Motor rotary transformer troubleshooting device and method

Abstract

The invention discloses a motor resolver troubleshooting device and method, and relates to the technical field of electric vehicle motor resolver, and the method comprises the steps: constructing a motor resolver troubleshooting device, selecting a power board working mode as an external power supply mode through a display screen, and supplying power to an MCU at low voltage; the motor rotary transformer troubleshooting device is in butt joint with the MCU, a voltage signal is collected, and a broken line fault is judged according to a threshold value; switching the power board into a power-off mode, collecting a visual signal to detect the abnormality of a terminal, and collecting a humidity signal to detect a water inlet fault; butting a rotary transformer terminal, performing insulation voltage injection and resistance detection, judging an insulation abnormal fault, and if the insulation is normal, collecting the resistance of the MCU / wire harness butting end. Parameters of all parts do not need to be measured one by one in a manual mode and manual analysis does not need to be carried out, the labor and time cost for troubleshooting is reduced, and the working efficiency is improved; parameter acquisition is carried out on components, the sampling frequency is high, the period is long, and the method is especially effective for troubleshooting and analysis of accidental faults.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle motor resolver, and in particular to a motor resolver fault troubleshooting device and method. Background Art

[0002] The resolver (also called a rotary transformer) is a key component in the motor control system, used to detect the position and speed of the motor rotor. A resolver failure will cause the motor controller to be unable to accurately identify the motor rotor position, thereby affecting the motor control strategy, which may cause the vehicle to lose power and pose a safety hazard.

[0003] In the prior art, resolver fault detection is mainly performed manually, which has a long troubleshooting process and consumes a lot of manpower and analysis time. In addition, for occasional resolver faults, manual detection and troubleshooting often takes a longer time (even months), and due to the low sampling frequency of manual detection data, in many cases, even the data of occasional faults cannot be collected, resulting in troubleshooting failure.

[0004] The present invention designs a device for automatically detecting and troubleshooting motor resolver faults, which can quickly and accurately locate and analyze resolver faults, greatly improve work efficiency, and reduce after-sales labor costs. Summary of the invention

[0005] In view of the above-mentioned problems, the present invention is proposed.

[0006] Therefore, the problem to be solved by the present invention is: how to solve the problem that the existing manual detection and troubleshooting often takes a longer time (even months), and because the sampling frequency of the manual detection data is low, in many cases it is even impossible to collect data on occasional faults, resulting in troubleshooting failure.

[0007] To solve the above technical problems, the present invention provides the following technical solutions: a motor resolver fault troubleshooting device, comprising a power module, an MCU / wiring harness docking terminal and a resolver docking terminal; the power module is electrically connected to the MCU / wiring harness docking terminal and electrically connected to the resolver docking terminal; the MCU / wiring harness docking terminal is used to physically connect the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal; the resolver docking terminal is used to physically connect the corresponding conductor core of the resolver terminal; the power module is used to perform insulation voltage injection and insulation resistance collection on the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal and the corresponding conductor core of the resolver terminal, to determine whether there is an insulation fault in the connector plugged into the MCU / wiring harness docking terminal and the resolver docking terminal; the power module is also used to obtain the first excitation resistance, the first sine resistance, and the first cosine resistance of the MCU / wiring harness docking terminal, obtain the second excitation resistance, the second sine resistance, and the second cosine resistance of the resolver docking terminal, and determine whether there is an abnormal resolver resistance fault.

[0008] As a preferred solution of the motor resolver fault troubleshooting device described in the present invention, wherein: the MCU / wiring harness docking end includes at least 6 low-voltage wiring harnesses, which are respectively a positive excitation wiring harness connected to the positive pole of the MCU excitation winding, a negative excitation wiring harness connected to the negative pole of the MCU excitation winding, a sine signal positive wiring harness connected to the MCU signal processing circuit, a sine signal negative wiring harness connected to the MCU signal processing circuit, a cosine signal positive wiring harness connected to the MCU signal processing circuit, and a cosine signal negative wiring harness connected to the MCU signal processing circuit; a first excitation resistance is measured between the positive excitation wiring harness connected to the positive pole of the MCU excitation winding and the negative excitation wiring harness connected to the negative pole of the MCU excitation winding, a first sinusoidal resistance is measured between the positive sinusoidal signal wiring harness connected to the MCU signal processing circuit and the negative sinusoidal signal wiring harness connected to the MCU signal processing circuit, and a first sinusoidal resistance is measured between the positive cosine signal wiring harness connected to the MCU signal processing circuit and the negative cosine signal wiring harness connected to the MCU signal processing circuit. The first cosine resistance is measured between the two terminals; the resolver docking end comprises at least 6 low-voltage wiring harnesses, which are respectively a resolver positive pole excitation wiring harness connected to the positive pole of the resolver excitation winding, a resolver negative pole excitation wiring harness connected to the negative pole of the resolver excitation winding, a wiring harness connected to the positive pole of the resolver output sine signal, a wiring harness connected to the negative pole of the resolver output sine signal, a wiring harness connected to the positive pole of the resolver output cosine signal, and a wiring harness connected to the negative pole of the resolver output cosine signal; the second excitation resistance is measured between the resolver positive pole excitation wiring harness connected to the positive pole of the resolver excitation winding and the resolver negative pole excitation wiring harness connected to the negative pole of the resolver excitation winding, the second sine resistance is measured between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the negative pole of the resolver output sine signal, and the second cosine resistance is measured between the wiring harness connected to the positive pole of the resolver output cosine signal and the wiring harness connected to the negative pole of the resolver output cosine signal.

