Range extender power assembly offline detection method
By conducting comprehensive inspection of CAN communication, software and hardware versions, rotational self-learning, external characteristics and NVH detection on the range extender powertrain, the problem of insufficient offline detection in the existing technology is solved, the reliability and comfort of the product are improved, and the risk of control failure is reduced.
Patent Information
- Application Number
- CN202510150887.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-11
- Publication Date
- 2025-04-08
AI Technical Summary
In the prior art, the detection of the powertrain of the range extender is not comprehensive enough to ensure that there will be no control failure problems after the range extender powertrain is installed into the vehicle.
A down-line detection method for range extender powertrain is adopted, including detection controller CAN communication, software and hardware version, motor rotation self-learning, motor external characteristics and NVH detection, and comprehensive detection of range extender powertrain is carried out through these steps.
The objective evaluation of the performance of the range extender powertrain is achieved, effectively intercepting unqualified products, improving the reliability and comfort of the products, and reducing the problem of failure in control after loading into the entire vehicle.
Smart Images
Figure CN119779414A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of new energy vehicle powertrain, and in particular to an off-line detection method for a range extender powertrain. Background Art
[0002] With the development of new energy vehicles, the range extender powertrain has been widely used in new energy vehicles due to its simple structure, high flexibility and low cost. As an important component of the power system of new energy vehicles, the range extender powertrain consists of a controller, a motor and a transmission. At present, more and more new energy vehicles use range extender powertrain products. How to ensure the comfort and reliability of the powertrain has become an important issue in the driving and safety of new energy vehicles.
[0003] The main problems of the range extender powertrain in the whole vehicle include poor NVH (vibration, noise and harshness) effect during power generation and low power generation efficiency, which in turn affects the customer experience. The end-of-line inspection of the range extender powertrain is an effective way to control these problems. It can conduct targeted and effective end-of-line inspection of products, and has a reliable and reasonable end-of-line inspection method to monitor the quality of products, which will also enhance the market competitiveness of corporate products and the overall strength of the company. However, the existing technology for end-of-line inspection of the range extender powertrain is not comprehensive enough, and thus cannot ensure that there will be no control failure after the range extender powertrain is installed in the whole vehicle. Summary of the invention
[0004] In view of the above-mentioned deficiencies in the prior art, the technical problem to be solved by the present invention is: how to provide a method for off-line detection of a range extender powertrain that can perform comprehensive detection on the range extender powertrain, improve product reliability, and reduce the problem of control failure after the range extender powertrain is installed in the whole vehicle.
[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions: A method for detecting an off-line powertrain of a range extender comprises the following steps: Step 1) Detect the CAN communication of the controller in the range extender powertrain; Step 2) Detect the software version and hardware version of the controller in the range extender powertrain; Step 3) Detect the motor rotary transformer self-learning in the range extender powertrain; Step 4) Detecting the external characteristics of the motor in the range extender powertrain; Step 5) Perform NVH testing on the range extender powertrain.
[0006] Preferably, in step 1), according to the CAN communication protocol of the controller in the range extender powertrain, a specific signal in the CAN communication protocol is used to detect whether the communication between the controller and the external test station is normal.
[0007] Preferably, in step 2), detection is performed according to the signal address location where the software version number and the hardware version number of the controller in the range extender powertrain are stored, and the signal address location where the software version number and the hardware version number of the controller are stored is obtained in real time through CAN communication or UDS instruction.
[0008] Preferably, step 3) includes the following steps: Step 3.1) Install the range extender powertrain on the test bench, supply low voltage and high voltage to the controller of the range extender powertrain respectively, and according to the CAN communication protocol of the controller, use the motor resolver self-learning trigger signal therein to trigger the motor to perform resolver self-learning and obtain the resolver self-learning result signal; Step 3.2) detecting whether the resolver self-learning is successful according to the resolver self-learning result signal in step 3.1); Step 3.3) obtaining the resolver initial angle value according to the resolver self-learning result signal in step 3.1); Step 3.4) Repeat steps 3.1) to 3.3) for n times, and then proceed to step 3.5); Step 3.5) Determine whether the n resolver initial angle values obtained by repeated learning n times are all within the range of 0-360°, and whether the difference between the maximum and minimum values of the n resolver initial angle values is less than 1°. If so, the resolver self-learning is determined to be successful, otherwise, the resolver self-learning is determined to have failed.
