Motor controller test system and method

Abstract

The invention discloses a motor controller testing system and method, and relates to the field of electric vehicle high-voltage system testing, a first energy conversion unit is connected with a mains supply, the output end of a direct current bus is connected with the input end of a battery simulation unit and the output end of a motor simulation unit, and the output end of the battery simulation unit is connected with the input end of a tested motor controller; the input end of the motor simulation unit is connected with the output end of the tested motor controller, and the output signal line of the motor simulation unit is connected with the tested motor controller. The tested motor controller takes electric energy from a direct current side according to a preset value and outputs three-phase current to the motor simulation unit, the motor simulation unit simulates information such as torque, rotating speed and temperature according to the magnitude of the three-phase current and feeds back the information to the tested motor controller, and the tested motor controller performs closed-loop adjustment according to a feedback value and the preset value. And the three-phase output current is dynamically adjusted. The motor controller test system provided by the invention is simple in platform, simple to control and high in test precision.

Description

Technical Field

[0001] The present invention relates to the field of electric vehicle high voltage system testing, and in particular to a motor controller testing system and method. Background Art

[0002] The high-voltage system components of electric vehicles, including motor controllers, are strictly tested during the production process and vehicle debugging. Motor controller testing involves vehicle dynamics simulation and electrical controller system simulation. There are three common testing methods for motor controllers. The first is to use a bench towing method to simulate the vehicle power transmission process. This test method has a large mechanical power platform, poor safety, many electrical control devices, and a complex cooling system, as described in 202410599929.4, a durability test method for motor controllers. The second is that some systems with simulators, such as CN118707326A, a stall heating test bench, method, device, industrial computer, medium and product, have the disadvantages of being unable to separate from mechanical power transmission equipment, many electrical equipment, and low power cycle efficiency. The third is hardware-in-the-loop testing. This test method is a semi-physical model, the data lacks realism, and the accuracy is low, as described by Su Jianhua in the design and development of hardware-in-the-loop test system for automotive permanent magnet synchronous motor controllers.

[0003] It is of certain forward-looking significance and engineering value to develop a motor controller testing method and system with less electrical equipment, less or no mechanical power simulation structure, a simple cooling system or no cooling system, and high power circulation efficiency. Summary of the invention

[0004] The purpose of the present invention is to provide a motor controller testing system and method, which can solve the problems of the prior art that the mechanical power platform is large, the safety is poor, the electrical control equipment is numerous, the cooling system is complex, the power circulation efficiency is low, and the semi-physical simulation accuracy is low.

[0005] In order to achieve the above object, the present invention is implemented through the following technical solutions: A motor controller test system comprises: a first energy conversion unit, a battery simulation unit, a motor simulation unit, and a motor controller to be tested; The first energy conversion unit is connected to the mains, and is used to convert the mains into a DC bus and achieve electrical isolation. The DC bus output end of the first energy conversion unit is respectively connected to the battery simulation unit input end and the motor simulation unit output end; The output terminal of the battery simulation unit is connected to the input terminals DC+ and DC- of the motor controller under test, so as to input electric energy to the motor controller under test; The motor simulation unit input terminals L1, L2, and L3 are connected to the output terminals of the motor controller under test for receiving electric energy, and the motor simulation unit output signal line is connected to the motor controller under test for providing motor information.

[0006] Furthermore, the host computer is connected to the first energy exchange unit, the battery simulation unit, the motor simulation unit, and the motor controller under test through a communication bus.

[0007] Furthermore, the motor information includes speed, torque, and temperature.

[0008] Optionally, the first energy conversion unit includes a three-phase transformer, a first four-quadrant rectifier and a second four-quadrant rectifier, the three-phase transformer includes a group of primary sides and two groups of secondary sides, the primary sides are connected to the AC power, the two groups of secondary sides are respectively connected to the input end of the first four-quadrant rectifier and the input end of the second four-quadrant rectifier, the output end of the first four-quadrant rectifier is connected to the input ends Udc1+ and Udc1- of the battery simulation unit, and the output end of the second four-quadrant rectifier is connected to the output ends Udc2+ and Udc2- of the motor simulation unit.

