Range extender simulation method, device and system

Abstract

The invention relates to a range extender simulation method, device and system, and relates to the technical field of engineering machinery. The simulation method of the range extender comprises the following steps: simulating an engine by using a driving motor and a motor controller; a range extender system is simulated in conjunction with a generator, a range extender controller, and a simulated engine.

Description

Technical Field

[0001] The present disclosure relates to the technical field of engineering machinery, and in particular to a simulation method, device, and system for a range extender. Background Art

[0002] Range extender technology is increasingly being used in modern electric vehicles, playing a crucial role in improving power output and meeting environmental regulations. Conventional range extender testing requires the combined engine and generator commissioning, a complex process that requires a test site that meets engine exhaust emission standards. Summary of the Invention

[0003] A technical problem to be solved by the present disclosure is: how to improve the test efficiency of the range extender.

[0004] According to a first aspect of some embodiments of the present disclosure, a range extender simulation method is provided, comprising: simulating an engine using a drive motor and a motor controller; and simulating a range extender system by combining a generator, a range extender controller, and the simulated engine.

[0005] In some embodiments, simulating an engine using a drive motor and a motor controller includes: simulating an engine body using a drive motor and a motor controller; simulating an engine controller using a first simulated communication node; and combining the simulated engine body and the simulated engine controller to simulate an engine system.

[0006] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system includes: connecting a drive motor and a generator through a coupling, connecting the drive motor and a motor controller through a three-phase power line, connecting a domain controller to a first simulated communication node through a CAN communication line and to the three-phase power line of the generator, and connecting the motor controller to the first simulated communication node through a CAN communication line to simulate the range extender system, wherein the domain controller is integrated with the range extender controller and the generator controller.

[0007] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system further includes: connecting the busbar harness of the motor controller and the busbar harness of the domain controller to a battery simulator to provide a high-voltage power supply through the battery simulator; connecting the motor controller and the domain controller to a low-voltage power supply; connecting the motor controller, the drive motor, the domain controller, and the generator to a cooling water circulation system to dissipate heat for the range extender system through the cooling water circulation system; and connecting the motor controller, the drive motor, the domain controller, and the generator to a resolver line and a motor temperature detection line.

[0008] In some embodiments, combining the generator, the range extender controller and the simulated engine to simulate the range extender system also includes: connecting the first sampling line of the power analyzer to the bus of the domain controller to collect the bus voltage and bus current of the domain controller; connecting the second sampling line of the power analyzer to the three-phase end of the generator to collect the voltage and current of the three-phase end of the generator; and connecting a speed torque meter between the generator and the drive motor to collect the speed and torque of the generator.

[0009] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system further includes: connecting a speed torque meter to a power analyzer for signal connection so as to parse the signal collected by the speed torque meter through the power analyzer; and connecting the power analyzer to a host computer for signal connection so as to monitor the status of the generator through the host computer.

[0010] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system further includes: configuring a domain controller to be connected to a second simulated communication node via a CAN communication line, connecting the range extender controller to a first simulated communication node via a CAN communication line, and communicating between the range extender controller and the generator controller via inter-core communication, wherein the second simulated communication node is used to simulate a vehicle controller.

[0011] In some embodiments, the aforementioned simulation method further includes: sending instructions to the domain controller through the second simulation communication node, so that the domain controller interacts with the generator controller and the first simulation communication node according to the instructions, thereby making the generator and the drive motor work.

[0012] In some embodiments, the aforementioned simulation method further includes: after performing a functional test on the range extender system, performing a performance test on the generator in the range extender system, wherein the functional test includes at least one of communication function debugging, start-stop function debugging, power generation function debugging, and power function debugging, and the performance test includes at least one of a generator efficiency test and a generator temperature rise test.

[0013] According to a second aspect of some embodiments of the present disclosure, a simulation device for a range extender is provided, comprising: a first simulation module configured to simulate an engine using a drive motor and a motor controller; and a second simulation module configured to combine a generator, a range extender controller, and a simulated engine to simulate a range extender system.

[0014] According to a third aspect of some embodiments of the present disclosure, a range extender simulation device is provided, comprising: an engine, which is simulated using a drive motor and a motor controller; a generator; and a range extender controller.

[0015] In some embodiments, the aforementioned simulation device further includes: a generator controller; and a first simulation communication node configured to simulate an engine controller.

[0016] In some embodiments, the range extender controller and the generator controller are integrated into a domain controller.

[0017] In some embodiments, the drive motor is connected to the generator through a coupling, the drive motor is connected to the motor controller through a three-phase power line, the domain controller is connected to the first analog communication node through a CAN communication line and to the three-phase power line of the generator, and the motor controller is connected to the first analog communication node through a CAN communication line.

[0018] According to a fourth aspect of some embodiments of the present disclosure, a simulation system for a range extender is provided, comprising: a simulation device as described above; a battery simulator, connected to the busbar harness of the motor controller and the busbar harness of the domain controller, and configured to provide a high-voltage power supply; a low-voltage power supply, connected to the motor controller and the domain controller; a cooling water circulation system, connected to the motor controller, the drive motor, the domain controller, and the generator, and configured to dissipate heat for the range extender; a resolver line, connected to the motor controller, the drive motor, the domain controller, and the generator; and a motor temperature detection line, connected to the motor controller, the drive motor, the domain controller, and the generator.

