Energy management test system based on four-motor rack and application method

Abstract

The invention provides an energy management test system based on a four-motor rack and an application method. The energy management test system comprises a rack system, a main control system, a data acquisition system and an environment adjusting system, the main control system is used for setting and receiving an operation signal of the rack system; the rack system is used for realizing curve operation of the vehicle under various working conditions based on an operation signal of the rack system; the environment adjusting system is used for adjusting environment conditions including temperature, humidity, illumination intensity and wind speed; and the data acquisition system is used for acquiring data related to energy management of the whole vehicle under various working conditions and different environmental conditions. According to the invention, the energy loss of a dynamic working condition is known by measuring current, voltage (electrical loss), rotating speed, torque (mechanical loss), temperature (heat loss) and flow pressure (liquid loss); the whole vehicle energy consumption distribution condition can be comprehensively known, the difference between a real vehicle and a development target is analyzed, and the optimization direction is defined.

Description

Technical Field

[0001] The present invention relates to the technical field of four-motor test benches, and in particular to an energy management test system and an application method based on a four-motor test bench. Background Art

[0002] With the popularization of new energy vehicles, users' demands for optimization of vehicle energy loss, verification of extreme working conditions and energy management testing are increasing. This requires the test system to not only have conventional energy management testing capabilities, but also to perform high-precision energy flow testing under different environmental conditions.

[0003] Although the normal temperature four-motor test bench in the prior art can perform normal temperature energy management tests, such as vehicle resistance decomposition and efficiency tests, it lacks adaptability to high and low temperature environments, which limits its testing capabilities in complex environments; although the high and low temperature rotating hub test bench in the prior art can perform high and low temperature energy management tests, due to large measurement errors, it is impossible to perform high-precision tests such as vehicle resistance decomposition, affecting the reliability of the test results.

[0004] Patent document CN115817277A (application number: 202211730454.5) discloses a vehicle energy consumption prediction management method, device, equipment and storage medium, the method comprising: identifying whether the target vehicle has turned on the predictive energy management function; if it is determined that the predictive energy management function has been turned on, the target vehicle is not controlled by the predictive energy management function within a preset time period after the start of operation, and the actual driving energy consumption data of the target vehicle within the preset time period after the start of operation is obtained; the historical driving energy consumption data pre-stored in the cloud by the target vehicle is obtained; it is determined that the actual driving energy consumption data is within a first preset range of the historical driving energy consumption data; if it is within the first preset range, the battery power of the target vehicle is predicted and managed according to the historical driving energy consumption data; if it is not within the first preset range, the battery power of the target vehicle is predicted and managed according to the pre-calibrated energy consumption data, so as to more accurately control the battery power of the target vehicle. Summary of the invention

[0005] In view of the defects in the prior art, the purpose of the present invention is to provide an energy management test system based on a four-motor test bench and an application method.

[0006] An energy management test system based on a four-motor test bench provided by the present invention includes: a test bench system, a main control system, a data acquisition system and an environmental adjustment system;

[0007] The main control system is used to set and receive operating signals of the test bench system;

[0008] The test bench system is used to realize various operating curve operations of the vehicle based on the operating signal of the test bench system;

[0009] The environmental conditioning system is used to control environmental conditions including temperature, humidity, light intensity and wind speed;

[0010] The data acquisition system is used to collect vehicle energy management related data under various working conditions and different environmental conditions.

[0011] Preferably, the main control system is connected with the bench system, data acquisition system and environmental adjustment system for low-latency communication equipment control and data transmission via industrial Ethernet or CAN communication.

[0012] Preferably, the test bench system comprises: a dynamometer system and a frequency converter;

[0013] The frequency converter is used to adjust the operating frequency and voltage of the motor based on the operating signal set by the main control system to simulate different loads and working conditions;

[0014] The dynamometer system is used for driving and braking conditions under different simulated load conditions;

[0015] The dynamometer system includes four motors that meet high and low temperature use conditions and a dynamometer adjustment system;

[0016] The dynamometer adjustment system is used to adjust the temperature of the dynamometer so that the temperature of the dynamometer is maintained within a preset constant temperature range.