[0009] Optionally, the first energy conversion unit includes a three-phase transformer and a four-quadrant rectifier, the three-phase transformer includes a group of primary sides and a group of secondary sides, the primary sides are connected to the AC power, and the secondary sides are connected to the input end of the four-quadrant rectifier, and the output ends Udc+ and Udc- of the four-quadrant rectifier are respectively connected to the input ends Udc1+ and Udc1- of the battery simulation unit and the output ends Udc2+ and Udc2- of the motor simulation unit.

[0010] Optionally, the first energy conversion unit includes a four-quadrant rectifier and an LLC resonant converter, the input end of the four-quadrant rectifier is connected to the AC power, the input end of the LLC resonant converter is connected to the output end of the four-quadrant rectifier, the output end Udc+ of the LLC resonant converter is respectively connected to the input end Udc1+ of the battery simulation unit and the output end Udc2+ of the motor simulation unit, and the output end Udc- of the LLC resonant converter is respectively connected to the input end Udc1- of the battery simulation unit and the output end Udc2- of the motor simulation unit.

[0011] Furthermore, the four-quadrant rectifier may be a two-level PWM rectifier, an I-type PWM rectifier or a T-type PWM rectifier.

[0012] A motor controller testing method is implemented according to the motor controller testing system, comprising the steps of: S1, the host computer sends the preset value of the motor information to the motor controller under test; S2, the motor controller under test takes power from the DC side DC+ and DC- according to the preset value, and outputs three-phase current to the motor simulation unit; S3, the motor simulation unit simulates the motor information according to the magnitude of the three-phase current and feeds it back to the motor controller under test; S4. The motor controller under test performs closed-loop regulation according to the feedback value and preset value of the motor information, dynamically adjusts the three-phase output current, and achieves a dynamic stable state.

[0013] Furthermore, the method further comprises the steps of: After the system is powered on and reaches a dynamic stable state, it is detected and determined whether there is an alarm signal on the communication bus. If there is no alarm signal, the test steps S1-S4 are executed; If there is an alarm signal, stop the test.

[0014] The advantages of the present invention are: Completely separated from the mechanical power transmission system, all motor controller tests are reduced to the control and measurement of electrical energy.

[0015] The existence of a complete physical system improves the realism and accuracy of the data and overcomes the shortcomings of the traditional hardware-in-the-loop semi-physical testing method.

[0016] A unique electric energy circulation loop is designed to improve the circulation efficiency of electric energy.

[0017] The motor controller test system provided by the present invention has a simple platform, simple control, high test accuracy and high energy efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a schematic diagram of a motor controller test system according to Embodiment 1 of the present invention; Figure 2 This is a flow chart of a motor controller testing method according to Embodiment 2 of the present invention; Figure 3 Schematic diagram of a motor controller test system according to Embodiment 3 of the present invention; Figure 4 Schematic diagram of a motor controller test system according to Embodiment 4 of the present invention; Figure 5 Schematic diagram of a motor controller test system according to Embodiment 5 of the present invention; Figure 6 is a circuit diagram of a four-quadrant rectifier as a two-level rectifier in Embodiment 6 of the present invention; Figure 7 4 is a circuit diagram of a four-quadrant rectifier in Embodiment 6 of the present invention that is a type I three-level rectifier; Figure 8 This is a circuit diagram of a four-quadrant rectifier in Embodiment 6 of the present invention, which is a T-type three-level rectifier. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0020] Example 1 This embodiment discloses a motor controller test system, including: a host computer, a first energy conversion unit, a battery simulation unit, a motor simulation unit, and a motor controller to be tested. Figure 1 .

[0021] The first energy conversion unit is connected to the mains, and is used to convert the mains into a DC bus and achieve electrical isolation. The DC bus output end of the first energy conversion unit is respectively connected to the battery simulation unit input end and the motor simulation unit output end; The output terminal of the battery simulation unit is connected to the input terminals DC+ and DC- of the motor controller under test, so as to input electric energy to the motor controller under test; The motor simulation unit input terminals L1, L2, and L3 are connected to the output terminals of the motor controller under test for receiving electric energy. The motor simulation unit output signal line is connected to the motor controller under test for providing motor information, including speed, torque, temperature, etc. The host computer is connected to the first energy exchange unit, the battery simulation unit, the motor simulation unit, and the motor controller under test through a communication bus.

[0022] Example 2 This embodiment proposes a motor controller testing method, which is based on the system implementation of embodiment 1. For the specific process, please refer to Figure 2 .

[0023] First, after the system is powered on, determine whether there is an alarm signal on the communication bus. If there is an alarm, stop testing, check the fault, and clear the fault.