[0019] In some embodiments, the aforementioned simulation system also includes: a power analyzer, the first sampling line of the power analyzer is connected to the bus of the domain controller, and is configured to collect the bus voltage and bus current of the domain controller, the second sampling line of the power analyzer is connected to the three-phase end of the generator, and is configured to collect the voltage and current of the three-phase end of the generator; a speed torque meter, connected to the coupling between the generator and the drive motor, and configured to collect the speed and torque of the generator; the power analyzer is connected to the power analyzer signal, and the power analyzer is configured to parse the signal collected by the speed torque meter.

[0020] In some embodiments, the aforementioned simulation system further includes: a host computer connected to the power analyzer and configured to monitor the status of the generator.

[0021] In some embodiments, the aforementioned simulation system further includes: a second simulation communication node, configured to simulate a vehicle controller, and connected to the domain controller via a CAN communication line.

[0022] In some embodiments, the range extender controller is connected to the first analog communication node via a CAN communication line, and the range extender controller is connected to the generator controller via inter-core communication.

[0023] According to a fifth aspect of some embodiments of the present disclosure, a simulation device for a range extender is provided, comprising: a processor; and a memory coupled to the processor, for storing instructions, which, when executed by the processor, causes the processor to execute the above-mentioned range extender simulation method.

[0024] According to a sixth aspect of some embodiments of the present disclosure, a computer-readable storage medium is provided, on which computer instructions are stored, wherein the instructions, when executed by a processor, implement the above-mentioned range extender simulation method.

[0025] According to a seventh aspect of some embodiments of the present disclosure, there is provided a computer program product comprising instructions, which, when executed by a processor, cause the processor to perform the range extender simulation method as described above.

[0026] This paper uses a drive motor and motor controller to simulate an engine, combined with a generator and range extender to simulate a range extender system. This allows for range extender testing using motor-to-motor traction, which not only improves test efficiency but also eliminates the need for exhaust emissions testing at the test site, making range extender testing more convenient.

[0027] Other features and advantages of the present disclosure will become apparent from the following detailed description of exemplary embodiments of the present disclosure with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present disclosure or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0029] Figure 1 A schematic flow chart of a method for simulating a range extender according to some embodiments of the present disclosure is shown.

[0030] Figure 2 A schematic structural diagram of a simulated range extender system according to some embodiments of the present disclosure is shown.

[0031] Figure 3 A schematic structural diagram of a simulated range extender system according to other embodiments of the present disclosure is shown.

[0032] Figure 4 A schematic diagram of a communication network of a simulated range extender system according to some embodiments of the present disclosure is shown.

[0033] Figure 5 A schematic diagram illustrating a test process of a simulated range extender system according to some embodiments of the present disclosure is shown.

[0034] Figure 6 A schematic structural diagram of a range extender simulation device according to some embodiments of the present disclosure is shown.

[0035] Figure 7 A schematic structural diagram of a range extender simulation device according to other embodiments of the present disclosure is shown.

[0036] Figure 8 A schematic structural diagram of a range extender simulation system according to some embodiments of the present disclosure is shown.

[0037] Figure 9 A schematic structural diagram of a range extender simulation device according to other embodiments of the present disclosure is shown.

[0038] Figure 10 A schematic structural diagram of a range extender simulation device according to some further embodiments of the present disclosure is shown. DETAILED DESCRIPTION

[0039] The following will be combined with the drawings in the embodiments of the present disclosure to clearly and completely describe the technical solutions in the embodiments of the present disclosure. Obviously, the described embodiments are only part of the embodiments of the present disclosure, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present disclosure and its application or use. Based on the embodiments in the present disclosure, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present disclosure.

[0040] Figure 1 FIG. 1 is a flow chart showing a method for simulating a range extender according to some embodiments of the present disclosure. Figure 1 As shown, the method of this embodiment includes steps S102 to S104.

[0041] In step S102 , a driving motor and a motor controller are used to simulate an engine.

[0042] A range extender is used to extend the vehicle's range when the vehicle's battery is low. It consists of an engine and a generator. The engine typically converts chemical energy (such as from gasoline combustion) into kinetic energy, which is then converted into electrical energy by the generator and stored in the battery pack.

[0043] During the test process of the range extender, it is necessary to provide chemical energy to the engine, and the engine will also emit exhaust gas. This will not only increase the complexity of the test and consume manpower and material resources, but also place high requirements on the test site. The test work of the range extender cannot be completed in an ordinary laboratory.

[0044] Therefore, the present disclosure utilizes a drive motor and a motor controller to simulate an engine, that is, to provide electrical energy to the simulated engine. The simulated engine can convert electrical energy into kinetic energy, so that the simulated engine can drive the generator to work. This process simulates the working process of the range extender and can be used for performance testing of the range extender.

[0045] In some embodiments, simulating an engine using a drive motor and a motor controller includes: simulating an engine body using a drive motor and a motor controller; simulating an engine controller using a first simulated communication node; and combining the simulated engine body and the simulated engine controller to simulate an engine system.

[0046] The first simulated communication node is, for example, a bus analysis tool (eg, CANOE), which is used to control the engine and communicate with other devices (eg, a motor controller) in real time, ultimately simulating the operating state of the engine.

