Off-line test method for all-in-one oil-cooled electric drive assembly

Abstract

The invention relates to an off-line test method for an all-in-one oil-cooling electric drive assembly, the all-in-one oil-cooling electric drive assembly comprises a controller, a power supply, an oil pump, a drive motor and a speed reducer, and the off-line test method comprises the following steps: installing the all-in-one oil-cooling electric drive assembly on a rack according to a preset installation process; the upper computer performs testing according to a preset testing sequence; the control rack is used for carrying out AC interlocking test, communication test, CP wake-up test, IPU software and hardware version verification, PDU software and hardware version verification, motor general parameter acquisition, all-in-one electric drive assembly software writing, oil pump control function test, motor resolver self-learning and motor resolver self-learning state confirmation on the all-in-one oil cooling electric drive assembly; motor three-phase current fluctuation detection, high-voltage power-on, NVH and external characteristic test and shutdown process test are carried out; when all the tests are qualified, the upper computer determines that the all-in-one oil cooling electric drive assembly is qualified.

Description

Technical Field

[0001] The present invention relates to the technical field of testing for an integrated oil-cooled electric drive assembly, and particularly relates to a testing method for an integrated oil-cooled electric drive assembly. Background Art

[0002] With the development of society, low-carbon transportation means are increasingly favored by people. Electric vehicles are a type of low-carbon transportation means that are currently under key research and have broad development prospects. Among them, the electric drive system, as a very important component in the research and development of electric vehicles, is an important part of the vehicle system. Its basic performance and control effect directly affect the performance indicators of the vehicle. With the development of new energy vehicles, the integrated oil-cooled electric drive assembly has been widely used in new energy vehicles due to its advantages such as compact structure, high software and hardware integration, etc. The integrated oil-cooled electric drive assembly, as an important part of the power system of new energy vehicles, is composed of a controller, a power supply, an oil pump, a drive motor, a reducer, etc. At present, domestic new energy vehicle companies generally adopt the method of separately testing the motor and the reducer offline in the field of producing three-in-one electric drive assemblies. That is, for the motor assembly line, a counter-rotating test bench is used to test the electrical parameters and mechanical properties of the motor, and for the reducer assembly line, a three-dynamometer test bench is used to test the reduction ratio and NVH performance. However, due to the inconsistent testing methods for the two products, such a production method also has obvious problems: 1. The investment is large. Separate test benches need to be built for the drive motor and the reducer. These test benches have single test content and poor compatibility, greatly increasing the production cost; 2. The testing of the electric drive assembly, due to including motor testing, is significantly longer than the testing rhythm of the reducer. This results in the mismatch between the testing rhythm of the test bench for the electric drive assembly and the testing of the single reducer and single motor, causing serious waste of production capacity.

[0003] The offline detection of the integrated oil-cooled electric drive assembly is an effective method for controlling these problems. It can conduct targeted and effective offline detection of products. Having a reliable and reasonable offline detection method to monitor the product quality will also enhance the market competitiveness of the enterprise's products and the comprehensive strength of the enterprise. In the existing technology, there is no offline detection for the pure electric integrated power assembly, so it is impossible to ensure that there will be no control failure problems when installed in the vehicle. Summary of the Invention

[0004] The purpose of the present invention is to provide an offline testing method for an integrated oil-cooled electric drive assembly, which has comprehensive testing functions, high automation, strong compatibility, high reliability, and low testing cost.

[0005] To achieve the above purpose, the present invention adopts the following technical solutions: An offline testing method for an integrated oil-cooled electric drive assembly, the integrated oil-cooled electric drive assembly includes a controller, a power supply, an oil pump, a drive motor, and a reducer. The offline testing method includes: Install the integrated oil-cooled electric drive assembly on the test bench according to the preset installation procedure; The host computer, according to the predetermined test sequence, controls the test bench to conduct AC interlock test, communication test, CP wake-up test, IPU software and hardware version verification, PDU software and hardware version verification, motor general parameter acquisition, integrated electric drive assembly software flashing, oil pump control function test, motor resolver self-learning, motor resolver self-learning status confirmation, motor three-phase current fluctuation detection, high-voltage power-on, NVH and external characteristic tests, and shutdown process test on the integrated oil-cooled electric drive assembly; When all the above tests are qualified, the host computer determines that the integrated oil-cooled electric drive assembly is qualified.

[0006] Preferably, before the step of installing the integrated oil-cooled electric drive assembly on the test bench according to the preset installation procedure, the offline test method further includes: Conduct insulation performance test, low-voltage port connection test, and high-voltage port connection test on the integrated oil-cooled electric drive assembly; When all the above tests pass, then execute the step of installing the integrated oil-cooled electric drive assembly on the test bench according to the preset installation procedure.

[0007] Preferably, the step of installing the integrated oil-cooled electric drive assembly on the test bench according to the preset installation procedure includes: Remove the motor terminal box cover; Install the integrated oil-cooled electric drive assembly with the motor terminal box cover removed on the test bench; Add test oil to the reducer sub-assembly of the integrated oil-cooled electric drive assembly; Connect the cooling pipeline of the test bench to the integrated oil-cooled electric drive assembly, and inject coolant into the cooling pipeline.

[0008] Preferably, the step of controlling the test bench to conduct communication test on the integrated oil-cooled electric drive assembly includes: The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; the data field in the working mode request signal includes: the working mode request for the rear motor is initialization, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; The host computer sends a battery instant heating gear request signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; the data field in the battery instant heating gear request signal includes: the maximum charging voltage of the battery is the first preset voltage, and the rest of the fields are all sent as zero; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; The host computer sends an electric drive speed signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; The host computer sends a battery instant heating gear request signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; The host computer sends an electric drive coolant inlet temperature signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; The host computer sends an electric drive assembly locked-rotor heating request signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; The host computer sends a local time signal to the integrated oil-cooled electric drive assembly multiple times through CAN messages in a loop; The console rack connects a 12V low voltage to the integrated oil-cooled electric drive assembly; The host computer reads the fault status of the integrated oil-cooled electric drive assembly; If the fault status of the integrated oil-cooled electric drive assembly indicates no fault, it is determined that the communication test of the integrated oil-cooled electric drive assembly is qualified.