[0024] If there is no alarm, the test steps are executed: the host computer sends the preset value of the motor speed or torque to the motor controller under test. The motor controller under test takes power from the DC side DC+ and DC- according to the preset value, and outputs three-phase current to the motor simulation unit. The motor simulation unit simulates the motor information according to the size of the three-phase current and feeds it back to the motor controller under test. The motor controller under test performs closed-loop regulation according to the feedback value and preset value of the motor information, dynamically adjusts the three-phase output current, and achieves a dynamically stable state.

[0025] Check again whether there is an alarm signal on the communication bus. If there is no alarm, continue to perform the above test steps. If there is an alarm, stop testing, check the fault, and clear the fault.

[0026] Example 3 This embodiment provides an implementation of the first energy conversion unit. Please refer to Figure 3The motor controller test system includes a first energy conversion unit, a battery simulation unit, a motor controller under test and a motor simulation unit. The first energy conversion unit includes a three-phase transformer, a first four-quadrant rectifier and a second four-quadrant rectifier. The three-phase transformer includes a set of primary sides and two sets of secondary sides. The primary side is connected to the mains, and the two sets of secondary sides are respectively connected to the input end of the first four-quadrant rectifier and the input end of the second four-quadrant rectifier. The output end of the first four-quadrant rectifier is connected to the input ends Udc1+ and Udc1- of the battery simulation unit, and the output end of the second four-quadrant rectifier is connected to the output ends Udc2+ and Udc2- of the motor simulation unit. The output end of the battery simulation unit is connected to the input ends DC+ and DC- of the motor controller under test, and the input ends L1, L2 and L3 of the motor simulation unit are connected to the output end of the motor controller under test. The output signal lines of the motor simulation unit such as speed, torque and temperature are connected to the motor controller under test.

[0027] Example 4 This embodiment provides an implementation of the first energy conversion unit. Please refer to Figure 4 The first energy conversion unit includes a three-phase transformer and a four-quadrant rectifier. The three-phase transformer includes a group of primary sides and a group of secondary sides. The primary side is connected to the mains, and the secondary side is connected to the input end of the four-quadrant rectifier. The output ends Udc+ and Udc- of the four-quadrant rectifier are respectively connected to the input ends Udc1+ and Udc1- of the battery simulation unit and the output ends Udc2+ and Udc2- of the motor simulation unit. The output end of the battery simulation unit is connected to the input ends DC+ and DC- of the motor controller under test, and the input ends L1, L2, and L3 of the motor simulation unit are connected to the output end of the motor controller under test. The output signal lines of the motor simulation unit such as speed, torque, and temperature are connected to the motor controller under test.

[0028] Example 5 This embodiment provides an implementation of the first energy conversion unit. Please refer to Figure 5 The first energy conversion unit includes a four-quadrant rectifier and an LLC resonant converter. The input end of the four-quadrant rectifier is connected to the mains, the input end of the LLC resonant converter is connected to the output end of the four-quadrant rectifier, the output end Udc+ of the LLC resonant converter is respectively connected to the input end Udc1+ of the battery simulation unit and the output end Udc2+ of the motor simulation unit, and the output end Udc- of the LLC resonant converter is respectively connected to the input end Udc1- of the battery simulation unit and the output end Udc2- of the motor simulation unit. The output end of the battery simulation unit is connected to the input ends DC+ and DC- of the motor controller under test, the input ends L1, L2, and L3 of the motor simulation unit are connected to the output end of the motor controller under test, and the output signal lines of the motor simulation unit such as speed, torque, and temperature are connected to the motor controller under test.

[0029] Example 6 This embodiment provides several implementation methods of the four-quadrant rectifier in Embodiment 5. Please refer to Figure 6 , Figure 7 , Figure 8 .

[0030] Figure 6 It is a two-level PWM rectifier. Each bridge arm consists of two switching tubes and their body diodes. The three-phase electricity is connected to the midpoints of the three bridge arms respectively.

[0031] Figure 7 It is a type I PWM rectifier. Taking phase A as an example, the bridge arm is composed of Ta1~Ta4 and their body diodes. Two diodes Da5 and Da6 are connected in series between the midpoints of Ta3, Ta4 and the midpoints of Ta1, Ta2. The positive pole of Da6 is connected to the midpoints of Ta3, Ta4, and the negative pole of Da5 is connected to the midpoints of Ta1, Ta2. The phase A is connected to the midpoint of the bridge arm (i.e., the midpoint of Ta2, Ta3).