[0047] In step S104 , the generator, the range extender controller, and the simulated engine are combined to simulate the range extender system.

[0048] The range extender system consists of an engine system, a generator system, and a range extender controller. After simulating the engine using the drive motor and motor controller, and the engine controller using CANOE, the entire range extender system is simulated by combining the generator system (composed of the generator and generator controller) with the range extender controller. Testing based on a simulated range extender system simplifies the test system, enabling quick completion of range extender testing while also meeting laboratory requirements for prohibiting exhaust emissions.

[0049] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system includes: connecting a drive motor and a generator through a coupling, connecting the drive motor and a motor controller through a three-phase power line, connecting a domain controller to a first simulated communication node through a CAN communication line and to the three-phase power line of the generator, and connecting the motor controller to the first simulated communication node through a CAN communication line to simulate the range extender system, wherein the domain controller is integrated with the range extender controller and the generator controller.

[0050] The Domain Control Unit (DCU) integrates the functions of the Generator Control Unit (GCU) and the Range Extender Control Unit (RCU). This can further simplify the range extender system, improve system integration, reduce product costs, and make the test system more concise.

[0051] The drive motor and generator are connected through a coupling to simulate the operation process of the range extender by using the motor-to-motor dragging method, so as to carry out performance testing.

[0052] Figure 2 FIG. 1 shows a schematic structural diagram of a simulated range extender system according to some embodiments of the present disclosure. Figure 2 As shown, the simulated range extender system in this embodiment includes a drive motor 001, a motor controller 002 for simulating an engine; a DCU 003 integrating the functions of a generator controller and a range extender controller; a generator 004; and a CANOE 010 for simulating an engine controller.

[0053] Drive motor 001 and generator 004 are connected via a coupling, allowing drive motor 001 to drive generator 004. CAN communication lines connect the domain controller to CANOE, and between CANOE and the click controller. Three-phase power lines connect the domain controller to the generator, and between the motor controller and the drive motor, to control the simulated engine and generator according to commands.

[0054] The above constitutes a basic simulated range extender system, and other components are needed to complete the range extender test.

[0055] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system further includes: connecting the busbar harness of the motor controller and the busbar harness of the domain controller to a battery simulator to provide a high-voltage power supply through the battery simulator; connecting the motor controller and the domain controller to a low-voltage power supply; connecting the motor controller, the drive motor, the domain controller, and the generator to a cooling water circulation system to dissipate heat for the range extender system through the cooling water circulation system; and connecting the motor controller, the drive motor, the domain controller, and the generator to a resolver line and a motor temperature detection line.

[0056] The battery simulator provides high-voltage power to the range extender system. During the range extender test, the power provided by the battery simulator enables energy exchange between the range extender's power and electrical energy to meet the normal operation of the simulated range extender test system.

[0057] The motor controller, drive motor, domain controller, and generator are connected to the resolver line and motor temperature detection line to timely monitor the operating status of the generator and simulated engine, and to accurately control and adjust the range extender system during the test to achieve debugging of the range extender system.

[0058] In addition to setting up the test scenario for the range extender system, data analysis tools are also needed to record the test data for subsequent analysis of the test results of the range extender system.

[0059] In some embodiments, combining the generator, the range extender controller and the simulated engine to simulate the range extender system also includes: connecting the first sampling line of the power analyzer to the bus of the domain controller to collect the bus voltage and bus current of the domain controller; connecting the second sampling line of the power analyzer to the three-phase end of the generator to collect the voltage and current of the three-phase end of the generator; and connecting a speed torque meter between the generator and the drive motor to collect the speed and torque of the generator.

[0060] By collecting the bus voltage and bus current of the domain controller and the voltage and current of the three-phase terminal of the generator through the power analyzer, the input and output of the range extender system can be recorded, which facilitates the subsequent analysis of the efficiency of the range extender system.

[0061] By collecting the speed and torque of the generator through the speed and torque meter, the detailed working status of the generator can be recorded, which is convenient for the subsequent determination of the performance of the range extender.

[0062] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system further includes: connecting a speed torque meter to a power analyzer for signal connection so as to parse the signal collected by the speed torque meter through the power analyzer; and connecting the power analyzer to a host computer for signal connection so as to monitor the status of the generator through the host computer.

[0063] Users can monitor the status of the generator through the host computer, integrate the range extender detection, and improve the convenience of test result analysis.

[0064] Figure 3 FIG2 shows a schematic structural diagram of a simulated range extender system according to other embodiments of the present disclosure. Figure 3 As shown, in the simulated range extender system in this embodiment, the drive motor 001 and the generator 004 are connected through a test bench coupling, the DCU 003 is connected to the battery simulator 005, and the generator 004, DCU 003, the motor controller 002, and the drive motor 001 are respectively connected through power lines to realize the transmission of high-voltage power provided by the battery simulator.

[0065] The drive motor 001 and motor controller 002 are connected via a three-phase power line (represented by a thick black solid line in the figure). The motor controller 002 and CANOE 010 are connected via a CAN communication line. CANOE 010 and DCU 003 are connected via a CAN communication line. The DCU 003 and generator 004 are also connected via a three-phase power line. The DCU 003 is also connected to a second simulated communication node via a CAN communication line. The figure shows Tsmaster 009 as this second simulated communication node, which simulates the vehicle controller.