[0009] Preferably, the steps for the console rack to perform a CP wake-up test on the integrated oil-cooled electric drive assembly include: After the host computer reads the specific frame message sent by the integrated oil-cooled electric drive assembly, it checks whether there are electric drive wake-up messages and power supply wake-up messages sent on the CAN bus; If the host computer receives the specific frame message and there are electric drive wake-up messages and power supply wake-up messages sent on the CAN bus, it is determined that the CP wake-up test on the integrated oil-cooled electric drive assembly is qualified.

[0010] Preferably, the steps for the console rack to perform IPU software and hardware version verification on the integrated oil-cooled electric drive assembly include: The host computer reads the IPU software and hardware version message sent by the integrated oil-cooled electric drive assembly and parses out the IPU software version number and the IPU hardware version number; If the parsed IPU software version number and IPU hardware version number are respectively consistent with their corresponding preset versions, it is determined that the IPU software and hardware version verification of the integrated oil-cooled electric drive assembly is qualified; The steps for the console rack to perform PDU software and hardware version verification on the integrated oil-cooled electric drive assembly include: The host computer reads the PDU software and hardware version message sent by the integrated oil-cooled electric drive assembly and parses out the PDU software version number and the PDU hardware version number; If the parsed PDU software version number and PDU hardware version number are respectively consistent with their corresponding preset versions, it is determined that the PDU software and hardware version verification of the integrated oil-cooled electric drive assembly is qualified.

[0011] Preferably, the steps for the console rack to perform an oil pump control function test on the integrated oil-cooled electric drive assembly include: The console rack connects a 12V low voltage to the low-voltage pins of the integrated oil-cooled electric drive assembly; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly; the data in the working mode request signal includes: the working mode request for the rear motor is high-voltage standby, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; The host computer sets the bus voltage of the rear motor to the preset voltage and starts the DC power supply; The host computer waits for feedback that the bus voltage of the rear motor is within the preset voltage range; The host computer reads the fault level flag of the rear motor; If the fault level flag of the rear motor indicates no fault, the host computer reads the target speed actually executed by the oil pump, the actual speed feedback by the oil pump, and the oil pump fault code; If the target speed actually executed by the oil pump reaches the preset speed range, the actual speed feedback by the oil pump reaches the first preset speed, and the oil pump fault code indicates no fault, it is confirmed that the oil pump control function test is qualified.

[0012] Preferably, the steps for the console rack to perform motor resolver self-learning on the integrated oil-cooled electric drive assembly include: The console rack disconnects the ignition circuit of the integrated oil-cooled electric drive assembly; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly; the data in the working mode request signal includes: the working mode request for the rear motor is initialization, the maximum allowable torque of the rear motor is the first preset torque, the minimum allowable torque of the rear motor is the second preset torque, the torque compensation enable of the rear motor is disabled, and the maximum torque gradient of the rear motor is the preset gradient; The console rack connects the ignition circuit of the integrated oil-cooled electric drive assembly; The host computer sends a working mode request for the rear motor to the torque control mode to the integrated oil-cooled electric drive assembly. The rear motor speed request first sends the first speed, then sends the second speed greater than the first speed, and finally sends zero; Read the resolver self-learning status of the rear motor; If the resolver self-learning status of the rear motor is successful, the console rack disconnects the ignition circuit of the integrated oil-cooled electric drive assembly; The console rack connects the ignition circuit of the integrated oil-cooled electric drive assembly and reads the resolver self-learning status of the rear motor; If the resolver self-learning status of the rear motor is successful, read the long-term maximum torque of the rear motor; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly; the data in the working mode request signal includes: the working mode request for the rear motor is initialization, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; The host computer sets the bus voltage of the rear motor to the preset voltage and starts the DC power supply; After the host computer waits for feedback, the motor bus voltage is within the preset voltage range; The host computer reads the motor fault level flag and the motor fault code; If both the motor fault level flag and the motor fault code indicate no fault, read the stator temperature of the rear motor; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is torque control, the maximum allowable torque of the rear motor is the first preset torque, the minimum allowable torque of the rear motor is the second preset torque, the torque compensation enable of the rear motor is disabled, and the preset gradient of the maximum torque gradient of the rear motor; The host computer sets the dynamometer speed; Read the long-term maximum torque of the rear motor; If the long-term maximum torque of the rear motor exceeds the preset torque, read the motor fault level flag and the motor fault code of the rear motor; If both the motor fault level flag and the motor fault code of the rear motor indicate no fault, set the dynamometer speed to zero; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is high-voltage standby, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; Set the bus voltage to the second preset voltage; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is active discharge, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; After the bus voltage of the rear motor is lower than the third preset voltage, the console frame disconnects the ignition circuit of the integrated oil-cooled electric drive assembly.

[0013] Preferably, the steps for the console frame to confirm the motor resolver self-learning state of the integrated oil-cooled electric drive assembly include: The console frame connects the ignition circuit of the integrated oil-cooled electric drive assembly; Read the resolver self-learning state of the rear motor; If the resolver self-learning state of the rear motor is that the rear motor completes the self-learning function within the set time, read the long-term maximum torque of the rear motor; If the long-term maximum torque of the rear motor is greater than or equal to the third preset torque, read the initial position of the resolver of the rear motor.