[0017] Preferably, the dynamometer adjustment system comprises: using a PT100 temperature sensor to monitor the temperature of the dynamometer in real time; when the monitored temperature of the dynamometer is higher than a preset target temperature range, the proportional valve is automatically adjusted by PID to control the inlet and return water until the dynamometer temperature drops to within the preset target temperature range; when the monitored temperature of the dynamometer is within the preset target temperature range, the heater is turned on by temperature control to adjust the inlet and return water until the dynamometer temperature rises to within the preset target temperature range.

[0018] Preferably, the system comprises: an auxiliary device; the auxiliary device comprises a driving robot;

[0019] Based on the operating signals of the test bench system, the driving robot is used to realize various operating curves of the vehicle.

[0020] Preferably, the environmental conditioning system comprises: an environmental chamber system and an oncoming fan;

[0021] The environmental chamber system includes a walk-in environmental chamber and a full-spectrum sunlight simulation system;

[0022] The walk-in environmental chamber is used to simulate the temperature and humidity in the natural environment;

[0023] The full-spectrum sunlight simulation system is used to simulate the light intensity in the natural environment;

[0024] The oncoming wind fan is used to simulate the wind speed in the natural environment to achieve vehicle speed following.

[0025] Preferably, the data acquisition system includes: measuring data including torque, rotation speed, current, voltage, temperature, pressure and flow rate through a multi-channel power analyzer, a multi-function data acquisition and different types of sensors.

[0026] Preferably, the vehicle energy data collected by the data acquisition system and the environmental conditions set by the environmental adjustment system are transmitted to the main control system, and the main control system performs clock synchronization on the received data, and displays and stores the clock-synchronized data in real time.

[0027] According to the present invention, an energy management test application method based on a four-motor test bench is provided, comprising:

[0028] Step S1: using the main control system to set and receive the operating signal of the gantry system;

[0029] Step S2: using the test bench system to perform various operating curve operations of the vehicle based on the operating signal of the test bench system;

[0030] Step S3: using an environmental conditioning system to control environmental conditions including temperature, humidity, light intensity and wind speed;

[0031] Step S4: Utilize the data acquisition system to collect vehicle energy management related data under various working conditions and different environmental conditions.

[0032] Preferably, the test bench system comprises: a dynamometer system and a frequency converter;

[0033] The frequency converter is used to adjust the operating frequency and voltage of the motor based on the operating signal set by the main control system to simulate different loads and working conditions;

[0034] The dynamometer system is used for driving and braking conditions under different simulated load conditions;

[0035] The dynamometer system includes four motors that meet high and low temperature use conditions and a dynamometer adjustment system;

[0036] The dynamometer adjustment system is used to adjust the temperature of the dynamometer so that the temperature of the dynamometer is maintained within a preset constant temperature range;

[0037] The dynamometer adjustment system comprises: using a PT100 temperature sensor to monitor the temperature of the dynamometer in real time; when the monitored temperature of the dynamometer is higher than a preset target temperature range, the proportional valve is automatically adjusted by PID to control the inlet and return water until the dynamometer temperature drops to the preset target temperature range; when the monitored temperature of the dynamometer is lower than the preset target temperature range, the heater is turned on by temperature control to adjust the inlet and return water until the dynamometer temperature rises to the preset target temperature range;

[0038] The environmental conditioning system comprises: an environmental chamber system and an oncoming fan;

[0039] The environmental chamber system includes a walk-in environmental chamber and a full-spectrum sunlight simulation system;

[0040] The walk-in environmental chamber is used to simulate the temperature and humidity in the natural environment;

[0041] The full-spectrum sunlight simulation system is used to simulate the light intensity in the natural environment;

[0042] The oncoming wind fan is used to simulate the wind speed in the natural environment to achieve vehicle speed following;

[0043] The data acquisition system includes: measuring data including torque, speed, current, voltage, temperature, pressure and flow rate through a multi-channel power analyzer, a multi-function data acquisition and different types of sensors;