[0009] As a preferred solution of the motor resolver fault troubleshooting device described in the present invention, the power module is also used to collect visual signals from the MCU / wiring harness docking end and the resolver docking end, and determine whether there is a fault in the connector plugged into the MCU / wiring harness docking end and the resolver docking end, wherein the fault includes bending and breaking of the conductor core, expansion of the connector and the presence of foreign matter; the power module is also used to collect humidity signals from the MCU / wiring harness docking end and the resolver docking end, and determine whether there is a terminal water ingress fault in the connector plugged into the MCU / wiring harness docking end and the resolver docking end; the power module is also used to collect voltage signals from the MCU / wiring harness docking end when the MCU is powered and the MCU / wiring harness docking end and the MCU or the wiring harness connector directly connected to the MCU are plugged in, to determine whether there is a wire break fault in the excitation of the MCU or the wiring harness directly connected to the MCU.

[0010] Another object of the present invention is to provide a method for troubleshooting a motor resolver fault. By constructing a motor resolver fault troubleshooting method, a motor resolver fault troubleshooting problem is solved.

[0011] To solve the above technical problems, the present invention provides the following technical solutions: a method for troubleshooting motor resolver faults, comprising: after injecting an insulation voltage into a conductor core corresponding to the resolver terminal, detecting the insulation resistance of the conductor core corresponding to the resolver terminal, comparing the insulation resistance with a preset insulation fault threshold, and determining whether there is an abnormal insulation fault; if there is no abnormal insulation fault, collecting a first excitation resistance, a first sine resistance, a first cosine resistance, a second excitation resistance, a second sine resistance and a second cosine resistance to determine whether there is an abnormal resolver resistance fault.

[0012] As a preferred solution of the motor resolver fault troubleshooting method described in the present invention, wherein: after injecting the insulation voltage into the conductor core corresponding to the resolver terminal, detecting the insulation resistance of the conductor core corresponding to the resolver terminal, comparing the insulation resistance with a preset insulation fault threshold, and determining whether there is an insulation abnormality fault includes:

[0013] Detect the insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding, the wiring harness connected to the positive pole of the resolver output sine signal, and the wiring harness connected to the positive pole of the resolver output cosine signal. The resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output sine signal is R sti-sin The insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output cosine signal is R sti-cos The resistance between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the positive pole of the resolver output cosine signal is R sin-cos If R sti-sin >R f , or R sti-cos >R f , or R sin-cos >R f , it is determined that there is an abnormal insulation resistance fault, where R f is the preset insulation fault threshold.

[0014] As a preferred solution of the motor resolver fault troubleshooting method described in the present invention, wherein: the determination of whether there is an abnormal resolver resistance fault includes a manual parameter setting mode; the manual parameter setting mode includes the user inputting the maximum threshold value R1 of the excitation resistance value, the minimum threshold value R2 of the excitation resistance value, the maximum threshold value R3 of the sine resistance value, the minimum threshold value R4 of the sine resistance value, the maximum threshold value R5 of the cosine resistance value, and the minimum threshold value R6 of the cosine resistance value; if R sti <R1, or R sti > R2, it is determined that the rotary transformer of the motor has an abnormal excitation resistance fault; if R sin <R3, or R sin > R4, it is determined that the rotary transformer of the motor has an abnormal sinusoidal resistance fault; if R cos <R5, or R cos >R6, it is determined that the rotary transformer of the motor has an abnormal cosine resistance fault; wherein, R sti R is the resistance between the resolver positive excitation wire connected to the positive pole of the resolver excitation winding and the resolver negative excitation wire connected to the negative pole of the resolver excitation winding. sin R is the resistance between the wiring harness connected to the positive pole of the resolver output sinusoidal signal and the wiring harness connected to the negative pole of the resolver output sinusoidal signal. cos It is the resistance value between the wiring harness connected to the positive electrode of the rotary transformer output cosine signal and the wiring harness connected to the negative electrode of the rotary transformer output cosine signal.

[0015] As a preferred solution of the motor resolver fault troubleshooting method described in the present invention, wherein: the determination of whether there is an abnormal resolver resistance fault includes an automatic determination mode; when R7≤(R sti +R sin +R cos )≤R8, and k1≤R sin / R cos ≤k2 and k3≤(R sin +R cos ) / 2R sti ≤k4, it is determined that the resolver does not have an abnormal resolver resistance fault; otherwise, it is determined that the resolver has an abnormal resolver resistance fault; wherein R7, R8, k1, k2, k3, and k4 are all preset values, R sti R is the resistance between the resolver positive excitation wire connected to the positive pole of the resolver excitation winding and the resolver negative excitation wire connected to the negative pole of the resolver excitation winding. sin R is the resistance between the wiring harness connected to the positive pole of the resolver output sinusoidal signal and the wiring harness connected to the negative pole of the resolver output sinusoidal signal. cosIt is the resistance value between the wiring harness connected to the positive electrode of the rotary transformer output cosine signal and the wiring harness connected to the negative electrode of the rotary transformer output cosine signal.

[0016] As a preferred solution of the motor resolver fault troubleshooting device described in the present invention, the motor resolver fault troubleshooting method also includes connecting the motor resolver fault troubleshooting device to the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal, collecting the first excitation voltage, the first sine voltage, and the first cosine voltage signals, and judging whether there is a wire break fault based on the comparison result between the voltage signal and the preset threshold.

