (i.e., power switches) on the controller's power board. Simultaneously, upon receiving the torque command, the real-time control system calculates the position signal (i.e., the simulated position signal) using an incremental encoder (ABZ) type / PWM type / Hall switch type / sine / cosine type / resolver type position signal simulation interface. The electronic load module acquires the dual-three-phase voltage signals from the power board and sends them to the real-time control system. The dual-three-phase motor model algorithm in the real-time control system receives the dual-three-phase voltage and position signals, calculates the dual-three-phase current signals, and sends them to the electronic load module. The electronic load module follows the received dual-three-phase current command, controlling the three-phase inverter bridge to allow current to flow through the resistive-inductive load network, thus simulating the dual-three-phase current of the fully redundant motor. The real-time control system feeds back the operating parameters, including the position and dual-three-phase current signals, to the host computer. The host computer then issues the motor torque command for the next moment based on the operating conditions. Simultaneously, the host computer can control the fully redundant motor controller, thereby controlling the motor model to recover and reuse the power lost by the electronic load module, feeding it back to the uninterruptible power supply (UPS), significantly reducing energy consumption.

[0178] In this embodiment, the entire testing process verifies and evaluates the output of the fully redundant motor controller by simulating a real motor operating environment.

[0179] Based on any of the above embodiments, the motor controller under test includes an external power board;

[0180] The control module is communicatively connected to the power board;

[0181] The host computer is also used to send a second test command to the control module according to the preset second test condition;

[0182] The control module is also used to send a modulation signal to the power board according to the second operating condition test command;

[0183] The power board is used to generate a third voltage signal based on the modulation signal;

[0184] The electronic load module is also used to simulate the motor current behavior based on the third voltage signal collected from the power board, and to send the third voltage signal and the modulated current signal generated by simulating the motor current behavior to the host computer through the control module;

[0185] The host computer is also used to generate the test results of the power board under the second test condition based on the third voltage signal and the modulation current signal.

[0186] It should be noted that in this embodiment, the power board is externally placed on the motor controller. The power board is connected to the main body of the controller as an independent module, and the power board is tested separately through the power stage hardware-in-the-loop (HIL) test system.

[0187] It should be understood that the second test condition is specifically designed for external power boards and aims to evaluate their performance under different operating conditions. These conditions may directly relate to the power board's electrical characteristics, thermal management, efficiency, and compatibility with other system components. Specifically, the second test condition may include the following aspects:

[0188] Electrical performance testing:

[0189] Voltage range: Test the stability and accuracy of the power board's output voltage under different input voltages.

[0190] Current carrying capacity: Evaluate the stability and heat dissipation capacity of the power board under continuous high current load.

[0191] Switching frequency: Test the efficiency and response speed of the power board at different PWM switching frequencies.

[0192] Thermal management test:

[0193] Temperature cycling: Simulates the operation of the power board under extreme temperature conditions to evaluate its thermal stability and thermal protection mechanisms.

[0194] Heat dissipation efficiency: Measure the temperature rise of the power board under different loads to evaluate its heat dissipation design and heat conduction efficiency.

[0195] Fault simulation and protection:

[0196] Overcurrent protection: Simulate current overload conditions to test the effectiveness of the power board's overcurrent protection mechanism.

[0197] Short circuit protection: Simulate output short circuit conditions to verify the short circuit protection capability of the power board.

[0198] Overheat protection: When the temperature exceeds the safety threshold, test whether the power board can cut off the output in time to protect itself and the motor.

[0199] Compatibility testing:

[0200] Communication with the control module: Verify the accuracy and stability of the communication protocol and data transmission between the power board and the control module.

[0201] Integration with other system components: Test the integration performance and compatibility of the power board in the entire motor control system.

[0202] Understandably, the modulation signal can be a PWM (Pulse Width Modulation) signal, which controls the average level of the output signal by changing the width of the pulse.

[0203] Power semiconductor devices (such as MOSFETs) on the power board switch according to the duty cycle of the PWM signal. When these devices are turned on, they allow current to flow, thereby generating a voltage drop across the load (such as an analog motor-electronic load module). The magnitude and shape of this voltage drop (i.e., the third voltage signal) depend on the duty cycle of the PWM signal, the characteristics of the power semiconductor devices, and the impedance of the load.

[0204] The modulated current signal is the current signal generated by the electronic load module based on a third voltage signal to simulate the current behavior of the motor. The electronic load module can send the third voltage signal to the control module, so that the control module can input the third voltage signal into the motor model for calculation, obtain the current parameters of the motor current behavior simulated by the electronic load module, and generate the modulated current signal based on the current parameters.