[0009] Preferably, step 4) includes the following steps: Step 4.1) According to the CAN communication protocol of the controller, request the motor torque in the range extender powertrain to be the external characteristic test torque, and then gradually increase the motor speed and motor torque according to the time required by the test; Step 4.2) Determine whether the external characteristics of the motor in the range extender powertrain meet the powertrain requirements based on the output torque and speed fed back by the test bench.
[0010] Preferably, step 4.1) comprises the following steps: Step 4.1.1) Switch the motor mode to the torque mode and request the motor torque in the range extender powertrain to be 0 NM; Step 4.1.2) gradually request the motor speed to be the target speed with a gradient of 0.2 seconds, and the request time is 5 seconds; Step 4.1.3) After 5 seconds, gradually request the motor torque to be the target torque with a gradient of 0.2 seconds for a request time of 2 seconds.
[0011] Preferably, in step 4.2), it is determined whether the output end torque fed back by the loading motor end of the test bench is within the range of ±3% of the target torque, and it is also determined whether the output end speed fed back by the loading motor end of the test bench is within the range of ±5rpm of the target speed. If both are true, it is determined that the motor external characteristics of the range extender powertrain meet the requirements of the range extender powertrain; otherwise, it is determined that the motor external characteristics of the range extender powertrain do not meet the requirements of the range extender powertrain.
[0012] Preferably, step 5) includes forward low torque acceleration condition bump and scratch detection, constant torque acceleration condition detection, constant power acceleration condition detection, constant torque deceleration condition detection and reverse low torque deceleration condition bump and scratch detection.
[0013] Preferably, step 5) includes the following steps: Step 5.1) Control the torque and speed of the motor of the range extender powertrain according to the CAN communication protocol of the range extender powertrain controller; Step 5.2) Forward low-torque acceleration condition bump and damage detection: The motor of the range extender powertrain is set to the first torque and the speed is increased, and the gears of the transmission in the range extender powertrain are tested for bump and damage using the NVH detection system; Step 5.3) Constant torque acceleration condition detection: The motor of the range extender powertrain is set to a fixed torque and the speed is increased, and the NVH detection system is used to detect the abnormal noise of the range extender powertrain when the motor outputs a constant torque and increases the speed; Step 5.4) Constant power acceleration condition detection: The motor of the range extender powertrain is operated at a fixed torque setting and a speed increase, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs a constant power and increases speed; Step 5.5) Constant torque deceleration condition detection: The motor of the range extender powertrain is decelerated at a fixed torque setting and speed, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs constant torque and decelerates; Step 5.6) Reverse low-torque speed reduction condition bump and dent detection: The motor of the range extender powertrain is set to the reverse first torque and speed reduction operation, and the gears of the transmission part of the powertrain are tested for gear bump and dent using the NVH detection system.
[0014] Compared with the prior art, the range extender powertrain off-line inspection method provided by the present invention realizes an objective evaluation of the range extender powertrain performance during the range extender powertrain off-line inspection stage, and effectively intercepts unqualified products based on the actual situation of the whole vehicle, thereby improving the product reliability.
[0015] The present invention can effectively solve the problem of insufficient comprehensive off-line testing of range extender powertrains in the prior art, greatly improve the reliability and comfort of the product, reduce the problem of control failure after the range extender powertrain is installed in the vehicle, and reduce the occurrence of safety accidents. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Attached Figure 1 It is a flow chart of the off-line detection method of the range extender powertrain of the present invention; Attached Figure 2 Characteristic example diagram of motor rotary transformer self-learning in the range extender powertrain off-line detection method of the present invention. DETAILED DESCRIPTION
[0017] In order to make the purpose, technical scheme and advantages of the embodiments of the present invention clearer, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work belong to the scope of protection of the present invention.