[0014] Preferably, the steps for the console frame to detect the three-phase current fluctuation of the motor of the integrated oil-cooled electric drive assembly include: The console frame disconnects the ignition circuit of the integrated oil-cooled electric drive assembly; The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is initialization, the maximum allowable torque of the rear motor is the first preset torque, the minimum allowable torque of the rear motor is the second preset torque, the torque compensation enable of the rear motor is disabled, and the maximum torque gradient of the rear motor is the preset gradient; The console frame turns on the ignition circuit of the integrated oil-cooled electric drive assembly; Collect three-phase current data within a certain period of time, and calculate the current fluctuation value of each phase within this period according to the maximum and minimum values of each phase current data; If the three-phase current fluctuation value is less than or equal to the preset current, it is determined that the three-phase current fluctuation value is qualified.

[0015] The beneficial effects of the present invention are: For the offline test method of this integrated oil-cooled electric drive assembly, only one test bench is required to test the drive motor and the reducer, which greatly reduces the waste of resources and lowers the production cost; it realizes accurate and efficient detection of the performance of the integrated oil-cooled electric drive assembly during the offline detection stage, and can thus ensure the ex-factory quality of the integrated oil-cooled electric drive assembly. Moreover, this test process has a high degree of automation, precise detection, simple operation method, and low cost, and can well meet the detection requirements for the integrated oil-cooled electric drive assembly of new energy electric vehicles. This offline test method can be simultaneously applied to the ex-factory offline detection of various models of electric drive assemblies, and has a very wide application prospect. Description of the Drawings

[0016] Figure 1 It is a flow chart of the offline test method of the integrated oil-cooled electric drive assembly of the present invention; Figure 2 It is an example diagram of the NVH test conditions of the integrated oil-cooled electric drive assembly of the present invention; Figure 3 It is an example diagram of the external characteristic test conditions of the integrated oil-cooled electric drive assembly of the present invention; Detailed Embodiments The following further details the specific embodiments of the present invention in conjunction with the drawings to help those skilled in the art have a more complete, accurate, and in-depth understanding of the inventive concept and technical solutions of the present invention, but it does not mean that the technical scope of the present invention is limited to these specific embodiments.

[0017] As Figures 1 to 3 shown, an offline test and detection method for an integrated oil-cooled electric drive assembly includes the following steps: S1. Prerequisites for the integrated oil-cooled electric drive assembly before offline testing.

[0018] This step S1 includes: S101. Short-circuit the positive and negative poles of the high-voltage DC input power terminal of the multi-in-one oil-cooled electric drive assembly into one point.

[0019] S102. Short-circuit the AC input L terminal and N terminal of the power supply replenishment system of the multi-in-one oil-cooled electric drive assembly.

[0020] S103. Short-circuit the DC / DC output terminal of the power supply replenishment system of the multi-in-one oil-cooled electric drive assembly to the housing.

[0021] S104. Select an insulation detector with a display accuracy ≤ 1 MΩ, a test accuracy of ±7%, and a reference range ≥ 500 MΩ.

[0022] When conducting the off-line test on the multi-in-one oil-cooled electric drive assembly, one end of the insulation detector needs to be connected to the high-voltage DC of the multi-in-one oil-cooled electric drive assembly.

[0023] S105. Connect one end of the power end of the test bench to the motor housing of the multi-in-one oil-cooled electric drive assembly.

[0024] S106. Correctly connect the low-voltage port of the test bench to the multi-in-one oil-cooled electric drive assembly through the tray wiring harness, and set the wake-up power parameters as: 12V small battery, 2A current output capacity.

[0025] S107. Correctly connect the high-voltage port of the test bench to the multi-in-one oil-cooled electric drive assembly through the tray wiring harness.

[0026] S108. Set the test temperature at the ambient temperature.

[0027] S2. Install the multi-in-one oil-cooled electric drive assembly on the test bench.

[0028] This step S2 includes: S201. Remove the motor junction box cover of the multi-in-one oil-cooled electric drive assembly, and place the removed bolts and motor junction box cover in the specified positions.

[0029] S202. Install the multi-in-one oil-cooled electric drive assembly with the motor junction box cover removed on the test bench.

[0030] Before installing the half shaft with the motor junction box cover removed, remove the oil seal protective sleeve in the axial direction of the transmission shaft; adopt oil seal protection measures during the installation of the half shaft to avoid scratching the oil seal, and at the same time ensure the cleanliness of the oil seal protective sleeve during the subsequent process so that it can be reused after the test is completed.

[0031] S203. Remove the reducer oil filling plug of the multi-in-one oil-cooled electric drive assembly, fill 1.5L (example) of detection oil into the reducer, and after the oil filling is completed, tighten the reducer oil filling plug with the specified torque tightening torque.

[0032] S204. Connect the cooling pipeline. The cooling conditions in the embodiments of the present application are as follows: a mixture of deionized water and ethylene glycol is used as the coolant, where the volume ratio of ethylene glycol is 45% - 55%; the maximum temperature at the coolant inlet is 60 °C, and the flow rate is 8 - 12 L / min; if the pH value of the coolant is between 8 and 11, it is qualified, and if it is unqualified, the water tank needs to be cleaned and new coolant needs to be replaced.

[0033] S3. Conduct a high-voltage interlock test on the multi-in-one oil-cooled electric drive assembly.

[0034] At the low-voltage interface of the multi-in-one oil-cooled electric drive assembly, conduct a continuity test between the high-voltage interlock signal pins.

[0035] The qualified condition for the high-voltage interlock test is that when the high-voltage interlock signal at the low-voltage interface is conducting, the resistance range between the two high-voltage interlock signal pins is within the preset resistance range, for example, 0 - 10 Ω.

[0036] S4. Conduct an AC interlock test on the multi-in-one oil-cooled electric drive assembly.