[0066] The drive motor 001, motor controller 002, DCU 003, and generator 004 are also connected to the cooling water circulation system through a water circulation pipeline (indicated by a dotted line in the figure) for heat dissipation.

[0067] The power analyzer 011 is connected to the DCU 003 (indicated by a solid line without an arrow in the figure, indicating a signal connection) to collect data from the range extender system, and the power analyzer is also connected to the test bench host computer 012 to transmit data to the test bench host computer 012 for the user to monitor the status of the generator and record the generator test data.

[0068] Generator 004 and drive motor 001 are connected via a coaxial test bench coupling and a speed and torque meter 013 to collect data such as generator speed and torque. Speed ​​and torque meter 013 is also connected to power analyzer 012, which analyzes the data and transmits it to the test bench host computer 012.

[0069] like Figure 3 As shown, the range extender system primarily consists of two parts: the generator control system 014 and the engine control system 015. The generator control system 014 comprises a generator 004 and a DCU controller 003. The generator 004 acts as a generator, generating electricity. The DCU controller 003 consists of two parts: the RCU and the GCU. The RCU transmits commands from the vehicle controller, transmitting torque commands to the GCU and speed commands to the engine controller, enabling the range extender to operate and generate electricity. The Tsmaster 009 simulates commands from the vehicle controller to conduct relevant tests and receives status information from the RCU for related control.

[0070] The engine control system 015 consists of a drive motor 001, a motor controller 002, and a CANOE 010. The drive motor 001 and motor controller 002 simulate the engine itself, providing a certain speed to cooperate with the generator 004 for power generation. The CANOE 010 primarily simulates the engine controller, serving as a command transfer point, receiving commands from the RCU and monitoring the engine system status.

[0071] The communication network of the simulated range extender system is described below.

[0072] In some embodiments, combining a generator, a range extender controller, and a simulated engine to simulate a range extender system further includes: configuring a domain controller to be connected to a second simulated communication node via a CAN communication line, connecting the range extender controller to a first simulated communication node via a CAN communication line, and communicating between the range extender controller and the generator controller via inter-core communication, wherein the second simulated communication node is used to simulate a vehicle controller.

[0073] That is, the communication between the simulated domain controller and the vehicle controller is realized, the operation of the range extender system is controlled according to the instructions of the vehicle controller, and the status of the range extender system is fed back to the vehicle controller, thereby realizing the full simulation of the operation of the range extender system in the vehicle.

[0074] In some embodiments, the aforementioned simulation method further includes: sending instructions to the domain controller through the second simulation communication node, so that the domain controller interacts with the generator controller and the first simulation communication node according to the instructions, thereby making the generator and the drive motor work.

[0075] Figure 4 A schematic diagram of a communication network of a simulated range extender system according to some embodiments of the present disclosure is shown.

[0076] like Figure 4 As shown, VCU 020 is the vehicle controller, which consists of the CAN bus analysis tool Tsmaster 009; DCU 003 is a two-in-one domain controller, which consists of RCU 021 and GCU 022; ECU 023 is the engine controller, which consists of the CAN bus analysis tool CANOE 010. VCU 020 and DCU 003 are connected through the CAN1 communication line, and RCU 021 and ECU023 in DCU 003 are connected through the CAN2 communication line. RCU 021 and GCU 022 transmit data through inter-core communication, which constitutes the test system network.

[0077] like Figure 4 As shown, the vehicle controller 020 sends start / stop commands for the range extender via CAN1 to the RCU 021. RCU 021 also feeds back range extender-related information via CAN1. After receiving the command from the vehicle controller 020, RCU 021 exchanges data with the GCU 022 via inter-core communication, controlling the GCU to drive the generator. Simultaneously, RCU 021 transmits the command to ECU 023 via CAN2. ECU 023 transmits the command to the motor controller, driving the drive motor. ECU 023 also feeds back engine-related information to RCU 021 via CAN2. The vehicle controller consists of Tsmaster 009, DCU 003 is a two-in-one domain controller consisting of RCU 021 and GCU 022, and ECU 023 is the engine controller, consisting of CANOE 010.

[0078] In some embodiments, the aforementioned simulation method further includes: after performing a functional test on the range extender system, performing a performance test on the generator in the range extender system, wherein the functional test includes at least one of communication function debugging, start-stop function debugging, power generation function debugging, and power function debugging, and the performance test includes at least one of a generator efficiency test and a generator temperature rise test.

[0079] Functional tests are conducted to verify whether the range extender system can work normally, and performance tests are conducted to determine the performance of the generator, so as to debug the range extender system and ultimately determine the performance of the range extender system.

[0080] Figure 5 Schematic diagram showing the test process of the range extender system according to some embodiments of the present disclosure. Figure 5 As shown, the test process includes steps S1 to S8.

[0081] In step S1, the engine system is simulated using a motor system to perform engine system bench construction. The motor system includes a drive motor and a motor controller. Engine system bench construction involves installing the drive motor and motor controller on a test bench and connecting them to other relevant components, such as a battery simulator, cooling water circulation system, and CAN communication cables. The specific steps for engine system bench construction are described in detail below.