[0205] Furthermore, embodiments of this application also provide a method for testing a separate control board. For example... Figure 5 As shown, Figure 5This is a schematic diagram of a standalone test control board provided in an embodiment of this application. When testing the control board separately, the control module must first be connected to the control board. During automated testing of the control board, the host computer uses the Teststand testing platform to call the Veristand project and sends test signals to the control module. Upon receiving the test signals, the control module sends instructions (including position, speed, and torque information) to the control board. Upon receiving the instructions, the control board processes them using its internal motor control algorithm and sends PWM signals to the control module. Upon receiving the PWM signals, the power board model in the control module sequentially turns on the power switches, generating corresponding three-phase AC signals. The control module sends the three-phase AC signals and position simulation signals to the control board. Upon receiving the three-phase AC signals and position simulation signals, the control board processes them using its internal motor controller algorithm and sends corresponding test signals or results to the control module. The control module then sends the test signals or results sent by the control board to the host computer, which processes them into a test report.

[0206] In this embodiment, by measuring and analyzing the third voltage signal generated by the power board and the modulated current signal generated by the electronic load module simulating the motor current behavior, the host computer can comprehensively evaluate the performance of the power board under various operating conditions and realize the individual testing of the power board.

[0207] Based on any of the above embodiments, the host computer is equipped with an automated testing platform and engineering software;

[0208] The automated testing platform is used to acquire test data input by the user;

[0209] The engineering software is used to generate test instructions based on the test data.

[0210] It should be noted that the automated testing platform can be the TestStand automated testing platform, and the engineering software can be the Veristand project. TestStand is a software platform independently developed and researched by National Instruments (NI). NI TestStand is a ready-to-execute test management software that helps users develop automated test and verification systems more quickly. NI TestStand can be used to develop, execute, and deploy test system software. Furthermore, users can develop test sequences using test code modules written in any programming language. Test sequences can specify execution flows, generate test reports, perform database logging, and connect to other company systems. Finally, users can deploy the test system in production using an easy-to-use interface. A Veristand project is an engineering project based on the VeriStand software developed by NI. VeriStand is a software platform for real-time testing, verification, and deployment of control systems, supporting the construction of various test environments from Model-in-the-Loop (MIL), Software-in-the-Loop (SIL), to Hardware-in-the-Loop (HIL).

[0211] Veristand and Teststand are highly compatible and easy to use, significantly reducing the learning time for developers and testers. The Veristand project manages and configures the HIL test system for the motor controller power level. Teststand performs automated testing by calling the Veristand project, replacing manual control and greatly improving testing efficiency. The Teststand automated testing platform includes an automated testing framework, a test case editing module, a test case execution module, and a test report output module. Each module is described in detail below.

[0212] Automated testing framework: Teststand provides an automated testing framework based on a graphical library. By defining the test process and steps, an automated testing framework can be quickly built.

[0213] Test case editing module: Teststand provides graphical libraries such as calibration tool library, data evaluation library, fault injection library, action library, variable acquisition library, and inspection library, and supports calling third-party devices. When editing test cases, testers can import graphical libraries, obtain operational variables, and modify the values ​​of operational variables by dragging and dropping according to the test requirements of the fully redundant motor controller, thereby completing the test case editing.

[0214] Test Case Execution Module: Teststand allows you to change the execution order of test cases, execute a single test case, or execute multiple test cases according to testing requirements.

[0215] Test report output module: Teststand automatically generates test reports, which record test steps and are freely editable. Reports can be generated in formats such as HTML, CSV, TXT, and ATML.

[0216] Specifically, the automated testing platform provides a user interface (UI) that allows testers to input various test parameters and data. This data may include specific parameters of the test conditions (such as voltage range, current limits, speed requirements, etc.), test time, and number of tests. In addition to receiving input from testers, the automated testing platform is also responsible for managing the entire testing process. It can automatically execute a series of test steps based on the test plan set by the testers, including sending test commands, monitoring the test process, and collecting test data.

[0217] Engineering software typically contains a series of complex algorithms and models used to simulate the dynamic behavior of motors and calculate expected test results. These algorithms and models ensure the accuracy and effectiveness of test commands. It receives user input data from an automated testing platform and generates specific test commands based on this data. These test commands are then sent to the control module to control the power board's output and simulate the motor's operating conditions.

[0218] In this embodiment, the automated testing platform and engineering software are integrated into the host computer, providing robust support for motor controller testing. This integration not only improves the automation and efficiency of testing but also ensures the accuracy and reliability of test results. Through a user-friendly interface and powerful algorithm support, testers can easily set test parameters, monitor the testing process, and quickly obtain test results.