[0044] The vehicle energy data collected by the data acquisition system and the environmental conditions set by the environmental adjustment system are transmitted to the main control system, and the main control system performs clock synchronization on the received data, and displays and stores the clock-synchronized data in real time.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] 1. The main control system of the present invention uses industrial Ethernet or CAN communication to perform low-latency communication equipment control and data transmission with the test bench system, data acquisition system, and environmental adjustment system;

[0047] 2. The present invention can accurately measure the energy generation, conversion and transfer process of the whole vehicle under different environmental conditions in real time; identify and analyze the energy control problem of the whole vehicle, or analyze the energy loss problem of components under dynamic conditions;

[0048] 3. The present invention measures the current, voltage, speed, torque, temperature, and flow pressure to know the energy loss in dynamic working conditions, so as to fully understand the energy consumption distribution of the whole vehicle, analyze the difference between the actual vehicle and the development target, and clarify the optimization direction; in addition, based on the competing models, combined with the energy flow test and analysis method, it is possible to quantitatively find the energy consumption difference, clarify the reasonable and effective improvement direction, and also find the position of the target vehicle in the competing database, and reasonably evaluate the energy consumption level of the target vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0050] Figure 1 Schematic diagram of the energy management test system based on a four-motor test bench.

[0051] Figure 2 Schematic diagram of the energy management test system based on a four-motor test bench. DETAILED DESCRIPTION

[0052] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several changes and improvements can also be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0053] Example 1

[0054] According to the present invention, an energy management test system based on a four-motor test bench is provided. Figure 1 As shown, it includes: bench system, main control system, data acquisition system and environmental adjustment system;

[0055] The main control system is used to set and receive operating signals of the test bench system;

[0056] The test bench system is used to realize various operating curve operations of the vehicle based on the operating signal of the test bench system;

[0057] The environmental conditioning system is used to control environmental conditions including temperature, humidity, light intensity and wind speed;

[0058] The data acquisition system is used to collect vehicle energy management related data under various working conditions and different environmental conditions.

[0059] The main control system is connected with the bench system, data acquisition system and environmental adjustment system for low-latency communication equipment control and data transmission via industrial Ethernet or CAN communication.

[0060] Specifically, the test bench system includes: a dynamometer system and a frequency converter;

[0061] The frequency converter is used to adjust the operating frequency and voltage of the motor based on the operating signal set by the main control system to simulate different loads and working conditions;

[0062] The dynamometer system is used for driving and braking conditions under different simulated load conditions;

[0063] The dynamometer system includes four motors that meet high and low temperature use conditions and a dynamometer adjustment system;

[0064] The dynamometer adjustment system is used to adjust the temperature of the dynamometer so that the temperature of the dynamometer is maintained within a preset constant temperature range.

[0065] The dynamometer system also includes a CV drive shaft, a dynamometer vibration temperature flow pressure monitoring system, a dynamometer base, an axle protection cover and a wheel hub connector of the whole vehicle; the absorption, driving power, torque and speed of the dynamometer meet the basic parameters of the whole vehicle test piece, and realize the operation of various working condition curves of the vehicle.

[0066] Specifically, the dynamometer adjustment system includes: using a PT100 temperature sensor to monitor the temperature of the dynamometer in real time. When the monitored temperature of the dynamometer is higher than a preset target temperature range, the PID proportional valve is automatically adjusted to control the inlet and return water until the dynamometer temperature drops to within the preset target temperature range; when the monitored temperature of the dynamometer is within the preset target temperature range, the heater is turned on through temperature control to adjust the inlet and return water until the dynamometer temperature rises to within the preset target temperature range.

[0067] In this embodiment, the dynamometer is equipped with a PT100 temperature sensor. The temperature control principle is to provide the dynamometer with a constant temperature range. The current design target is 20-30°C. If the temperature in the cabin rises, the temperature control will automatically adjust the proportional valve through the PID to control the inlet and return water to lower the temperature of the dynamometer. If the temperature in the cabin drops, the temperature control will turn on the heater to adjust the inlet and return water to raise the temperature of the dynamometer.