[0082] In step S2, the generator system is bench-mounted. This involves installing the generator, domain controller, and other components on a test bench and connecting them to other relevant components. The specific steps for this setup are described in detail below.

[0083] Steps S1 and S2 are the process of setting up a test bench for the range extender system. After the test bench is set up, the test process is carried out.

[0084] In step S3 , the communication function of the range extender system is debugged to determine whether the communication function of the range extender system is normal.

[0085] In step S4, under the premise that the communication function is normal, the start and stop functions of the range extender system are debugged. By simulating the VCU node Tsmaster to send instructions to the domain controller, the start and stop functions of the range extender system are verified to ensure that the range extender system can run and stop according to the instructions.

[0086] In step S5, the range extender system's power generation function is debugged to ensure that it can generate power normally. Specifically, a battery simulator is used to provide high-voltage power to the range extender system. The simulated VCU node, Tsmaster, sends commands to the domain controller to control the range extender system's operation and monitor the generator's power generation.

[0087] In step S6, the power function of the range extender system is debugged. The simulated VCU node Tsmaster sends a power command to the domain controller. After receiving the command, the domain controller processes the internal data and transmits the parsed target speed command to the simulated engine controller node CANOE via the CAN communication line. The parsed target torque command is then transmitted to the generator controller GCU via inter-core communication. After receiving the speed command, the CANOE adjusts the simulated engine speed to the target speed. After receiving the torque command, the GCU adjusts the generator torque to the target torque. The generator's current output power can be determined from its current speed and torque. Combined with the VCU's power command, the generator is ensured to operate within the target power range.

[0088] The above functional test (or functional test) is used to determine that the range extender system can operate normally and the power of the generator is within the target range. Then a performance test is carried out to determine the performance of the generator when the generator achieves power output within the target range.

[0089] In step S7, an efficiency test, such as a MAP test, is performed on the generator in the range extender system. The generator efficiency MAP is used to reflect the efficiency distribution of the generator at different speeds and torques, and can be used to optimize system design and operating conditions.

[0090] In step S8, a temperature rise test is performed on the generator in the range extender system. This test involves operating the generator at rated load for a long period of time until it reaches thermal equilibrium, and then operating it at peak load for one minute. The temperature changes at various locations are measured to assess its performance and reliability.

[0091] The performance of the range extender system is determined through the above-mentioned performance test (or performance test) to determine whether the range extender system can meet the expected goals so that subsequent adjustments can be made.

[0092] The following describes the process of building the engine test bench and the generator test bench. The process of building the engine test bench includes steps S11 to S16, and the process of building the generator test bench includes steps S21 to S211. Figure 3 The number in .

[0093] In step S11 , the drive motor 001 and the motor controller 002 are installed on the test bench.

[0094] In step S12 , the busbar harness of the motor controller 002 is connected to the battery simulator 005 , and the three-phase wires of the drive motor 001 are connected to the output three phases of the motor controller 002 .

[0095] In step S13, the motor controller 002 and the drive motor 001 are connected to the cooling water circulation system 006 to dissipate heat for the simulated engine system and to ensure that the required water temperature, flow rate and other information are correct.

[0096] In step S14 , the motor controller 002 is connected to a low-voltage power supply.

[0097] In step S15, the motor controller 002 and CANOE 010 are connected to the CAN communication line;

[0098] In step S16 , the motor controller 002 and the drive motor 001 are connected to the resolver line and the motor temperature detection line.

[0099] The above steps complete the construction of the motor system simulation engine bench, which consists of Figure 3 The simulated engine control system 015 is shown in FIG.

[0100] In step S21 , the generator 004 and the DCU 003 are installed on the test bench.

[0101] In step S22 , the busbar harness of the DCU 003 is connected to the battery simulator 005 , and the three-phase wires of the generator 004 are connected to the three-phase output of the DCU controller 003 .

[0102] In step S23, the DCU 003 and the generator 004 are connected to the cooling water circulation system 006 to dissipate heat for the generator control system and to ensure that the required water temperature, flow rate and other information are correct.

[0103] In step S24, the DCU 003 is connected to a low-voltage power supply.

[0104] In step S25, DCU 003 and Tsmaster 009 connect the CAN communication line.

[0105] In step S26 , the DCU 003 and the generator 004 are connected to the resolver line and the motor temperature detection line.

[0106] In step S27 , the power analyzer 011 connects the sampling line to the DCU 003 bus, collects the bus voltage and bus current, and transmits the signal to the test bench host computer 012 .

[0107] In step S28 , the power analyzer 011 is connected to the three-phase terminals of the generator 004 through a sampling line to collect the voltage and current of the three-phase terminals of the motor and transmit the signals to the test bench host computer 012 .

[0108] In step S29 , the speed and torque information collected by the torque and speed meter 013 is processed by the power analyzer 011 and transmitted to the test bench host computer 012 .

[0109] In step S210 , the generator 004 and the drive motor 001 are connected via a coaxial gantry coupling and a speed torque meter 013 .

[0110] In step S211 , the DCU 003 integrates the functions of the RCU 021 and the GCU 022 through inter-core communication.

[0111] The above steps complete the construction of the generator system bench, which consists of Figure 3 The generator control system 014 shown in FIG. Furthermore, the engine system and the generator system were connected to form a simulated range extender system. That is, the simulated engine control system 015 and the generator control system 014 formed the range extender system to be tested. The relevant test was performed on the range extender system composed of the above.