[0018] The problems exposed by the range extender powertrain that usually fails to meet the off-line requirements mainly include: motor resolver self-learning failure, motor external characteristic failure (output speed exceeds the limit or torque exceeds the limit), NVH failure (peak state or order determination failure), etc. According to different models of range extender powertrains and their performance in the vehicle, the indicators that should be tested and the corresponding functions of each indicator are shown in Table 1.
[0019] Table 1: Off-line test indicators of the range extender powertrain off-line test station In order to meet the above requirements for off-line detection of the range extender powertrain, a method for off-line detection of the range extender powertrain is provided in this embodiment, as shown in the attached figure. Figure 1 As shown, the following steps are included: Step 1) Detect the CAN communication of the controller in the range extender powertrain; Step 2) Detect the software version and hardware version of the controller in the range extender powertrain; Step 3) Detect the motor rotary transformer self-learning in the range extender powertrain; Step 4) Detecting the external characteristics of the motor in the range extender powertrain; Step 5) Perform NVH testing on the range extender powertrain.
[0020] In this specific embodiment, in step 1), according to the CAN communication protocol of the controller in the range extender powertrain, a specific signal in the CAN communication protocol is used to detect whether the communication between the controller and the external test station is normal. Specifically, the Counter signal and Check_Sum signal in the 155 frame on the CAN communication protocol are used to check and detect whether the communication between the controller and the test station is normal.
[0021] In this specific embodiment, in step 2), detection is performed according to the DID signal address location where the software version number and hardware version number of the controller in the range extender powertrain are stored, and the signal address location where the software version number and hardware version number of the controller are stored is obtained in real time through CAN communication or UDS instructions.
[0022] In this specific embodiment, step 3) includes the following steps: Step 3.1) Install the range extender powertrain on the test bench, supply low voltage and high voltage (350V) to the controller of the range extender powertrain respectively, and according to the CAN communication protocol of the controller, use the motor resolver self-learning trigger signal therein to trigger the motor to perform resolver self-learning and obtain the resolver self-learning result signal; Step 3.2) detecting whether the resolver self-learning is successful according to the resolver self-learning result signal in step 3.1); Step 3.3) obtaining the resolver initial angle value according to the resolver self-learning result signal in step 3.1); Step 3.4) Repeat step 3.1) to step 3.3) for n times, and then execute step 3.5); In this specific embodiment, repeat step 3.1) to step 3.3) for 3 times, and then execute step 3.5); As shown in the attached Figure 2 As shown; Step 3.5) Determine whether the n resolver initial angle values obtained by repeating the learning n times are all within the range of 0-360°, and whether the maximum and minimum values of the n resolver initial angle values differ by less than 1°. If so, the resolver self-learning is determined to be successful, otherwise, the resolver self-learning fails. In this specific embodiment, it is determined whether the three resolver initial angle values obtained by repeating the learning three times are all within the range of 0-360°, and whether the maximum and minimum values of the three resolver initial angle values differ by less than 1°. If so, the resolver self-learning is determined to be successful, otherwise, the resolver self-learning fails.
[0023] In this specific embodiment, step 4) includes the following steps: Step 4.1) According to the CAN communication protocol of the controller, the motor torque in the range extender powertrain is requested to be the external characteristic test torque, and then the motor speed and motor torque are gradually increased according to the test required time.
[0024] Specifically, step 4.1) includes the following steps: Step 4.1.1) Switch the motor mode to the torque mode and request the motor torque in the range extender powertrain to be 0 NM; Step 4.1.2) gradually request the motor speed to be the target speed with a gradient of 0.2 seconds, and the request time is 5 seconds; Step 4.1.3) After 5 seconds, gradually request the motor torque to be the target torque with a gradient of 0.2 seconds for a request time of 2 seconds.