[0017] As a preferred solution of the motor resolver fault troubleshooting device described in the present invention, wherein: the determination of whether there is a disconnection fault includes collecting voltage signals of three pairs of cores, including the excitation voltage U between the positive excitation wire harness connected to the positive pole of the MCU excitation winding and the negative excitation wire harness connected to the negative pole of the MCU excitation winding. sti , a first sinusoidal voltage U between the positive wiring harness of the sinusoidal signal connected to the MCU signal processing circuit and the negative wiring harness of the sinusoidal signal connected to the MCU signal processing circuit sin The first cosine voltage signal U is a cosine voltage signal between the positive wiring harness of the cosine signal connected to the MCU signal processing circuit and the negative wiring harness of the cosine signal connected to the MCU signal processing circuit. cos ;if U sti If it is less than U1, it is determined that there is an excitation disconnection fault in the transmission line between the positive excitation wiring harness connected to the positive pole of the MCU excitation winding and the negative excitation wiring harness connected to the negative pole of the MCU excitation winding; if U sin If U is greater than U2, it is determined that there is a sinusoidal disconnection fault in the transmission line between the positive wiring harness of the sinusoidal signal connected to the MCU signal processing circuit and the negative wiring harness of the sinusoidal signal connected to the MCU signal processing circuit; if U cos If it is greater than U3, it is determined that there is a cosine line break fault in the transmission line between the cosine signal positive wiring harness connected to the MCU signal processing circuit and the cosine signal negative wiring harness connected to the MCU signal processing circuit; wherein U1, U2, and U3 are the preset first voltage threshold, second voltage threshold, and third voltage threshold, respectively.

[0018] As a preferred solution of the motor resolver fault troubleshooting device described in the present invention, the motor resolver fault troubleshooting method also includes collecting humidity signals of the MCU / wiring harness docking end and the resolver docking end, and determining whether there is a terminal water ingress fault in the connector plugged into the MCU / wiring harness docking end and the resolver docking end.

[0019] As a preferred solution of the motor resolver fault troubleshooting device described in the present invention, wherein: the determination of whether there is a terminal water ingress fault in the connector plugged into the MCU / wiring harness docking end and the resolver docking end includes: the humidity signal of the MCU / wiring harness docking end is H con , the humidity signal at the resolver docking end is H res If H con >H air +δ, or H res >H air +δ, it is determined that there is a terminal water ingress fault in the transmission line between the connector plugged into the MCU / wiring harness docking end and the resolver docking end; where H air is the ambient humidity, and δ is the preset humidity increment threshold.

[0020] The beneficial effects of the present invention are as follows: the motor resolver fault troubleshooting method provided by the present invention does not require manual measurement of each component parameter and manual analysis, which greatly reduces the manpower and time cost of troubleshooting and improves work efficiency; when a vehicle has an occasional resolver fault, the sampling frequency of the manual detection data is low, and in many cases, even the data of the occasional fault cannot be collected, resulting in troubleshooting failure. The device can continuously and uninterruptedly collect parameters of the components, with a high sampling frequency and a long cycle, and is particularly effective for troubleshooting and analyzing occasional faults. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative labor.

[0022] Figure 1 A structural diagram of a motor resolver fault troubleshooting device provided in the first embodiment of the present invention. DETAILED DESCRIPTION

[0023] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0024] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0025] Example 1, reference Figure 1, which is the first embodiment of the present invention, provides a motor resolver fault troubleshooting device, including: a power module 100, an MCU / wiring harness docking terminal 200 and a resolver docking terminal 300.

[0026] MCU stands for Microcontroller Unit. It is an integrated circuit that includes a central processing unit (CPU), memory, input and output interfaces, and other functional modules, and is usually used in embedded systems. In this system, the MCU is responsible for controlling and coordinating the communication and data exchange between various components. Specifically, the MCU is connected to other parts, such as the power supply and control panel, through its pins (such as pins 1 to 6), so as to manage and operate the entire system.

[0027] The power module 100 includes a control board 101 and a power board 102 .

[0028] The MCU / wiring harness docking terminal 200 includes at least 6 (3 pairs in total) low-voltage wiring harnesses, namely, a positive excitation wiring harness connected to the positive pole of the MCU excitation winding, a negative excitation wiring harness connected to the negative pole of the MCU excitation winding, a sinusoidal signal positive wiring harness connected to the MCU signal processing circuit, a sinusoidal signal negative wiring harness connected to the MCU signal processing circuit, a cosine signal positive wiring harness connected to the MCU signal processing circuit, and a cosine signal negative wiring harness connected to the MCU signal processing circuit; that is, 1—excitation+, 2—excitation-, 3—sine+, 4—sine-, 5—cosine+, 6—cosine-.

[0029] The first excitation resistance is measured between the positive excitation wiring harness connected to the positive pole of the MCU excitation winding and the negative excitation wiring harness connected to the negative pole of the MCU excitation winding, the first sinusoidal resistance is measured between the positive sinusoidal signal wiring harness connected to the MCU signal processing circuit and the negative sinusoidal signal wiring harness connected to the MCU signal processing circuit, and the first cosine resistance is measured between the positive cosine signal wiring harness connected to the MCU signal processing circuit and the negative cosine signal wiring harness connected to the MCU signal processing circuit.

[0030] The power supply end includes at least 2 (1 pair) low-voltage wire harnesses, namely: +—positive power supply, -—negative power supply. The power supply end can output a variable power supply voltage, such as 3.0-25.6V, according to the host parameter settings.

[0031] The resolver docking terminal 300 includes at least 6 low-voltage wiring harnesses, which are respectively a resolver positive pole excitation wiring harness connected to the positive pole of the resolver excitation winding, a resolver negative pole excitation wiring harness connected to the negative pole of the resolver excitation winding, a wiring harness connected to the positive pole of the resolver output sine signal, a wiring harness connected to the negative pole of the resolver output sine signal, a wiring harness connected to the positive pole of the resolver output cosine signal, and a wiring harness connected to the negative pole of the resolver output cosine signal, namely a—excitation+, b—excitation-, c—sine+, d—sine-, e—cosine+, and f—cosine-.

[0032] The second excitation resistance is measured between the resolver positive pole excitation wiring harness connected to the positive pole of the resolver excitation winding and the resolver negative pole excitation wiring harness connected to the negative pole of the resolver excitation winding, the second sinusoidal resistance is measured between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the negative pole of the resolver output sine signal, and the second cosine resistance is measured between the wiring harness connected to the positive pole of the resolver output cosine signal and the wiring harness connected to the negative pole of the resolver output cosine signal.