[0068] The system comprises: an auxiliary device; the auxiliary device comprises a driving robot;

[0069] Based on the operating signals of the test bench system, the driving robot is used to realize various operating curves of the vehicle.

[0070] In this embodiment, the driving robot can replace the real driver to drive in high and low temperature environments, thereby improving the accuracy, sensitivity and consistency of the test; it can calculate or receive the accelerator and brake pedal positions, and achieve the tracking of the expected vehicle speed and the actual vehicle speed.

[0071] Specifically, the environmental conditioning system includes: an environmental chamber system and an oncoming fan;

[0072] The environmental chamber system includes a walk-in environmental chamber and a full-spectrum sunlight simulation system;

[0073] The walk-in environmental chamber is used to simulate the temperature and humidity in the natural environment;

[0074] The full-spectrum sunlight simulation system is used to simulate the light intensity in the natural environment;

[0075] The oncoming wind fan is used to simulate the wind speed in the natural environment to achieve vehicle speed following.

[0076] Specifically, the data acquisition system includes: measuring data including torque, speed, current, voltage, temperature, pressure and flow rate through a multi-channel power analyzer, a multi-function data acquisition and different types of sensors. Among them, the multi-function data acquisition can realize the measurement of multiple acquisition channels that support multiple acquisition frequencies in the same module. Among them, the different types of sensors include: sensors of torque, speed, current, voltage, temperature, pressure and flow rate.

[0077] Specifically, the vehicle energy data collected by the data acquisition system and the environmental conditions set by the environmental adjustment system are transmitted to the main control system, and the main control system performs clock synchronization on the received data, and displays and stores the clock-synchronized data in real time.

[0078] The present invention also provides an energy management test system based on a four-motor test bench. The energy management test system based on the four-motor test bench can be implemented by executing the process steps of the energy management test application method based on the four-motor test bench, that is, technical personnel in this field can understand the energy management test application method based on the four-motor test bench as a preferred implementation mode of the energy management test system based on the four-motor test bench.

[0079] Example 2

[0080] Embodiment 2 is a preferred embodiment of Embodiment 1

[0081] According to the present invention, an energy management test system based on a four-motor test bench is provided. Figure 2 As shown, including:

[0082] A high-performance shaft-coupled four-motor test bench has been built, integrating different types of high-precision sensors to achieve high-precision vehicle energy management testing that covers complex driving conditions and operating conditions and meets higher dynamic testing requirements under high and low temperature environmental conditions. The test results can comprehensively evaluate the performance of the energy management system and optimize and improve the energy management strategy.

[0083] The energy management test system based on the four-motor test bench includes five parts: a test bench system, a main control system, a data acquisition system, an environmental adjustment system and auxiliary equipment.

[0084] Test bench system: including dynamometer system, frequency converter, torque flanges of different ranges, etc. The dynamometer system consists of four motors that can meet high and low temperature conditions and dynamometer adjustment system, CV transmission shaft, dynamometer vibration temperature flow pressure monitoring system, dynamometer base, shaft protection cover, and wheel hub connector. The absorption, driving power, torque and speed of the dynamometer meet the basic parameters of the vehicle under test, and realize the operation of various working condition curves of the vehicle.

[0085] Main control system: including industrial computer, MORPHEE software, xMOD software, etc. MORPHEE software is based on RTX64 real-time operating system, which can monitor network data in real time and synchronize the clock of each network data received. The synchronized network data is displayed and stored in real time. It can control the power-on and idle speed of the dynamometer and the switching of road load simulation / throttle modes. xMOD software can simulate road load simulation, customize the input of vehicle parameters, set slope, throttle or speed, simulate rolling resistance, wind resistance, slope resistance, and conduct NEDC or customized driving cycle tests; the road adhesion coefficient can be set to simulate the slipping conditions of the four tires separately.