[0037] This step S4 includes: S401: Connect the constant power line (i.e., the KL30 power line) and the ground line (i.e., the KL31 power line) of the multi-in-one oil-cooled electric drive assembly to the 12V DC power supply of the test bench.

[0038] S402: Connect the OBC hard-wired wake-up pin of the multi-in-one oil-cooled electric drive assembly to the 6V - 12V DC level of the test bench.

[0039] S403: Send a message (such as the 2A9 message) requesting to enable the DCAC working mode through the host computer, and set the parameters for enabling the vehicle external discharge function.

[0040] S404: After 5s, the host computer reads the PDUErrNr fault code in the DCAC working mode enable message (such as the 0x2A9 message) fed back in the multi-in-one oil-cooled electric drive assembly.

[0041] The qualified condition for the AC interlock test is that there is no AC interlock fault code in the PDUErrNr fault code of the DCAC working mode enable message.

[0042] S5. Conduct a communication test on the multi-in-one oil-cooled electric drive assembly.

[0043] This step S5 includes: S501. Send a working mode request signal (such as the 1A1 signal): The host computer sends a working mode request signal to the multi-in-one oil-cooled electric drive assembly through a CAN message.

[0044] The data fields in the working mode request signal include: the rear motor working mode request is initialization (indicated by the value 0), the maximum allowable torque of the rear motor is the first preset torque (such as 290), and the minimum allowable torque of the rear motor is the second preset torque (such as -201).

[0045] The counter VcuCycCntr1A1 of the working mode request signal cycles from 0 to 15, and the checker VcuCrcChk1A1 sets a cyclic check on the data of the working mode request signal according to the CRC-16 algorithm, and the data length DLC is 64 bytes; when using the CRC-16 algorithm for checking, the 16-bit CCITT-FALSE CRC16 CRC algorithm is adopted, and the polynomial is x16+x12+x5+1 (i.e. 1021h).

[0046] S502, sending a battery instant heating gear position request signal (such as 1A5 signal): The host computer sends a battery instant heating gear position request signal to the all-in-one oil-cooled electric drive assembly through a CAN message. The data field in the battery instant heating gear position request signal includes: the maximum charging voltage of the battery is the first preset voltage (such as 500), and the remaining fields are all sent as 0.

[0047] The counter BcuCycCntr1A5 of the battery instant heating gear request signal cycles from 0 to 15, and the checker BcuCrcChk1A5 is set to check according to CRC-16, and the data length DLC is 64 bytes.

[0048] S503, sending a working mode request signal: the host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly through a CAN message.

[0049] The counter VcuCycCntr1A1 cycles from 0 to 15, the checker VcuCrcChk1A1 checks according to the CRC-16 setting, and the rest are all 0s, and the data length DLC is 64 bytes.

[0050] S504, sending PDU power communication signal electric drive speed signal (such as 1C2 signal): the host computer sends the electric drive speed signal to the all-in-one oil-cooled electric drive assembly through a CAN message.

[0051] The counter EspCycCntr1C2 of the electric drive speed signal will cycle from 0-15, and the checker EspCrcChk1C2 will check the data of the I2C signal according to the CRC-16 setting, and the rest will all be 0, and the data length DLC is 64 bytes.

[0052] S505, sending a PDU power communication signal battery instant heating gear position request signal: the host computer sends a battery instant heating gear position request signal to the all-in-one oil-cooled electric drive assembly through a CAN message. The values ​​of all data fields of the battery instant heating gear position request signal are all 0, and the data length DLC is 64 bytes.

[0053] S506, sending PDU power communication signal electric drive coolant inlet temperature signal (such as 2A8 signal): The host computer sends the electric drive coolant inlet temperature signal to the all-in-one oil-cooled electric drive assembly through the CAN message. The values ​​of all data fields of the electric drive coolant inlet temperature signal are all 0, and the data length DLC is 64 bytes.

[0054] S507, sending PDU power communication signal electric drive assembly blocking and forwarding heating request signal (such as 306 signal): The host computer sends the electric drive assembly blocking and forwarding heating request signal to the all-in-one oil-cooled electric drive assembly through the CAN message. The values ​​of all data fields of the electric drive assembly blocking and forwarding heating request signal are all 0, and the data length DLC is 64 bytes.

[0055] S508, sending PDU power communication signal local time signal 9 (such as 2F7 signal): The host computer sends the local time signal to the all-in-one oil-cooled electric drive assembly through the CAN message. The values ​​of all data fields of the local time signal are all 0, and the data length DLC is 8 bytes.

[0056] S509. Turn on each low-voltage relay of the all-in-one oil-cooled electric drive assembly and connect the 12V low voltage.

[0057] S510, read the fault status "ReIpuFltRnk" of the all-in-one oil-cooled electric drive assembly.

[0058] The qualified condition of the communication test is: the host computer reads the fault status "ReIpuFltRnk" of the all-in-one oil-cooled electric drive assembly. If the fault status "ReIpuFltRnk" of the all-in-one oil-cooled electric drive assembly is greater than 0 (indicating a fault), the low voltage is re-adjusted; if it is equal to 0 (i.e. no fault), the next step S6 is executed.

[0059] S6. Perform CP wake-up test on the all-in-one oil-cooled electric drive assembly.

[0060] After the host computer reads the specific frame message ((0x2A9)) sent by the all-in-one oil-cooled electric drive assembly through the CANOE tool or PCAN, it checks whether there are electric drive wake-up messages (such as 0x1A4 messages) and power wake-up messages (such as 0x10C messages) sent on the CAN bus.

[0061] The passing condition for the CP wake-up test is: if the host computer receives the 0x2A9 message, and there are electric drive wake-up messages and power supply wake-up messages sent on the CAN bus.