[0033] The MCU / wiring harness docking terminal 200 and the resolver docking terminal 300 are composed of an end face, a conductor core, a humidity sensor and a visual sensor. The conductor core and the humidity sensor are integrated in a two-in-one manner and arranged perpendicular to the end face. The visual sensor is arranged on the end face.

[0034] The motor resolver troubleshooting equipment includes a jumper harness. In the case of some special terminals (male and female ends cannot match), jumpers can be used to connect so that the equipment can work normally.

[0035] The functions of each module of the motor resolver fault troubleshooting equipment are as follows:

[0036] The MCU / wiring harness docking terminal 200 is used to physically connect with the MCU low voltage terminal or the corresponding conductor core of the wiring harness terminal connected to the MCU low voltage, to detect whether there is a fault in the MCU (motor controller) or the wiring harness connected thereto.

[0037] The resolver docking terminal 300 is used to physically connect with the corresponding conductor core of the resolver terminal and detect whether the resolver has a fault.

[0038] The power supply end is used to physically connect with the MCU low voltage terminal or the corresponding conductor core of the wiring harness terminal connected to the MCU low voltage, to provide low voltage power supply for the MCU to wake up the MCU to send an excitation signal.

[0039] The functions of the host power board include: converting the AC power into the power required by the battery to charge the battery; converting the electric energy of the battery or the AC power into the power required by the host to power the host; converting the electric energy of the battery or the AC power into the power required by the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300 visual sensor and temperature sensor to enable the sensors to work normally; according to the set parameters of the host control board, converting the electric energy of the battery or the AC power into the voltage required by the power supply terminal to power the power supply terminal.

[0040] The functions of the display screen include: communicating with the control board and displaying the data sent by the control board; inputting user commands and sending the user commands to the control board for execution.

[0041] The functions of the control board include: communicating with the display screen, displaying data through the display screen, and receiving and executing command data transmitted from the display screen; communicating with the power board to control the working mode and status of the power board. The working modes of the power board are divided into two categories: ① external power supply mode; ② external power off mode

[0042] The control board and power board also work together to achieve the following functions:

[0043] Visual signals of the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300 are collected, and it is determined whether the connectors plugged into the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300 have the following faults: ① the conductor core is bent or broken; ② the connector hole is enlarged; ③ there is foreign matter.

[0044] The power module 100 is used to perform insulation voltage injection and insulation resistance collection on the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal and the corresponding conductor core of the resolver terminal, so as to determine whether there is an insulation fault in the connector plugged into the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300.

[0045] The power module 100 is also used to obtain the first excitation resistance, the first sine resistance, and the first cosine resistance of the MCU / wiring harness docking terminal 200, and to obtain the second excitation resistance, the second sine resistance, and the second cosine resistance of the resolver docking terminal 300, to determine whether there is an abnormal resolver resistance fault.

[0046] The power module 100 is also used to collect humidity signals of the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300, and determine whether there is a terminal water ingress fault in the connector plugged into the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300.

[0047] The power module 100 is also used to collect the voltage signal of the MCU / wiring harness docking terminal 200 when the MCU is powered and the MCU / wiring harness docking terminal 200 and the MCU or the wiring harness connector directly connected to the MCU are plugged in, so as to determine whether there is a wire break fault in the excitation of the MCU or the wiring harness directly connected to the MCU.

[0048] Embodiment 2, the second embodiment of the present invention, is different from the previous embodiment in that it provides a method for troubleshooting motor resolver faults, comprising: after injecting an insulation voltage into the conductor core corresponding to the resolver terminal, detecting the insulation resistance of the conductor core corresponding to the resolver terminal, comparing the insulation resistance with a preset insulation fault threshold, and determining whether there is an abnormal insulation fault; if there is no abnormal insulation fault, collecting the first excitation resistance, the first sine resistance, the first cosine resistance, the second excitation resistance, the second sine resistance and the second cosine resistance to determine whether there is an abnormal resolver resistance fault.

[0049] Detect the insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding, the wiring harness connected to the positive pole of the resolver output sine signal, and the wiring harness connected to the positive pole of the resolver output cosine signal. The resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output sine signal is R sti-sin The insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output cosine signal is R sti-cos The resistance between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the positive pole of the resolver output cosine signal is R sin-cos .

[0050] If R sti-sin >R f , or R sti-cos >R f , or R sin-cos >R f , it is determined that there is an abnormal insulation resistance fault, where R f is the preset insulation fault threshold.

[0051] At this time, it indicates that there is an abnormality in the resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output sine signal, or the insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output cosine signal, or the resistance between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the positive pole of the resolver output cosine signal, resulting in a fault in the resolver in the motor system.

[0052] The abnormal failure of resolver resistance includes the manual setting parameter mode.

[0053] The user inputs the maximum threshold value R1 of the excitation resistance, the minimum threshold value R2 of the excitation resistance, the maximum threshold value R3 of the sine resistance, the minimum threshold value R4 of the sine resistance, the maximum threshold value R5 of the cosine resistance, and the minimum threshold value R6 of the cosine resistance.

[0054] If R sti <R1, or R sti >R2, it is determined that the motor's rotating transformer has an abnormal excitation resistance fault.

[0055] If R sin <R3, or R sin >R4, it is determined that the motor's resolver has an abnormal sinusoidal resistance fault.

[0056] If R cos <R5, or R cos >R6, it is determined that the motor's resolver has an abnormal cosine resistance fault.

[0057] Among them, R sti R is the resistance between the resolver positive excitation wire connected to the positive pole of the resolver excitation winding and the resolver negative excitation wire connected to the negative pole of the resolver excitation winding. sin R is the resistance between the wiring harness connected to the positive pole of the resolver output sinusoidal signal and the wiring harness connected to the negative pole of the resolver output sinusoidal signal. cos It is the resistance value between the wiring harness connected to the positive electrode of the rotary transformer output cosine signal and the wiring harness connected to the negative electrode of the rotary transformer output cosine signal.