[0086] Data acquisition system: including multi-channel power analyzer, integrated / portable multifunctional data acquisition and different types of high-precision sensors. It is an important part of the four-motor energy management system, and measures torque, speed, current, voltage, temperature, pressure and flow data. Multifunctional data acquisition can realize the measurement of multiple acquisition channels that support multiple acquisition frequencies in the same module. The present invention knows the energy loss of dynamic working conditions by measuring current, voltage (electrical loss), speed, torque (mechanical loss), temperature (heat loss), flow pressure (liquid loss); it can fully understand the energy consumption distribution of the whole vehicle, analyze the difference between the actual vehicle and the development target, and clarify the optimization direction; in this embodiment, energy is the calculation process of power loss. Taking the motor as an example, the motor efficiency refers to the ratio of the motor output mechanical power to the input electrical power, and the loss is the difference between the input electrical power and the output mechanical power. Use current sensors and power analyzers to measure current and voltage. Use the torque flange of the wheel dynamometer or the half-axle torque sensor to measure the speed and torque. Current and voltage calculate electric power, and speed and torque calculate mechanical power. For example, under braking conditions, the wheel dynamometer reads the speed and torque signals as the total braking energy, overcoming the energy loss of the brake bearing, the energy loss of the transmission shaft, the motor loss and the controller loss. The remaining energy is the energy recovered and stored in the battery.

[0087] Environmental condition system: including environmental chamber system and oncoming fan, etc. The environmental chamber system includes a walk-in environmental chamber and a full-spectrum sunlight simulation system, which can adjust the temperature, humidity and light intensity. The environmental chamber parts are selected based on the samples corresponding to different vehicle working conditions and the heat load of the oncoming fan. The environmental chamber is equipped with fire safety and environmental protection to detect the concentration of toxic gases. The sunlight simulation is close to the real outdoor working conditions and is suitable for related tests such as air conditioning performance and comfort.

[0088] Auxiliary equipment: including driving robots, lifts, etc. The driving robot can replace the real driver to drive in high and low temperature environments, improving the accuracy, sensitivity and consistency of the test. It can calculate or receive the accelerator and brake pedal positions to achieve the desired speed and actual speed.

[0089] Those skilled in the art know that, in addition to realizing the system and its various devices, modules, and units provided by the present invention in a purely computer-readable program code, it is entirely possible to realize the same functions in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers by logically programming the method steps. Therefore, the system and its various devices, modules, and units provided by the present invention can be considered as a hardware component, and the devices, modules, and units included therein for realizing various functions can also be regarded as structures within the hardware component; the devices, modules, and units for realizing various functions can also be regarded as both software modules for realizing the method and structures within the hardware component.

[0090] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which does not affect the essence of the present invention. In the absence of conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims

1. An energy management test system based on a four-motor test bench, characterized in that: include: Test bench system, main control system, data acquisition system and environmental control system; The main control system is used to set and receive operating signals of the test bench system; The test bench system is used to realize various operating curve operations of the vehicle based on the operating signal of the test bench system; The environmental conditioning system is used to control environmental conditions including temperature, humidity, light intensity and wind speed; The data acquisition system is used to collect vehicle energy management related data under various working conditions and different environmental conditions.

2. The energy management test system based on the four-motor test bench according to claim 1 is characterized in that: The main control system is connected with the bench system, data acquisition system and environmental adjustment system for low-latency communication equipment control and data transmission via industrial Ethernet or CAN communication.

3. The energy management test system based on the four-motor test bench according to claim 1 is characterized in that: The bench system includes: a dynamometer system and a frequency converter; The frequency converter is used to adjust the operating frequency and voltage of the motor based on the operating signal set by the main control system to simulate different loads and working conditions; The dynamometer system is used for driving and braking conditions under different simulated load conditions; The dynamometer system includes four motors that meet high and low temperature use conditions and a dynamometer adjustment system; The dynamometer adjustment system is used to adjust the temperature of the dynamometer so that the temperature of the dynamometer is maintained within a preset constant temperature range.