[0062] S7. Perform software and hardware version verification on the IPU of the multi-hardware integrated oil-cooled electric drive assembly.

[0063] IPU refers to the Intelligent Power Unit of the multi-in-one oil-cooled electric drive assembly.

[0064] The host computer reads the IPU software and hardware version messages sent by the multi-in-one oil-cooled electric drive assembly through the CANOE tool or PCAN, and parses out the IPU software version number and the IPU hardware version number.

[0065] The passing condition for the IPU to perform software and hardware version verification is: the parsed IPU software version number and IPU hardware version number are respectively consistent with their corresponding preset versions.

[0066] S8. Perform software and hardware version verification on the PDU of the multi-hardware integrated oil-cooled electric drive assembly.

[0067] PDU refers to the Power Distribution Unit of the multi-in-one oil-cooled electric drive assembly.

[0068] The host computer reads the PDU software and hardware version messages sent by the multi-in-one oil-cooled electric drive assembly through the CANOE tool or PCAN, and parses the PDU software version number and the PDU hardware version number respectively according to the fields PduHwVers0 - PduHwVers6 and PduSwVers0 - PduSwVers6 in the PDU software and hardware version messages.

[0069] The passing condition for the PDU to perform software and hardware version verification is: the parsed PDU software version number and hardware version number are consistent with the preset software version number and hardware version number.

[0070] S9. Collect the general motor parameters of the multi-hardware integrated oil-cooled electric drive assembly.

[0071] Connect the low-voltage pins of the multi-in-one oil-cooled electric drive assembly to 12V low voltage.

[0072] The host computer reads the electric drive wake-up message sent by the multi-in-one oil-cooled electric drive assembly through the CANOE tool or PCAN, and parses the electric drive wake-up message to obtain the static IGBT temperature (ReIpuTIgbt), stator temperature (ReMotTStatr), DC current (ReIpuIDc), DC voltage (ReIpuUDc), assembly torque (RmipuReWhlActTq) of the multi-in-one oil-cooled electric drive assembly, and obtains the rotor temperature (ReMotTRotr) of the motor through the IPU software and hardware version message.

[0073] S10. Perform software flashing on the multi-in-one oil-cooled electric drive assembly.

[0074] Step S10 includes: S1001. Connect the multi-in-one oil-cooled electric drive assembly to the 12V low-voltage power supply, connect the multi-in-one oil-cooled electric drive assembly and the host computer to the CANFD bus, and the host computer starts the flashing program. The host computer selects the corresponding version software, driver program and corresponding ID to flash the multi-in-one oil-cooled electric drive assembly by identifying the part number of the multi-in-one oil-cooled electric drive assembly.

[0075] S1002. When the program flashing fails, manually check whether the CANFD bus connection is normal; after checking that the CANFD bus connection is normal, manually try to restart the program flashing process again. If the program flashing fails after repeated attempts 3 times, it is determined that the product of this part is unqualified and the subsequent tests are stopped.

[0076] S1003. After the program flashing is completed, the host computer reads and verifies the version number of the program. If the verification fails, stop the subsequent tests, and the host computer alarms to prompt that the program version flashing is incorrect and the product is unqualified.

[0077] S11. Test the oil pump control function.

[0078] Step S11 includes: S1101: Connect the IPU and the oil pump to the 12V low-voltage power supply respectively, and connect the CANFD bus to the IPU. The two 12V low-voltage power supplies need to share the same ground.

[0079] S1102: The host computer sends a working mode request signal to the multi-in-one oil-cooled electric drive assembly. The data in the working mode request signal includes: the host computer sends a working mode request signal to the multi-in-one oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is high-voltage standby (using the value 3 instead of high-voltage standby), the maximum allowable torque of the rear motor is the first preset torque (such as 290), and the minimum allowable torque of the rear motor is the second preset torque (such as -201).

[0080] S1103: The host computer sets the rear motor bus voltage (ReIpuUDc) to a preset voltage (eg, 350V) and starts the DC power supply.

[0081] S1104: The host computer waits for feedback on whether the rear motor bus voltage (ReIpuUDc) reaches the preset voltage, taking into account the detection deviation. If the rear motor bus voltage is within the preset voltage range (such as 345-355V), it is considered successful.

[0082] S1105: The host computer reads the rear motor fault level flag (ReIpuFltRnk). If there is no fault level flag, the next step is executed.

[0083] Qualified conditions: record the target speed signal (EOP_Fdk_TargetSpeed) actually executed by the oil pump at this time as 600±50rpm (i.e. the preset speed range), the actual speed value fed back by the oil pump (EOP_Actual_Speed) ≥500rpm (i.e. the first preset speed) and the oil pump fault code (EOP_ErrErrNrGb) indicates no fault, then proceed to the next step.

[0084] S12. Perform motor rotation self-learning.

[0085] The step S12 includes: S1201: Disconnect the ignition circuit of the all-in-one oil-cooled electric drive assembly (i.e., the KL15 power circuit).

[0086] S1202: The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly. The data in the working mode request signal include: the rear motor working mode request is initialization (indicated by the value 0), the maximum allowable torque of the rear motor is the first preset torque (290), the minimum allowable torque of the rear motor is the second preset torque (-201), the rear motor torque compensation enable is disabled, and the rear motor maximum torque gradient is the preset gradient (such as 2000).

[0087] S1203: After waiting for 2 seconds, the ignition line is connected and the controller wakes up.

[0088] S1204: Send a rear motor operating mode request of torque control mode (such as represented by 12), and first send a rear motor speed request of a first speed (such as 5000), then send a second speed greater than the first speed (such as 10000), and finally send 0.

[0089] S1205: Observe whether the rear motor rotary transformer self-learning state is successful, if not, repeat the previous step.