[0025] Step 4.2) Determine whether the external characteristics of the motor in the range extender powertrain meet the powertrain requirements based on the output torque and speed fed back by the test bench.
[0026] Specifically, in step 4.2), it is determined whether the output end torque fed back by the loading motor end of the test bench is within the range of ±3% of the target torque, and at the same time, it is determined whether the output end speed fed back by the loading motor end of the test bench is within the range of ±5rpm of the target speed. If both are true, it is determined that the motor external characteristics of the range extender powertrain meet the requirements of the range extender powertrain; otherwise, it is determined that the motor external characteristics of the range extender powertrain do not meet the requirements of the range extender powertrain.
[0027] In this specific embodiment, step 5) includes forward low torque acceleration condition bump and scratch detection, constant torque acceleration condition detection, constant power acceleration condition detection, constant torque deceleration condition detection and reverse low torque deceleration condition bump and scratch detection.
[0028] Specifically, step 5) includes the following steps: Step 5.1) Control the torque and speed of the motor of the range extender powertrain according to the CAN communication protocol of the range extender powertrain controller; Step 5.2) Forward low-torque acceleration condition bump and damage detection: The motor of the range extender powertrain is subjected to a 6-second acceleration run at the first torque setting and speed, and the gears of the transmission in the range extender powertrain are subjected to a gear bump and damage detection using the NVH detection system; Step 5.3) Constant torque acceleration condition detection: The motor of the range extender powertrain is subjected to a 6-second acceleration operation with a fixed torque setting and a speed, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs a constant torque and accelerates; Step 5.4) Constant power acceleration condition detection: The motor of the range extender powertrain is subjected to a 6-second acceleration operation with a fixed torque setting and speed, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs a constant power acceleration condition; Step 5.5) Constant torque deceleration condition detection: The motor of the range extender powertrain is decelerated for 6 seconds with a fixed torque setting and speed, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs constant torque and decelerates; Step 5.6) Reverse low torque deceleration condition bump and damage detection: The motor of the range extender powertrain is set to the reverse first torque and the speed is decelerated for 6 seconds, and the gears of the transmission part of the powertrain are tested for gear bump and damage using the NVH detection system.
[0029] Compared with the prior art, the range extender powertrain offline detection method provided by the present invention realizes an objective evaluation of the range extender powertrain performance during the range extender powertrain offline detection stage, and effectively intercepts unqualified products in combination with the actual situation of the vehicle, thereby improving the reliability of the product. At the same time, the present invention can effectively solve the problem of insufficient comprehensiveness of the offline detection of the range extender powertrain in the prior art, greatly improve the reliability and comfort of the product, reduce the control failure problem of the range extender powertrain after it is installed in the vehicle, and reduce the occurrence of safety accidents.
[0030] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit the technical solution. Those skilled in the art should understand that those modifications or equivalent substitutions of the technical solution of the present invention that do not depart from the purpose and scope of the technical solution should be included in the scope of the claims of the present invention.
Claims
1. A method for detecting the off-line operation of a range extender powertrain, characterized in that: The following steps are involved: Step 1) Detect the CAN communication of the controller in the range extender powertrain; Step 2) Detect the software version and hardware version of the controller in the range extender powertrain; Step 3) Detect the motor rotary transformer self-learning in the range extender powertrain; Step 4) Detecting the external characteristics of the motor in the range extender powertrain; Step 5) Perform NVH testing on the range extender powertrain.
2. The off-line detection method for a range extender powertrain according to claim 1, characterized in that: In step 1), according to the CAN communication protocol of the controller in the range extender powertrain, a specific signal in the CAN communication protocol is used to detect whether the communication between the controller and the external test bench is normal.
3. The off-line detection method for the range extender powertrain according to claim 2, characterized in that: In step 2), detection is performed according to the signal address location where the software version number and the hardware version number of the controller in the range extender powertrain are stored, and the signal address location where the software version number and the hardware version number of the controller are stored is obtained in real time through CAN communication or UDS instructions.