4. The energy management test system based on the four-motor test bench according to claim 3 is characterized in that: The dynamometer adjustment system comprises: using a PT100 temperature sensor to monitor the temperature of the dynamometer in real time; when the monitored temperature of the dynamometer is higher than a preset target temperature range, automatically adjusting the proportional valve through PID to control the inlet and return water until the dynamometer temperature drops to within the preset target temperature range; when the monitored temperature of the dynamometer is within the preset target temperature range, turning on the heater through temperature control to adjust the inlet and return water until the dynamometer temperature rises to within the preset target temperature range.

5. The energy management test system based on the four-motor test bench according to claim 1 is characterized in that: The system comprises: an auxiliary device; the auxiliary device comprises a driving robot; Based on the operating signals of the test bench system, the driving robot is used to realize various operating curves of the vehicle.

6. The energy management test system based on the four-motor test bench according to claim 1 is characterized in that: The environmental conditioning system comprises: an environmental chamber system and an oncoming fan; The environmental chamber system includes a walk-in environmental chamber and a full-spectrum sunlight simulation system; The walk-in environmental chamber is used to simulate the temperature and humidity in the natural environment; The full-spectrum sunlight simulation system is used to simulate the light intensity in the natural environment; The oncoming wind fan is used to simulate the wind speed in the natural environment to achieve vehicle speed following.

7. The energy management test system based on the four-motor test bench according to claim 1 is characterized in that: The data acquisition system includes: measuring data including torque, rotation speed, current, voltage, temperature, pressure and flow rate through a multi-channel power analyzer, a multi-function data acquisition and different types of sensors.

8. The energy management test system based on the four-motor test bench according to claim 7 is characterized in that: The vehicle energy data collected by the data acquisition system and the environmental conditions set by the environmental adjustment system are transmitted to the main control system, and the main control system performs clock synchronization on the received data, and displays and stores the clock-synchronized data in real time.

9. An energy management test application method based on a four-motor test bench, characterized in that: include: Step S1: using the main control system to set and receive the operating signal of the gantry system; Step S2: using the test bench system to perform various operating curve operations of the vehicle based on the operating signal of the test bench system; Step S3: using an environmental conditioning system to control environmental conditions including temperature, humidity, light intensity and wind speed; Step S4: Utilize the data acquisition system to collect vehicle energy management related data under various working conditions and different environmental conditions.

10. The energy management test application method based on the four-motor test bench according to claim 9 is characterized in that: The bench system includes: a dynamometer system and a frequency converter; The frequency converter is used to adjust the operating frequency and voltage of the motor based on the operating signal set by the main control system to simulate different loads and working conditions; The dynamometer system is used for driving and braking conditions under different simulated load conditions; The dynamometer system includes four motors that meet high and low temperature use conditions and a dynamometer adjustment system; The dynamometer adjustment system is used to adjust the temperature of the dynamometer so that the temperature of the dynamometer is maintained within a preset constant temperature range; The dynamometer adjustment system comprises: using a PT100 temperature sensor to monitor the temperature of the dynamometer in real time; when the monitored temperature of the dynamometer is higher than a preset target temperature range, the proportional valve is automatically adjusted by PID to control the inlet and return water until the dynamometer temperature drops to the preset target temperature range; when the monitored temperature of the dynamometer is lower than the preset target temperature range, the heater is turned on by temperature control to adjust the inlet and return water until the dynamometer temperature rises to the preset target temperature range; The environmental conditioning system comprises: an environmental chamber system and an oncoming fan; The environmental chamber system includes a walk-in environmental chamber and a full-spectrum sunlight simulation system; The walk-in environmental chamber is used to simulate the temperature and humidity in the natural environment; The full-spectrum sunlight simulation system is used to simulate the light intensity in the natural environment; The oncoming wind fan is used to simulate the wind speed in the natural environment to achieve vehicle speed following; The data acquisition system includes: measuring data including torque, speed, current, voltage, temperature, pressure and flow rate through a multi-channel power analyzer, a multi-function data acquisition and different types of sensors; The vehicle energy data collected by the data acquisition system and the environmental conditions set by the environmental adjustment system are transmitted to the main control system, and the main control system performs clock synchronization on the received data, and displays and stores the clock-synchronized data in real time.

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