[0058] At this time, it indicates that there is an abnormality in the resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the resolver negative excitation wiring harness connected to the negative pole of the resolver excitation winding, or the resistance between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the negative pole of the resolver output sine signal, or the resistance between the wiring harness connected to the positive pole of the resolver output cosine signal and the wiring harness connected to the negative pole of the resolver output cosine signal, resulting in a fault in the resolver in the motor system.

[0059] Determine whether there is an abnormal resolver resistance fault including an automatic determination mode;

[0060] When R7≤(R sti +R sin +R cos )≤R8, and k1≤R sin / R cos ≤k2 and k3≤(Rsin +R cos ) / 2R sti ≤k4, it is determined that the resolver transformer does not have an abnormal resolver resistance fault; otherwise, it is determined that the resolver transformer has an abnormal resolver resistance fault.

[0061] Among them, R7, R8, k1, k2, k3, and k4 are all preset values. sti R is the resistance between the resolver positive excitation wire connected to the positive pole of the resolver excitation winding and the resolver negative excitation wire connected to the negative pole of the resolver excitation winding. sin R is the resistance between the wiring harness connected to the positive pole of the resolver output sinusoidal signal and the wiring harness connected to the negative pole of the resolver output sinusoidal signal. cos It is the resistance value between the wiring harness connected to the positive electrode of the rotary transformer output cosine signal and the wiring harness connected to the negative electrode of the rotary transformer output cosine signal.

[0062] At this time, it indicates that there is an abnormality in the resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the resolver negative excitation wiring harness connected to the negative pole of the resolver excitation winding, or the resistance between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the negative pole of the resolver output sine signal, or the resistance between the wiring harness connected to the positive pole of the resolver output cosine signal and the wiring harness connected to the negative pole of the resolver output cosine signal, resulting in a fault in the resolver in the motor system.

[0063] Embodiment 3, the third embodiment of the present invention, provides a motor resolver fault troubleshooting method, the motor resolver fault troubleshooting method also includes: connecting the motor resolver fault troubleshooting device with the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal, collecting the first excitation voltage, the first sine voltage, and the first cosine voltage signal, and judging whether there is a wire break fault based on the comparison result of the voltage signal with the preset threshold.

[0064] Collect voltage signals of three pairs of cores, including the excitation voltage between the positive excitation wire harness connected to the positive pole of the MCU excitation winding and the negative excitation wire harness connected to the negative pole of the MCU excitation winding. The first excitation voltage U sti , a first sinusoidal voltage U between the positive wiring harness of the sinusoidal signal connected to the MCU signal processing circuit and the negative wiring harness of the sinusoidal signal connected to the MCU signal processing circuit sin The first cosine voltage signal U is a cosine voltage signal between the positive wiring harness of the cosine signal connected to the MCU signal processing circuit and the negative wiring harness of the cosine signal connected to the MCU signal processing circuit. cos .

[0065] If U stiIf it is less than U1, it is determined that there is an excitation line break fault in the transmission line between the positive excitation harness connected to the positive pole of the MCU excitation winding and the negative excitation harness connected to the negative pole of the MCU excitation winding.

[0066] If U sin If it is greater than U2, it is determined that there is a sinusoidal disconnection fault in the transmission line between the positive wiring harness of the sinusoidal signal connected to the MCU signal processing circuit and the negative wiring harness of the sinusoidal signal connected to the MCU signal processing circuit.

[0067] If U cos If it is greater than U3, it is determined that there is a cosine wire break fault in the transmission line between the cosine signal positive wiring harness connected to the MCU signal processing circuit and the cosine signal negative wiring harness connected to the MCU signal processing circuit.

[0068] Among them, U1, U2, and U3 are respectively a preset first voltage threshold, a second voltage threshold, and a third voltage threshold.

[0069] At this time, it indicates that there is an abnormality in the excitation voltage between the positive excitation wiring harness connected to the positive pole of the MCU excitation winding and the negative excitation wiring harness connected to the negative pole of the MCU excitation winding, or the sinusoidal voltage between the sinusoidal signal positive wiring harness connected to the MCU signal processing circuit and the sinusoidal signal negative wiring harness connected to the MCU signal processing circuit, or the cosine voltage between the cosine signal positive wiring harness connected to the MCU signal processing circuit and the cosine signal negative wiring harness connected to the MCU signal processing circuit, resulting in a fault in the rotating transformer in the motor system.

[0070] Embodiment 4, the fourth embodiment of the present invention, provides a motor resolver fault troubleshooting method, the motor resolver fault troubleshooting method also includes: collecting humidity signals of the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300, and determining whether there is a terminal water ingress fault in the connector plugged into the MCU / wiring harness docking terminal 200 and the resolver docking terminal 300.

[0071] The humidity signal at the MCU docking end is H con , the humidity signal at the resolver docking end is H res ;

[0072] If H con >H air +δ, or H res >H air +δ, it is determined that there is a terminal water ingress fault in the transmission line between the connector plugged into the MCU / wiring harness docking end (200) and the resolver docking end (300);

[0073] Among them, H air is the ambient humidity, and δ is the preset humidity increment threshold.

[0074] At this time, it indicates that the humidity at the MCU docking end or the humidity at the resolver docking end is abnormal, resulting in a fault in the resolver in the motor system.

[0075] Embodiment 5, the fifth embodiment of the present invention, provides a motor resolver fault troubleshooting method, including: constructing a motor resolver fault troubleshooting device; connecting the motor resolver fault troubleshooting device to the MCU, collecting excitation, sine, and cosine voltage signals, and judging whether there is a line break fault based on the comparison result between the voltage signal and a preset threshold value; switching the power board to a power-off mode, collecting visual signals to detect terminal abnormalities, and collecting humidity signals to detect water ingress faults; connecting the resolver terminals, performing insulation voltage injection and resistance detection, judging insulation abnormality faults, and if the insulation is normal, collecting the resistance of the MCU / wiring harness connection terminal.