[0090] S1206: Disconnect the ignition line and stop sending CAN messages.

[0091] S1207: Turn on the ignition circuit and start sending CAN messages.

[0092] S1208: Read whether the post-motor resolver self-learning status is successful. If successful, proceed to the next step.

[0093] S1209: Read the long-term maximum torque of the post-motor; S1210: The host computer sends a work mode request signal to the multi-in-one oil-cooled electric drive assembly. The data in the work mode request signal includes: the post-motor work mode request is initialization (represented by 0), the maximum allowable torque of the post-motor is the first preset torque (such as 290), and the minimum allowable torque of the post-motor is the second preset torque (such as -201).

[0094] S1211: Set the post-motor bus voltage to 350V (preset voltage) and start the DC power supply.

[0095] S1212: Wait for feedback that the post-motor bus voltage reaches 350V (preset voltage). Considering the detection deviation, if the post-motor bus voltage is within the preset voltage range (such as 345V - 355V), it is considered successful.

[0096] S1213: Read the post-motor fault level flag and the post-motor fault code. If it indicates no fault, proceed to the next step.

[0097] S1214: Read the stator temperature of the post-motor.

[0098] S1215: The host computer sends a work mode request signal to the multi-in-one oil-cooled electric drive assembly. The data in the work mode request signal includes: the post-motor work mode request is torque control (represented by the value 8), the maximum allowable torque of the post-motor is the first preset torque (such as 290), the minimum allowable torque of the post-motor is the second preset torque (such as -201), the post-motor torque compensation enable is disabled, and the maximum torque gradient of the post-motor is the preset gradient (such as 2000).

[0099] S1216: Set the dynamometer speed to 5500 rpm / speed ratio (assembly end), wait for the dynamometer to reach the set speed (recommended acceleration time 5s). Considering the deviation, if the assembly speed is within the set speed range (such as 395 - 415 rpm), it is qualified.

[0100] S1217: Read the long-term maximum torque of the post-motor. If the long-term maximum torque of the post-motor ≥ 285 Nm (preset torque), it is considered successful.

[0101] S1218: Read the post-motor fault level flag and the post-motor fault code. If both indicate no fault, proceed to the next step.

[0102] S1219: Set the dynamometer speed to 0 rpm and wait for the dynamometer to reach the set speed (decelerate for 5 s).

[0103] S1220: The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is high-voltage standby (represented by the value 3), the maximum allowable torque of the rear motor is the first preset torque (e.g., 290), and the minimum allowable torque of the rear motor is the second preset torque (e.g., -201).

[0104] S1221: Set the bus voltage to the second preset voltage (e.g., 24 V).

[0105] S1222: The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is active discharge (represented by the value 14), the maximum allowable torque of the rear motor is the first preset torque (290), and the minimum allowable torque of the rear motor is the second preset torque (-201).

[0106] S1223: Wait for the bus voltage of the rear motor to be lower than 60 V. Considering the detection deviation, it is considered successful if it is lower than the third preset voltage (e.g., 65 V).

[0107] S1224: Wait for 0.1 s, disconnect the ignition circuit, and stop sending CAN messages.

[0108] S13. Confirm the resolver self-learning status of the motor.

[0109] Step S13 includes: S1301. The console frame connects the ignition circuit of the integrated oil-cooled electric drive assembly.

[0110] S1302. Read the resolver self-learning status of the rear motor. If the resolver self-learning status of the rear motor is that the rear motor completes the self-learning function within the set time, proceed to the next step.

[0111] S1303. Read the long-term maximum torque of the rear motor. If the long-term maximum torque of the motor ≥ the third preset torque (e.g., 225 Nm), it is considered successful.

[0112] S1304. Read and record the initial position of the resolver of the rear motor.

[0113] S14. Detect the three-phase current fluctuation of the motor.

[0114] Step S14 includes: S1401. The console frame disconnects the ignition circuit of the integrated oil-cooled electric drive assembly and starts sending CAN messages; S1402. The host computer sends a working mode request signal to the integrated oil-cooled electric drive assembly. The data in the working mode request signal includes: the working mode request for the rear motor is initialization (represented by the value 0), the maximum allowable torque of the rear motor is the first preset torque (such as 290), the minimum allowable torque of the rear motor is the second preset torque (such as -201), the torque compensation enable of the rear motor is disabled, and the maximum torque gradient of the rear motor is the preset gradient (such as 2000); S1403. The console frame connects the ignition circuit of the integrated oil-cooled electric drive assembly. When the pipe is not opened (not opening the pipe means the state of low voltage but not high voltage on the PDU power supply), collect the three-phase current data of ReMotIPhaA, ReMotIPhaB, and ReMotIPhaC of the 1A4 message within no less than 0.5 s, and calculate the difference between the maximum value and the minimum value of each phase during this period as the three-phase current fluctuation value.

[0115] Qualified condition: If the three-phase current fluctuation value ≤ the preset current (such as 10 A).

[0116] S15. High-voltage power-on High-voltage power-on at 350 V (power-on time ≥ 1.8 s) Qualified condition: The mode request "ReMotOperModReq" of the test piece is the identification code indicating that the duration of high-voltage power-on at 350 V exceeds the set duration.

[0117] S16. NVH and external characteristic tests Test conditions: The low-voltage port is correctly connected to the test equipment through the tray harness; the high-voltage port is correctly connected to the equipment through the tray harness; the fuel filling amount; the NVH sensor is correctly docked; the product clamping is normal. NVH test is as Figure 2 ; Equipment data processing requirements: ① It can display the test data in the form of a curve; ② It can export the test data to other media.

[0118] Detection working conditions: The electric drive assembly operates on the test bench according to Figure 2 the working conditions, and record the vibration values of each measuring point of the product in each test section respectively.