[0112] The simulation method of the range extender provided by the present disclosure simulates the range extender in the form of motor towing, which simplifies the test system, saves manpower and material resources, can complete functional testing in a short time, and realizes a new and efficient range extender testing method. The simulation method disclosed in the present disclosure also integrates the functions of GCU and RCU, which can improve product integration, reduce product costs, and make the test system more concise. In addition, by simulating VCU and ECU through TSmaster and CANOE bus analysis tools, a simple, efficient, low-cost, and easy-to-promote range extender test system and method is formed to realize functional verification and performance testing of the range extender. Among them, RCU and GCU transmit data through inter-core communication, which greatly improves the quality of CAN communication and improves system stability.

[0113] This paper uses a drive motor and motor controller to simulate an engine, combined with a generator and range extender to simulate a range extender system. This allows for range extender testing using motor-to-motor traction, which not only improves test efficiency but also eliminates the need for exhaust emissions testing at the test site, broadening the selection of test sites and increasing the convenience of range extender testing.

[0114] Figure 6 FIG. 1 shows a schematic diagram of a range extender simulation device according to some embodiments of the present disclosure. Figure 6 As shown, the simulation device of this embodiment includes a first simulation module 610, which is configured to simulate the engine using a drive motor and a motor controller; a second simulation module 620, which is configured to combine a generator, a range extender controller and a simulated engine to simulate the range extender system.

[0115] In some embodiments, the first simulation module 610 is configured to simulate the engine body using the drive motor and the motor controller; simulate the engine controller using the first simulated communication node; and combine the simulated engine body and the simulated engine controller to simulate the engine system.

[0116] In some embodiments, the second simulation module 620 is configured to connect the drive motor and the generator through a coupling, connect the drive motor and the motor controller through a CAN communication line, connect the domain controller and the generator and the first simulation communication node through a CAN communication line, and connect the motor controller and the first simulation communication node through a CAN communication line to simulate the range extender system, wherein the domain controller is integrated by the range extender controller and the generator controller.

[0117] In some embodiments, the second simulation module 620 is configured to connect the busbar harness of the motor controller and the busbar harness of the domain controller to the battery simulator to provide a high-voltage power supply through the battery simulator; connect the motor controller and the domain controller to a low-voltage power supply; connect the motor controller, the drive motor, the domain controller, and the generator to a cooling water circulation system to dissipate heat for the range extender system through the cooling water circulation system; and connect the motor controller, the drive motor, the domain controller, and the generator to the resolver line and the motor temperature detection line.

[0118] In some embodiments, the second simulation module 620 is configured to connect the first sampling line of the power analyzer to the bus of the domain controller to collect the bus voltage and bus current of the domain controller; connect the second sampling line of the power analyzer to the three-phase end of the generator to collect the voltage and current of the three-phase end of the generator; a speed and torque meter is connected between the generator and the drive motor to collect the speed and torque of the generator.

[0119] In some embodiments, the second simulation module 620 is configured to connect the speed torque meter to the power analyzer for signal connection so as to analyze the signal collected by the speed torque meter through the power analyzer; and connect the power analyzer to the host computer for signal connection so as to monitor the status of the generator through the host computer.

[0120] In some embodiments, the second simulation module 620 is configured to configure the domain controller to be connected to the second simulation communication node via a CAN communication line, the range extender controller to be connected to the first simulation communication node via a CAN communication line, and the range extender controller to be communicated with the generator controller through inter-core communication, wherein the second simulation communication node is used to simulate the vehicle controller.

[0121] In some embodiments, the simulation device 60 is further configured to send instructions to the domain controller through the second simulation communication node, so that the domain controller exchanges data with the generator controller and the first simulation communication node according to the instructions, thereby operating the generator and the drive motor.

[0122] In some embodiments, the simulation device 60 is further configured to perform a performance test on the generator in the range extender system after performing a functional test on the range extender system, wherein the functional test includes at least one of communication function debugging, start-stop function debugging, power generation function debugging, and power function debugging, and the performance test includes at least one of generator efficiency test and generator temperature rise test.

[0123] The simulator disclosed herein utilizes a drive motor and motor controller to simulate an engine, combined with a generator and range extender to simulate a range extender system. This simulator can test range extenders using motor-to-motor traction, improving test efficiency and eliminating the need for exhaust emissions monitoring at the test site, making range extender testing more convenient.

[0124] Figure 7 FIG. 1 shows a schematic structural diagram of a range extender simulation device according to other embodiments of the present disclosure. Figure 7 As shown, the simulation device 70 of this embodiment includes an engine 710 , which is simulated using a drive motor and a motor controller; a generator 720 ; and a range extender controller 730 .

[0125] In some embodiments, the simulation device 70 further includes: a generator controller; and a first simulated communication node configured to simulate an engine controller.

[0126] In some embodiments, the range extender controller and the generator controller are integrated into a domain controller.

[0127] In some embodiments, the drive motor is connected to the generator through a coupling, the drive motor is connected to the motor controller through a three-phase power line, the domain controller is connected to the first analog communication node through a CAN communication line and to the three-phase power line of the generator, and the motor controller is connected to the first analog communication node through a CAN communication line.