[0076] The types of resolver failures are divided into three categories: resolver body failure; MCU failure; transmission line failure. Transmission line failure is further divided into terminal failure and signal line failure.

[0077] S1. Construct a motor resolver fault troubleshooting device.

[0078] Select the power board working mode as external power supply mode through the display screen.

[0079] The power supply end of the motor resolver fault troubleshooting equipment is connected to the MCU low-voltage power supply core to provide low-voltage power to the MCU.

[0080] S2. Connect the motor resolver fault detection device to the MCU, collect excitation, sine, and cosine voltage signals, and determine whether there is a disconnection fault based on the comparison result between the voltage signal and the preset threshold.

[0081] The six cores at the MCU / wiring harness docking end of the motor resolver fault troubleshooting equipment are docked with the cores corresponding to the connector of the MCU (or the wiring harness directly connected to the MCU), which can be done by directly plugging the connector or by jumper wires.

[0082] The main engine of the motor resolver fault troubleshooting equipment divides the 6 cores at the MCU / harness docking end into pairs according to excitation, sine, and cosine, and collects the voltage signals of the three pairs of cores respectively, which are recorded as: U sti (excitation), U sin (sine) and U cos (cosine).

[0083] If U sti <U1, the display screen will report "Transmission line - excitation disconnection fault".

[0084] If U sin >U2, the display screen will report “Transmission line - sinusoidal disconnection fault”.

[0085] If U cos>U3, the display screen will report "Transmission line - cosine line break fault".

[0086] Among them, U1, U2, and U3 are the first voltage threshold, the second voltage threshold, and the third voltage threshold set by the host, respectively, and can be customized by the user through the display screen.

[0087] S3, switch the power board to power-off mode, collect visual signals to detect terminal abnormalities, and collect humidity signals to detect water ingress faults.

[0088] Switch the power board working mode to external power-off mode through the display screen.

[0089] The main unit of the motor resolver fault troubleshooting equipment collects visual signals from the MCU / harness docking terminal and the resolver docking terminal, and compares them with the visual signal parameters set inside the main unit. If the following faults are found: ① The conductor core is bent or broken; ② The connector is enlarged; ③ There is a foreign object, then the display screen will report "Transmission line-terminal abnormal fault".

[0090] The main unit of the motor resolver fault troubleshooting equipment collects humidity signals from the MCU / wiring harness docking end and the resolver docking end. The humidity signal from the MCU / wiring harness docking end is H con , the humidity signal at the resolver docking end is H res .

[0091] If H con >H air +δ, or H res >H air +δ, the display screen will report "transmission line - terminal water ingress fault".

[0092] Among them, H air is the ambient humidity, and δ is the humidity increment threshold set by the host.

[0093] S4. Connect the resolver terminals, perform insulation voltage injection and resistance detection, and determine if there is an insulation abnormality. If the insulation is normal, collect the resistance of the MCU / wiring harness connection terminal.

[0094] The 6 cores at the resolver docking end of the motor resolver fault troubleshooting equipment are docked with the cores corresponding to the resolver terminals, which can be done by directly plugging the connector or by jumper wires.

[0095] Insulation voltage is injected into the resolver terminal conductor core one by one and the insulation resistance between excitation, sine+ and cosine+ is detected, which is recorded as R sti-sin , R sti-cos , R sin-cos .

[0096] If R sti-sin ||R sti-cos ||R sin-cos>R f , the display screen will report "Resolver body - insulation abnormality fault".

[0097] Among them, || is the OR operation, R f The insulation fault threshold set for the system is user-definable via the display.

[0098] If the "Resolver Body - Abnormal Insulation Fault" is not found, the 6 cores at the MCU / harness docking end are divided into pairs according to excitation, sine, and cosine, and the resistance values ​​of the three pairs of cores are collected respectively, recorded as: R sti (Excitation), R sin (sine) and R cos (cosine).

[0099] The device can determine resolver faults in two ways, and users can select resolver fault mode through the display:

[0100] Manual parameter setting mode. This mode is suitable for fault diagnosis personnel who know the resolver parameters of the motor system, such as engineers who develop the part, after-sales personnel of the OEM of the part, etc. In this mode, fault diagnosis personnel can manually set the maximum threshold of excitation resistance R1, the minimum threshold of excitation resistance R2, the maximum threshold of sine resistance R3, the minimum threshold of sine resistance R4, the maximum threshold of cosine resistance R5, and the minimum threshold of cosine resistance R6 through the host. The resolver fault judgment rules are:

[0101] ①If (R sti <R1)||(R sti >R2), the display screen will report “Resolver body - abnormal excitation resistance fault”.

[0102] ②If (R sin <R3)||(R sin >R4), the display screen will report “Resolver body - abnormal sinusoidal resistance fault”.

[0103] ③If (R cos <R5)||(R cos >R6), the display screen will report “Resolver body - cosine resistance abnormal fault”.

[0104] Automatic judgment mode. This mode is suitable for fault diagnosis personnel who do not know the resolver parameters of this motor system, such as auto repair personnel in ordinary auto repair shops (not 4S shops). In this mode, fault diagnosis personnel can use the program provided by the host to judge the resolver fault without manually entering the resolver parameters. The judgment rules in this mode are:

[0105] If {R7≤(R sti +R sin +R cos)≤R8}&&(k1≤R sin / R cos ≤k2)&&{(k3≤(R sin +R cos ) / 2R sti ≤k4)} is true, the resolver is normal, otherwise it is a resolver fault.

[0106] Among them, && is an AND operation, the range of R7 is 10-30Ω, the range of R8 is 150-300Ω, the range of k1 is 0.5-1, the range of k2 is 1-2, the range of k3 is 0.1-0.5, and the range of k4 is 5-10.