4. The off-line detection method for a range extender powertrain according to claim 3, characterized in that: Step 3) includes the following steps: Step 3.1) Install the range extender powertrain on the test bench, supply low voltage and high voltage to the controller of the range extender powertrain respectively, and according to the CAN communication protocol of the controller, use the motor resolver self-learning trigger signal therein to trigger the motor to perform resolver self-learning and obtain the resolver self-learning result signal; Step 3.2) detecting whether the resolver self-learning is successful according to the resolver self-learning result signal in step 3.1); Step 3.3) obtaining the resolver initial angle value according to the resolver self-learning result signal in step 3.1); Step 3.4) Repeat steps 3.1) to 3.3) for n times, and then proceed to step 3.5); Step 3.5) Determine whether the n resolver initial angle values obtained by repeated learning n times are all within the range of 0-360°, and whether the difference between the maximum and minimum values of the n resolver initial angle values is less than 1°. If so, the resolver self-learning is determined to be successful, otherwise, the resolver self-learning is determined to have failed.
5. The off-line detection method for a range extender powertrain according to claim 4, characterized in that: Step 4) includes the following steps: Step 4.1) According to the CAN communication protocol of the controller, request the motor torque in the range extender powertrain to be the external characteristic test torque, and then gradually increase the motor speed and motor torque according to the time required by the test; Step 4.2) Determine whether the external characteristics of the motor in the range extender powertrain meet the powertrain requirements based on the output torque and speed fed back by the test bench.
6. The range extender powertrain off-line detection method according to claim 5, characterized in that: Step 4.1) includes the following steps: Step 4.1.1) Switch the motor mode to the torque mode and request the motor torque in the range extender powertrain to be 0 NM; Step 4.1.2) gradually request the motor speed to be the target speed with a gradient of 0.2 seconds, and the request time is 5 seconds; Step 4.1.3) After 5 seconds, gradually request the motor torque to be the target torque with a gradient of 0.2 seconds for a request time of 2 seconds.
7. The off-line detection method for a range extender powertrain according to claim 6, characterized in that: In step 4.2), it is determined whether the output torque fed back by the motor end of the test bench is within the range of ±3% of the target torque, and whether the output speed fed back by the motor end of the test bench is within the range of ±5rpm of the target speed. If both are true, it is determined that the motor external characteristics of the range extender powertrain meet the requirements of the range extender powertrain; otherwise, it is determined that the motor external characteristics of the range extender powertrain do not meet the requirements of the range extender powertrain.
8. The off-line detection method for a range extender powertrain according to claim 7, characterized in that: Step 5) includes forward low torque acceleration condition bump and scratch detection, constant torque acceleration condition detection, constant power acceleration condition detection, constant torque deceleration condition detection and reverse low torque deceleration condition bump and scratch detection.
9. The off-line detection method for a range extender powertrain according to claim 8, characterized in that: Step 5) includes the following steps: Step 5.1) Control the torque and speed of the motor of the range extender powertrain according to the CAN communication protocol of the range extender powertrain controller; Step 5.2) Forward low-torque acceleration condition bump and damage detection: The motor of the range extender powertrain is set to the first torque and the speed is increased, and the gears of the transmission in the range extender powertrain are tested for bump and damage using the NVH detection system; Step 5.3) Constant torque acceleration condition detection: The motor of the range extender powertrain is operated at a fixed torque setting and a speed increase, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs a constant torque and increases speed; Step 5.4) Constant power acceleration condition detection: The motor of the range extender powertrain is operated at a fixed torque setting and a speed increase, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs a constant power and increases speed; Step 5.5) Constant torque deceleration condition detection: The motor of the range extender powertrain is decelerated at a fixed torque setting and speed, and the NVH detection system is used to detect abnormal noise of the range extender powertrain when the motor outputs constant torque and decelerates; Step 5.6) Reverse low-torque speed reduction condition bump and dent detection: The motor of the range extender powertrain is set to the reverse first torque and speed reduction operation, and the gears of the transmission part of the powertrain are tested for gear bump and dent using the NVH detection system.