[0128] Figure 8 FIG. 1 shows a schematic diagram of a simulation system for a range extender according to some embodiments of the present disclosure. Figure 8 As shown, the simulation system 80 of this embodiment includes the simulation device 810 as described above; a battery simulator 820, connected to the busbar harness of the motor controller and the busbar harness of the domain controller, and configured to provide a high-voltage power supply; a low-voltage power supply 830, connected to the motor controller and the domain controller; a cooling water circulation system 840, connected to the motor controller, the drive motor, the domain controller, and the generator, and configured to dissipate heat for the range extender; a resolver line 850, connected to the motor controller, the drive motor, the domain controller, and the generator; and a motor temperature detection line 860, connected to the motor controller, the drive motor, the domain controller, and the generator.

[0129] In some embodiments, the simulation system 80 also includes: a power analyzer, wherein the first sampling line of the power analyzer is connected to the bus of the domain controller and is configured to collect the bus voltage and bus current of the domain controller; the second sampling line of the power analyzer is connected to the three-phase end of the generator and is configured to collect the voltage and current of the three-phase end of the generator; a speed torque meter, connected to the coupling between the generator and the drive motor, and configured to collect the speed and torque of the generator; the power analyzer is connected to the power analyzer signal, and the power analyzer is configured to parse the signal collected by the speed torque meter.

[0130] In some embodiments, the simulation system 80 further includes: a host computer connected to the power analyzer and configured to monitor the status of the generator.

[0131] In some embodiments, the simulation system 80 further includes: a second simulation communication node, configured to simulate a vehicle controller, and connected to the domain controller via a CAN communication line.

[0132] In some embodiments, the range extender controller is connected to the first analog communication node via a CAN communication line, and the range extender controller is connected to the generator controller via inter-core communication.

[0133] The range extender simulation device in the embodiment of the present disclosure can be implemented by various computing devices or computer systems. Figure 9 as well as Figure 10 Provide a description.

[0134] Figure 9 FIG. 1 shows a schematic structural diagram of a range extender simulation device according to other embodiments of the present disclosure. Figure 9 As shown, the device 90 of this embodiment includes: a memory 910 and a processor 920 coupled to the memory 910, and the processor 920 is configured to execute the simulation method of the range extender in any of some embodiments of the present disclosure based on instructions stored in the memory 910.

[0135] The memory 910 may include, for example, a system memory, a fixed non-volatile storage medium, etc. The system memory may store, for example, an operating system, application programs, a boot loader, a database, and other programs.

[0136] Figure 10 FIG. 1 shows a schematic structural diagram of a range extender simulation device according to some other embodiments of the present disclosure. Figure 10As shown, the device 100 of this embodiment includes: a memory 1010 and a processor 1020, which are similar to the memory 910 and the processor 920, respectively. It may also include an input / output interface 1030, a network interface 1040, a storage interface 1050, etc. These interfaces 1030, 1040, 1050 and the memory 1010 and the processor 1020 can be connected, for example, via a bus 1060. Among them, the input / output interface 1030 provides a connection interface for input / output devices such as a display, mouse, keyboard, and touch screen. The network interface 1040 provides a connection interface for various networked devices, such as a database server or a cloud storage server. The storage interface 1050 provides a connection interface for external storage devices such as SD cards and USB flash drives.

[0137] An embodiment of the present disclosure further provides a computer-readable storage medium having a computer program stored thereon, wherein the program, when executed by a processor, implements any of the aforementioned range extender simulation methods.

[0138] An embodiment of the present disclosure further provides a computer program product, comprising instructions, which, when executed by a processor, cause the processor to perform any of the aforementioned range extender simulation methods.

[0139] Those skilled in the art will appreciate that embodiments of the present disclosure may be provided as methods, systems, or computer program products. Thus, the present disclosure may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware. Furthermore, the present disclosure may take the form of a computer program product implemented on one or more computer-usable, non-transitory storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0140] The present disclosure is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present disclosure. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0141] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0142] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0143] The above description is only a preferred embodiment of the present disclosure and is not intended to limit the present disclosure. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present disclosure should be included in the scope of protection of the present disclosure.

Claims

1. A simulation method for a range extender, comprising: Use drive motors and motor controllers to simulate engines; Combines a generator, range extender controller, and simulated engine to simulate a range extender system.

2. The simulation method according to claim 1, wherein: The method of simulating an engine by using a driving motor and a motor controller comprises: Use the drive motor and motor controller to simulate the engine body; simulating an engine controller using a first simulated communication node; A simulated engine body and a simulated engine controller are combined to simulate the engine system.

3. The simulation method according to claim 2, wherein: The combination of the generator, the range extender controller and the simulated engine to simulate the range extender system includes: The drive motor and the generator are connected through a coupling, the drive motor and the motor controller are connected through a three-phase power line, the domain controller is connected to the first simulation communication node through a CAN communication line and is connected to the three-phase power line of the generator, and the motor controller is connected to the first simulation communication node through a CAN communication line to simulate the range extender system, wherein the domain controller is integrated by the range extender controller and the generator controller.