[0107] If no fault is detected through the above steps, the display screen reports "No fault with the resolver body and connecting harness was found, please focus on troubleshooting the MCU body fault."

[0108] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A motor resolver fault troubleshooting device, characterized in that: include, A power module (100), an MCU / wiring harness docking terminal (200) and a resolver docking terminal (300); The power module (100) is electrically connected to the MCU / wiring harness docking end (200), and is electrically connected to the resolver docking end (300); The MCU / wiring harness docking terminal (200) is used to physically connect with the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal; The resolver docking end (300) is used to physically connect with the corresponding conductor core of the resolver terminal; The power module (100) is used to perform insulation voltage injection and insulation resistance value collection on the conductor core corresponding to the wiring harness terminal connected to the MCU low-voltage terminal and the conductor core corresponding to the resolver terminal, and to determine whether there is an insulation fault in the connector plugged into the MCU / wiring harness docking terminal (200) and the resolver docking terminal (300); The power module (100) is also used to obtain a first excitation resistance value, a first sine resistance value, and a first cosine resistance value of an MCU / wiring harness docking terminal (200), obtain a second excitation resistance value, a second sine resistance value, and a second cosine resistance value of a resolver docking terminal (300), and determine whether there is an abnormal resolver resistance fault.

2. A motor resolver fault troubleshooting device as claimed in claim 1, characterized in that: The MCU / wiring harness docking terminal (200) comprises at least 6 low-voltage wiring harnesses, which are respectively a positive excitation wiring harness connected to the positive pole of the MCU excitation winding, a negative excitation wiring harness connected to the negative pole of the MCU excitation winding, a positive sine signal wiring harness connected to the MCU signal processing circuit, a negative sine signal wiring harness connected to the MCU signal processing circuit, a positive cosine signal wiring harness connected to the MCU signal processing circuit, and a negative cosine signal wiring harness connected to the MCU signal processing circuit; A first excitation resistance is measured between a positive excitation wiring harness connected to the positive pole of an MCU excitation winding and a negative excitation wiring harness connected to the negative pole of the MCU excitation winding, a first sinusoidal resistance is measured between a positive sinusoidal signal wiring harness connected to an MCU signal processing circuit and a negative sinusoidal signal wiring harness connected to the MCU signal processing circuit, and a first cosine resistance is measured between a positive cosine signal wiring harness connected to the MCU signal processing circuit and a negative cosine signal wiring harness connected to the MCU signal processing circuit; The resolver docking end (300) comprises at least 6 low-voltage wire harnesses, which are respectively a resolver positive pole excitation wire harness connected to the positive pole of the resolver excitation winding, a resolver negative pole excitation wire harness connected to the negative pole of the resolver excitation winding, a wire harness connected to the positive pole of the resolver output sine signal, a wire harness connected to the negative pole of the resolver output sine signal, a wire harness connected to the positive pole of the resolver output cosine signal, and a wire harness connected to the negative pole of the resolver output cosine signal; The second excitation resistance is measured between the resolver positive pole excitation wiring harness connected to the positive pole of the resolver excitation winding and the resolver negative pole excitation wiring harness connected to the negative pole of the resolver excitation winding, the second sinusoidal resistance is measured between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the negative pole of the resolver output sine signal, and the second cosine resistance is measured between the wiring harness connected to the positive pole of the resolver output cosine signal and the wiring harness connected to the negative pole of the resolver output cosine signal.

3. A motor resolver fault troubleshooting device as claimed in claim 2, characterized in that: The power module (100) is also used to collect visual signals from the MCU / wiring harness docking end (200) and the resolver docking end (300), and to determine whether a connector plugged into the MCU / wiring harness docking end (200) and the resolver docking end (300) has a fault, wherein the fault includes bending or breaking of the conductor core, expansion of the connector hole, and the presence of foreign matter; The power module (100) is also used to collect humidity signals of the MCU / wiring harness docking end (200) and the resolver docking end (300), and to determine whether a connector plugged into the MCU / wiring harness docking end (200) and the resolver docking end (300) has a terminal water ingress fault; The power module (100) is also used to collect a voltage signal of the MCU / wiring harness docking terminal (200) when the MCU is powered and the MCU / wiring harness docking terminal (200) and the MCU or a wiring harness connector directly connected to the MCU are plugged in, so as to determine whether there is a disconnection fault in the excitation of the MCU or the wiring harness directly connected to the MCU.

4. A motor resolver fault troubleshooting method, applied to the motor resolver fault troubleshooting device as claimed in any one of claims 1 to 3, characterized in that: include, After injecting an insulation voltage into the conductor core corresponding to the resolver terminal, detecting the insulation resistance of the conductor core corresponding to the resolver terminal, comparing the insulation resistance with a preset insulation fault threshold, and determining whether there is an insulation abnormality fault; If there is no abnormal insulation fault, the first excitation resistance, the first sine resistance, the first cosine resistance, the second excitation resistance, the second sine resistance and the second cosine resistance are collected to determine whether there is an abnormal resolver resistance fault.

5. A method for troubleshooting a motor resolver fault as claimed in claim 4, characterized in that: After injecting the insulation voltage into the conductor core corresponding to the resolver terminal, detecting the insulation resistance of the conductor core corresponding to the resolver terminal, comparing the insulation resistance with a preset insulation fault threshold, and determining whether there is an insulation abnormality fault includes: Detect the insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding, the wiring harness connected to the positive pole of the resolver output sine signal, and the wiring harness connected to the positive pole of the resolver output cosine signal. The resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output sine signal is R sti-sin The insulation resistance between the resolver positive excitation wiring harness connected to the positive pole of the resolver excitation winding and the wiring harness connected to the positive pole of the resolver output cosine signal is R sti-cos The resistance between the wiring harness connected to the positive pole of the resolver output sine signal and the wiring harness connected to the positive pole of the resolver output cosine signal is R sin-cos ; If R sti-sin >R f , or R sti-cos >R f , or R sin-cos >R f , it is determined that there is an abnormal insulation resistance fault, where R f is the preset insulation fault threshold.