[0219] This application also provides a testing apparatus, which includes a testing system as described in any of the above embodiments.

[0220] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can also be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions marked in the blocks may occur in a different order than those marked in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram and / or flowchart, and combinations of blocks in block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0221] In addition, the functional modules in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0222] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0223] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0224] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0225] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A power stage hardware-in-the-loop (HIL) test system for executing a motor controller, characterized in that, The test system is connected to the motor controller under test and the first power module respectively. The test system includes a host computer, a control module, an electronic load module, a second power module, a third power module, and a fourth power module. The host computer is used to send a first test command to the motor controller under test according to a preset first test condition. The motor controller under test is used to generate a voltage signal according to the first working condition test command; The electronic load module is used to simulate the current behavior of the motor based on the voltage signal acquired from the motor controller under test, and send the generated simulated current signal to the control module. The control module is used to generate operating parameters and send them to the host computer; the operating parameters include the analog current signal; The host computer is also used to generate the power level HIL test results of the motor controller under test under the first test condition based on the operating parameters. The first power module is used to supply AC power to the second power module; The second power module is used to supply AC power to the third power module, the fourth power module, and the control module; The third power module is used to rectify the AC power supplied by the second power module into DC power and then supply power to the electronic load module. The fourth power module is used to rectify the AC power supplied by the second power module into DC power and then supply power to the motor controller under test. The electronic load module includes a resistive-inductive load network for storing electrical energy; The host computer is also used to send energy recovery instructions to the motor controller under test; The motor controller under test is also used to generate a recovery signal according to the energy recovery command; The electronic load module is further configured to recover the electrical energy stored in the resistive-inductive load network to the second power module through the third power module based on the recovery signal collected from the motor controller under test.

2. The testing system as described in claim 1, characterized in that, The motor controller under test includes a power board; The motor controller under test is specifically used to control the power board to turn on the power switch to generate the voltage signal according to the first operating condition test command.

3. The testing system as described in claim 1, characterized in that, The host computer is also used to send the first working condition test command to the control module; The control module is also used to determine the simulated position signal according to the first working condition test command; The electronic load module is specifically used to send the acquired voltage signal to the control module; The control module is further configured to determine the analog current parameters based on the analog position signal and the voltage signal, and send the analog current parameters to the electronic load module; The electronic load module is specifically used to simulate the current behavior of the motor based on the simulated current parameters.

4. The testing system as described in claim 1, characterized in that, The testing system also includes a fault injection component; The host computer is also used to send fault test commands to the fault injection component through the control module according to preset fault conditions. The fault injection component is used to simulate the fault condition of the motor controller under test according to the fault test command. The motor controller under test is also used to perform fault diagnosis and send the diagnostic information to the host computer; The host computer is also used to generate a fault test report for the motor controller under test based on the diagnostic information.

5. The testing system as described in claim 1, characterized in that, The motor controller under test is a fully redundant motor controller; the electronic load module includes a first electronic load submodule and a second electronic load submodule. The fully redundant motor controller is used to generate a first voltage signal and a second voltage signal according to the first operating condition test command. The first electronic load submodule is used to simulate the motor current behavior based on the first voltage signal acquired from the fully redundant motor controller, and send the generated first simulated current signal to the control module; The second electronic load submodule is used to simulate the motor current behavior based on the second voltage signal acquired from the fully redundant motor controller, and send the generated second simulated current signal to the control module; The control module is specifically used to generate a first operating parameter and a second operating parameter and send them to the host computer; the first operating parameter includes the first analog current signal; the second operating parameter includes the second analog current signal. The host computer is also used to generate the power level HIL test results of the fully redundant motor controller under the first test condition based on the first operating parameters and the second operating parameters.

6. The testing system as described in claim 1, characterized in that, The motor controller under test includes an external power board; The control module is communicatively connected to the power board; The host computer is also used to send a second test command to the control module according to the preset second test condition; The control module is also used to send a modulation signal to the power board according to the second operating condition test command; The power board is used to generate a third voltage signal based on the modulation signal; The electronic load module is also used to simulate the motor current behavior based on the third voltage signal collected from the power board, and to send the third voltage signal and the modulated current signal generated by simulating the motor current behavior to the host computer through the control module; The host computer is also used to generate the test results of the power board under the second test condition based on the third voltage signal and the modulation current signal.

7. The testing system as described in any one of claims 1-6, characterized in that, The host computer is equipped with an automated testing platform and engineering software; The automated testing platform is used to acquire test data input by the user; The engineering software is used to generate test instructions based on the test data.

8. A testing apparatus, characterized in that, The testing apparatus includes the testing system as described in any one of claims 1-7.

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