[0032] Figure 8 It is a T-type PWM rectifier. Taking phase A as an example, the AC input is connected to the midpoint of the switch tubes Ta1 and Ta4 and one end of Ta3. After Ta3 and Ta2 are connected in reverse series, the other end of Ta2 is connected to point O.

[0033] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A motor controller test system, characterized in that: include: A first energy conversion unit, a battery simulation unit, a motor simulation unit, and a motor controller under test; The first energy conversion unit is connected to the mains power, and is used to convert the mains power into a DC bus and realize electrical isolation, and the DC bus output end of the first energy conversion unit is respectively connected to the battery simulation unit input end and the motor simulation unit output end; The output end of the battery simulation unit is connected to the input ends DC+ and DC- of the motor controller under test, so as to input electric energy to the motor controller under test; The motor simulation unit input terminals L1, L2, and L3 are connected to the output terminals of the motor controller under test for receiving electric energy, and the motor simulation unit output signal line is connected to the motor controller under test for providing motor information.

2. The motor controller test system according to claim 1, characterized in that: It also includes a host computer, which is connected to the first energy exchange unit, the battery simulation unit, the motor simulation unit, and the motor controller under test through a communication bus.

3. The motor controller test system according to claim 1, characterized in that: The motor information includes rotation speed, torque, and temperature.

4. The motor controller test system according to claim 1, characterized in that: The first energy conversion unit includes a three-phase transformer, a first four-quadrant rectifier and a second four-quadrant rectifier. The three-phase transformer includes a group of primary sides and two groups of secondary sides. The primary sides are connected to the AC power, and the two groups of secondary sides are respectively connected to the input end of the first four-quadrant rectifier and the input end of the second four-quadrant rectifier. The output end of the first four-quadrant rectifier is connected to the input ends Udc1+ and Udc1- of the battery simulation unit, and the output end of the second four-quadrant rectifier is connected to the output ends Udc2+ and Udc2- of the motor simulation unit.

5. The motor controller testing system according to claim 1, characterized in that: The first energy conversion unit includes a three-phase transformer and a four-quadrant rectifier. The three-phase transformer includes a group of primary sides and a group of secondary sides. The primary sides are connected to the AC power, and the secondary sides are connected to the input end of the four-quadrant rectifier. The output ends Udc+ and Udc- of the four-quadrant rectifier are respectively connected to the input ends Udc1+ and Udc1- of the battery simulation unit and the output ends Udc2+ and Udc2- of the motor simulation unit.

6. The motor controller testing system according to claim 1, characterized in that: The first energy conversion unit includes a four-quadrant rectifier and an LLC resonant converter, the input end of the four-quadrant rectifier is connected to the AC power, the input end of the LLC resonant converter is connected to the output end of the four-quadrant rectifier, the output end Udc+ of the LLC resonant converter is respectively connected to the input end Udc1+ of the battery simulation unit and the output end Udc2+ of the motor simulation unit, and the output end Udc- of the LLC resonant converter is respectively connected to the input end Udc1- of the battery simulation unit and the output end Udc2- of the motor simulation unit.

7. The motor controller testing system according to claim 1, characterized in that: The four-quadrant rectifier is a two-level PWM rectifier, an I-type PWM rectifier or a T-type PWM rectifier.

8. A motor controller testing method, characterized in that: The motor controller test system according to any one of claims 2 to 7 is implemented, comprising the steps of: S1, the host computer sends the preset value of the motor information to the motor controller under test; S2, the motor controller under test takes power from the DC side DC+ and DC- according to the preset value, and outputs three-phase current to the motor simulation unit; S3, the motor simulation unit simulates the motor information according to the magnitude of the three-phase current and feeds it back to the motor controller under test; S4. The motor controller under test performs closed-loop regulation according to the feedback value and preset value of the motor information, dynamically adjusts the three-phase output current, and achieves a dynamic stable state.

9. The motor controller testing method according to claim 8, characterized in that: Also includes the steps: After the system is powered on and reaches a dynamic stable state, it is detected and determined whether there is an alarm signal on the communication bus. If there is no alarm signal, the test steps S1-S4 are executed; If there is an alarm signal, stop the test.

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