6. A method for troubleshooting a motor resolver fault as claimed in claim 4, characterized in that: The determining whether there is an abnormal resolver resistance fault includes manually setting a parameter mode; The manual parameter setting mode includes the user inputting the maximum threshold value R1 of the excitation resistance, the minimum threshold value R2 of the excitation resistance, the maximum threshold value R3 of the sine resistance, the minimum threshold value R4 of the sine resistance, the maximum threshold value R5 of the cosine resistance, and the minimum threshold value R6 of the cosine resistance; If R sti <R1, or R sti >R2, it is determined that the rotary transformer of the motor has an abnormal excitation resistance fault; If R sin <R3, or R sin >R4, it is determined that the rotary transformer of the motor has an abnormal sinusoidal resistance fault; If R cos <R5, or R cos >R6, it is determined that the rotary transformer of the motor has an abnormal cosine resistance fault; Among them, R sti R is the resistance between the resolver positive excitation wire connected to the positive pole of the resolver excitation winding and the resolver negative excitation wire connected to the negative pole of the resolver excitation winding. sin R is the resistance between the wiring harness connected to the positive pole of the resolver output sinusoidal signal and the wiring harness connected to the negative pole of the resolver output sinusoidal signal. cos It is the resistance value between the wiring harness connected to the positive electrode of the rotary transformer output cosine signal and the wiring harness connected to the negative electrode of the rotary transformer output cosine signal.

7. A method for troubleshooting a motor resolver fault as claimed in claim 4, characterized in that: The determination of whether there is an abnormal resolver resistance fault includes an automatic determination mode; When R7≤(R sti +R sin +R cos )≤R8, and k1≤R sin / R cos ≤k2 and k3≤(R sin +R cos ) / 2R sti ≤k4, it is determined that the resolver transformer does not have an abnormal resolver resistance fault; otherwise, it is determined that the resolver transformer has an abnormal resolver resistance fault; Among them, R7, R8, k1, k2, k3, and k4 are all preset values. sti R is the resistance between the resolver positive excitation wire connected to the positive pole of the resolver excitation winding and the resolver negative excitation wire connected to the negative pole of the resolver excitation winding. sin R is the resistance between the wiring harness connected to the positive pole of the resolver output sinusoidal signal and the wiring harness connected to the negative pole of the resolver output sinusoidal signal. cos It is the resistance value between the wiring harness connected to the positive electrode of the rotary transformer output cosine signal and the wiring harness connected to the negative electrode of the rotary transformer output cosine signal.

8. A method for troubleshooting a motor resolver fault as claimed in claim 4, characterized in that: The motor resolver fault troubleshooting method further includes: The motor resolver fault troubleshooting device is connected to the corresponding conductor core of the wiring harness terminal connected to the MCU low-voltage terminal, and the first excitation voltage, the first sine voltage, and the first cosine voltage signals are collected. Based on the comparison result between the voltage signal and the preset threshold, it is determined whether there is a wire break fault.

9. A method for troubleshooting a motor resolver fault as claimed in claim 8, characterized in that: The determination of whether there is a disconnection fault includes collecting voltage signals of three pairs of cores, including an excitation voltage U between a positive excitation wire harness connected to the positive pole of the MCU excitation winding and a negative excitation wire harness connected to the negative pole of the MCU excitation winding. sti , a first sinusoidal voltage U between the positive wiring harness of the sinusoidal signal connected to the MCU signal processing circuit and the negative wiring harness of the sinusoidal signal connected to the MCU signal processing circuit sin The first cosine voltage signal U is a cosine voltage signal between the positive wiring harness of the cosine signal connected to the MCU signal processing circuit and the negative wiring harness of the cosine signal connected to the MCU signal processing circuit. cos ; If U sti If it is less than U1, it is determined that there is an excitation disconnection fault in the transmission line between the positive excitation harness connected to the positive pole of the MCU excitation winding and the negative excitation harness connected to the negative pole of the MCU excitation winding; If U sin If it is greater than U2, it is determined that there is a sinusoidal disconnection fault in the transmission line between the positive wiring harness of the sinusoidal signal connected to the MCU signal processing circuit and the negative wiring harness of the sinusoidal signal connected to the MCU signal processing circuit; If U cos If it is greater than U3, it is determined that there is a cosine disconnection fault in the transmission line between the cosine signal positive wiring harness connected to the MCU signal processing circuit and the cosine signal negative wiring harness connected to the MCU signal processing circuit; Among them, U1, U2, and U3 are respectively a preset first voltage threshold, a second voltage threshold, and a third voltage threshold.

10. A method for troubleshooting a motor resolver fault according to claim 4, characterized in that: The motor resolver fault troubleshooting method further includes: The humidity signals of the MCU / wiring harness docking end (200) and the resolver docking end (300) are collected, and it is determined whether a connector plugged into the MCU / wiring harness docking end (200) and the resolver docking end (300) has a terminal water ingress fault.

11. A method for troubleshooting water ingress to a motor resolver terminal according to claim 10, characterized in that: The method of judging whether a connector plugged into an MCU / wiring harness docking terminal (200) and a resolver docking terminal (300) has a terminal water ingress fault comprises: The humidity signal at the MCU / harness docking end is H con , the humidity signal at the resolver docking end is H res ; If H con >H air +δ, or H res >H air +δ, it is determined that there is a terminal water ingress fault in the transmission line between the connector plugged into the MCU / wiring harness docking end (200) and the resolver docking end (300); Among them, H air is the ambient humidity, and δ is the preset humidity increment threshold.

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