4. The simulation method according to claim 3, wherein the step of combining the generator, the range extender controller and the simulated engine to simulate the range extender system further comprises: Connecting the busbar harness of the motor controller and the busbar harness of the domain controller to a battery simulator to provide a high voltage power supply through the battery simulator; Connecting the motor controller and the domain controller to a low voltage power supply; Connecting the motor controller, the drive motor, the domain controller, and the generator to a cooling water circulation system to dissipate heat for the range extender system through the cooling water circulation system; The motor controller, the drive motor, the domain controller, and the generator are connected to the resolver line and the motor temperature detection line.

5. The simulation method according to claim 3, wherein: The combination of the generator, the range extender controller and the simulated engine to simulate the range extender system also includes: Connecting a first sampling line of a power analyzer to a bus of the domain controller to collect a bus voltage and a bus current of the domain controller; Connecting the second sampling line of the power analyzer to the three-phase end of the generator to collect the voltage and current of the three-phase end of the generator; A speed torque meter is connected between the generator and the drive motor to collect the speed and torque of the generator.

6. The simulation method according to claim 5, wherein: The combination of the generator, the range extender controller and the simulated engine to simulate the range extender system also includes: Connecting the speed torque meter to the power analyzer to analyze the signal collected by the speed torque meter through the power analyzer; The power analyzer is connected to a host computer via a signal so as to monitor the status of the generator through the host computer.

7. The simulation method according to any one of claims 3 to 6, wherein the step of combining the generator, the range extender controller and the simulated engine to simulate the range extender system further comprises: The domain controller is configured to be connected to the second simulated communication node via a CAN communication line, the range extender controller is connected to the first simulated communication node via a CAN communication line, the range extender controller and the generator controller communicate through inter-core communication, wherein the second simulated communication node is used to simulate the vehicle controller.

8. The simulation method according to claim 7, further comprising: An instruction is sent to the domain controller through the second simulated communication node, so that the domain controller exchanges data with the generator controller and the first simulated communication node according to the instruction, thereby making the generator and the drive motor work.

9. The simulation method according to any one of claims 1 to 6, further comprising: After performing a functional test on the range extender system, a performance test is performed on the generator in the range extender system, wherein the functional test includes at least one of communication function debugging, start-stop function debugging, power generation function debugging, and power function debugging, and the performance test includes at least one of an efficiency test of the generator and a temperature rise test of the generator.

10. A range extender simulation device, comprising: A first simulation module is configured to simulate an engine using a drive motor and a motor controller; The second simulation module is configured to combine the generator, the range extender controller and the simulated engine to simulate the range extender system.

11. A range extender simulation device, comprising: An engine, wherein the engine is simulated by using a drive motor and a motor controller; dynamo; Range extender controller.

12. The simulation device according to claim 11, further comprising: Generator controller; The first simulated communication node is configured to simulate an engine controller.

13. The simulation device according to claim 12, wherein: The range extender controller and the generator controller are integrated into a domain controller.

14. The simulation device according to claim 13, wherein: The drive motor is connected to the generator through a coupling, the drive motor is connected to the motor controller through a three-phase power line, the domain controller is connected to the first analog communication node through a CAN communication line and to the three-phase power line of the generator, and the motor controller is connected to the first analog communication node through a CAN communication line.

15. A range extender simulation system, comprising: The simulation device as claimed in claim 13 or 14; A battery simulator is connected to the bus harness of the motor controller and the bus harness of the domain controller and is configured to provide a high voltage power supply; A low-voltage power supply connected to the motor controller and the domain controller; a cooling water circulation system connected to the motor controller, the drive motor, the domain controller, and the generator, and configured to dissipate heat for the range extender; A resolver line connected to the motor controller, the drive motor, the domain controller, and the generator; The motor temperature detection line is connected to the motor controller, the drive motor, the domain controller, and the generator.

16. The simulation system according to claim 15, further comprising: A power analyzer, wherein a first sampling line of the power analyzer is connected to a bus of the domain controller and is configured to collect a bus voltage and a bus current of the domain controller, and a second sampling line of the power analyzer is connected to a three-phase terminal of the generator and is configured to collect a voltage and a current of the three-phase terminal of the generator; A speed torque meter connected to the coupling between the generator and the drive motor, and configured to collect the speed and torque of the generator; The power analyzer is connected to the power analyzer signal, and the power analyzer is configured to analyze the signal collected by the speed torque meter.

17. The simulation system according to claim 16, further comprising: The host computer is connected to the power analyzer and is configured to monitor the status of the generator.

18. The simulation system according to any one of claims 15 to 17, further comprising: The second simulated communication node is configured to simulate a vehicle controller and is connected to the domain controller via a CAN communication line.

19. The simulation system according to claim 18, wherein: The range extender controller is connected to the first analog communication node via a CAN communication line, and the range extender controller communicates with the generator controller through inter-core communication.

20. A range extender simulation device, comprising: processor; as well as A memory coupled to the processor, for storing instructions, wherein when the instructions are executed by the processor, the processor executes the range extender simulation method according to any one of claims 1 to 9.

21. A computer-readable storage medium having computer instructions stored thereon, wherein: When the instruction is executed by the processor, the simulation method of the range extender as described in any one of claims 1 to 9 is implemented.

22. A computer program product comprising instructions, which, when executed by a processor, cause the processor to perform the range extender simulation method according to any one of claims 1 to 9.

Images