[0119] External characteristic test is as Figure 3 : Under the 350 VDC voltage on the test bench / equipment, test the performance of the integrated oil-cooled electric drive assembly according to the working points in Table 3: The requested torque of the motor system should increase and decrease according to the gradient, and the time gradient of the motor system torque increase / decrease is 0.5 s. If the electric drive system can output the above torque and speed, the performance is judged to be qualified.

[0120] S17. Shutdown process S1701. Send a working mode request signal, and the information contained in the working mode request signal at this time is as follows: The working mode request of the rear motor (ReMotOperModReq) is high-voltage standby (represented by the value 3), The maximum allowable torque of the rear motor (ReMotTqLimMax) is the first preset torque (such as 290), The minimum allowable torque of the rear motor (ReMotTqLimMin) is the second preset torque (such as -201).

[0121] S1702. Set the bus voltage to the second preset voltage, and then send a working mode request signal. The information contained in the working mode request signal at this time is as follows: The working mode request of the rear motor (ReMotOperModReq) is active discharge (represented by the value 14), The maximum allowable torque of the rear motor (ReMotTqLimMax) is the first preset torque (such as 290), The minimum allowable torque of the rear motor (ReMotTqLimMin) is the second preset torque (such as -201).

[0122] S1703. Wait for 1S, and wait to see if the bus voltage of the rear motor (ReIpuUDc) is lower than 60V. Considering the detection deviation, if it is lower than the third preset voltage (such as 65V), it is considered successful.

[0123] S1704. Wait for 0.1S, disconnect the ignition circuit, and stop sending CAN messages.

[0124] Finally, perform relevant processing on the multi-in-one oil-cooled electric drive assembly under test according to the above test results. If all the test results are qualified, the multi-in-one oil-cooled electric drive assembly will be taken off the production line and loaded onto the vehicle. If there are unqualified test results, the multi-in-one oil-cooled electric drive assembly will be returned to the production line for inspection to complete the entire detection process. Through the above test system and test process of the present invention, it is possible to accurately and efficiently detect the multi-in-one oil-cooled electric drive assembly under test, thereby ensuring the ex-factory quality of the multi-in-one oil-cooled electric drive assembly. Moreover, this test process has a high degree of automation, accurate detection, simple method operation, and low cost, and can well meet the requirements for product detection. In addition, the test system and method of the present invention can be applied to the ex-factory off-line detection of various models of electric drive assemblies, and has a wide application prospect.

[0125] The above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An off-line testing method for an all-in-one oil-cooled electric drive assembly, characterized in that: The all-in-one oil-cooled electric drive assembly includes a controller, power supply, oil pump, drive motor and reducer. The off-line test method includes: Install the all-in-one oil-cooled electric drive assembly on the test bench according to the preset installation procedures; The host computer controls the rack to perform AC interlock test, communication test, CP wake-up test, IPU software and hardware version verification, PDU software and hardware version verification, motor general parameter collection, all-in-one electric drive assembly software flashing, oil pump control function test, motor resolver self-learning, motor resolver self-learning status confirmation, motor three-phase current fluctuation detection, high voltage power-on, NVH and external characteristics test and shutdown process test on the all-in-one oil-cooled electric drive assembly in accordance with the predetermined test sequence; When all the above tests are qualified, the host computer determines that the all-in-one oil-cooled electric drive assembly is qualified.

2. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: Before the step of installing the all-in-one oil-cooled electric drive assembly on the test bench according to the preset installation process, the off-line test method also includes: Conduct insulation performance test, low-voltage port connection test and high-voltage port connection test on the all-in-one oil-cooled electric drive assembly; When all the above tests are passed, the all-in-one oil-cooled electric drive assembly is installed on the test bench according to the preset installation procedures.

3. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of installing the all-in-one oil-cooled electric drive assembly on the test bench according to the preset installation process include: Remove the motor terminal box cover; Install the all-in-one oil-cooled electric drive assembly with the motor junction box cover removed on the bench; Adding test oil to the reducer subassembly of the all-in-one oil-cooled electric drive assembly; Connect the cooling pipe of the test bench to the all-in-one oil-cooled electric drive assembly and inject coolant into the cooling pipe.

4. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of the control rack to test the communication of the all-in-one oil-cooled electric drive assembly include: The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly through a CAN message cycle for multiple times; the data field in the working mode request signal includes: the rear motor working mode request is initialization, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; The host computer sends a battery instant heating gear position request signal to the all-in-one oil-cooled electric drive assembly through a CAN message cycle for multiple times; the data field in the battery instant heating gear position request signal includes: the maximum charging voltage of the battery is the first preset voltage, and the remaining fields are all zero; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly multiple times through the CAN message cycle; The host computer sends the electric drive speed signal to the all-in-one oil-cooled electric drive assembly through the CAN message cycle for multiple times; The host computer sends a battery instant heating gear request signal to the all-in-one oil-cooled electric drive assembly through the CAN message cycle for multiple times; The host computer sends the electric drive coolant inlet temperature signal to the all-in-one oil-cooled electric drive assembly through the CAN message cycle for multiple times; The host computer sends the electric drive assembly blocking and heating request signal to the all-in-one oil-cooled electric drive assembly through the CAN message cycle for multiple times; The host computer sends local time signals to the all-in-one oil-cooled electric drive assembly multiple times through CAN message cycles; The control rack is an all-in-one oil-cooled electric drive assembly connected to 12V low voltage; The host computer reads the fault status of the all-in-one oil-cooled electric drive assembly; If the fault status of the all-in-one oil-cooled electric drive assembly indicates no fault, it is determined that the communication test of the all-in-one oil-cooled electric drive assembly is qualified.

5. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of the control rack to perform a CP wake-up test on the all-in-one oil-cooled electric drive assembly include: After the host computer reads the specific frame message sent by the all-in-one oil-cooled electric drive assembly, it checks whether there is an electric drive wake-up message and a power supply wake-up message sent on the CAN bus; If the host computer receives a specific frame message and an electric drive wake-up message and a power supply wake-up message are sent on the CAN bus, it is determined that the CP wake-up test of the all-in-one oil-cooled electric drive assembly is qualified.

6. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps for the console rack to verify the IPU software and hardware versions of the all-in-one oil-cooled electric drive assembly include: The host computer reads the IPU software and hardware version message sent by the all-in-one oil-cooled electric drive assembly, and parses the IPU software version number and IPU hardware version number; If the parsed IPU software version number and IPU hardware version number are respectively consistent with their corresponding preset versions, it is determined that the all-in-one oil-cooled electric drive assembly has passed the IPU software and hardware version verification; The steps for the control rack to verify the PDU software and hardware versions of the all-in-one oil-cooled electric drive assembly include: The host computer reads the PDU software and hardware version message sent by the all-in-one oil-cooled electric drive assembly, and parses the PDU software version number and PDU hardware version number; If the parsed PDU software version number and PDU hardware version number are respectively consistent with their corresponding preset versions, it is determined that the all-in-one oil-cooled electric drive assembly has passed the PDU software and hardware version verification.

7. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of testing the oil pump control function of the all-in-one oil-cooled electric drive assembly on the control rack include: The control rack is connected to the 12V low voltage by the low voltage pin of the all-in-one oil-cooled electric drive assembly; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly; the data in the working mode request signal includes: the rear motor working mode request is high voltage standby, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; The upper computer sets the motor bus voltage to the preset voltage and starts the DC power supply; The host computer waits for feedback that the motor bus voltage is within the preset voltage range; The upper computer reads the motor fault level mark; If the rear motor fault level mark indicates no fault, the host computer reads the target speed actually executed by the oil pump, the actual speed fed back by the oil pump, and the oil pump fault code; If the target speed actually executed by the oil pump reaches the preset speed range, the actual speed fed back by the oil pump reaches the first preset speed and the oil pump fault code indicates no fault, it is confirmed that the oil pump control function test is qualified.

8. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of the control console to perform motor rotary transformer self-learning on the all-in-one oil-cooled electric drive assembly include: The control rack disconnects the ignition circuit of the all-in-one oil-cooled electric drive assembly; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly; the data in the working mode request signal includes: the rear motor working mode request is initialization, the maximum allowable torque of the rear motor is the first preset torque, the minimum allowable torque of the rear motor is the second preset torque, the rear motor torque compensation enable is disabled, and the maximum torque gradient of the rear motor is the preset gradient; The control console connects the ignition circuit of the all-in-one oil-cooled electric drive assembly; The host computer sends a rear motor working mode request to the all-in-one oil-cooled electric drive assembly, which is a torque control mode. The rear motor speed request first sends a first speed, then sends a second speed greater than the first speed, and finally sends zero; After reading, the motor rotary transformer self-learning status; If the rear motor rotary transformer self-learning status is successful, the control console disconnects the ignition circuit of the all-in-one oil-cooled electric drive assembly; The control console connects the ignition circuit of the all-in-one oil-cooled electric drive assembly and reads the self-learning status of the rear motor rotary transformer; If the rear motor rotary transformer self-learning status is successful, read the rear motor's long-term maximum torque; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly; the data in the working mode request signal includes: the rear motor working mode request is initialization, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; The upper computer sets the motor bus voltage to the preset voltage and starts the DC power supply; The host computer waits for feedback that the motor bus voltage is within the preset voltage range; The host computer reads the motor fault level mark and motor fault code; If the rear motor fault level mark and motor fault code both indicate no fault, read the rear motor stator temperature; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly, wherein the data in the working mode request signal include: the rear motor working mode request is torque control, the maximum allowable torque of the rear motor is a first preset torque, the minimum allowable torque of the rear motor is a second preset torque, the rear motor torque compensation enable is disabled, and the rear motor maximum torque gradient is a preset gradient; The host computer sets the dynamometer speed; Read the maximum torque of the rear motor for a long time; If the maximum torque of the rear motor exceeds the preset torque for a long time, the rear motor fault level mark and rear motor fault code are read; If the rear motor fault level mark and rear motor fault code both indicate no fault, set the dynamometer speed to zero; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly, wherein the data in the working mode request signal includes: the working mode request of the rear motor is high voltage standby, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; Setting the bus voltage to a second preset voltage; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly, wherein the data in the working mode request signal includes: the working mode request of the rear motor is active discharge, the maximum allowable torque of the rear motor is the first preset torque, and the minimum allowable torque of the rear motor is the second preset torque; After the rear motor bus voltage is lower than the third preset voltage, the control rack disconnects the ignition circuit of the all-in-one oil-cooled electric drive assembly.

9. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of confirming the motor rotary transformer self-learning status of the all-in-one oil-cooled electric drive assembly by the control rack include: The control console connects the ignition circuit of the all-in-one oil-cooled electric drive assembly; After reading, the motor rotary transformer self-learning status; If the rear motor rotary transformer self-learning state is that the rear motor completes the self-learning function within the set time, read the rear motor's long-term maximum torque; If the long-term maximum torque of the rear motor is greater than or equal to the third preset torque, the initial position of the rear motor resolver is read.

10. The off-line testing method of the all-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: The steps of performing motor three-phase current fluctuation detection on the all-in-one oil-cooled electric drive assembly by the control rack include: The control rack disconnects the ignition circuit of the all-in-one oil-cooled electric drive assembly; The host computer sends a working mode request signal to the all-in-one oil-cooled electric drive assembly, wherein the data in the working mode request signal include: the rear motor working mode request is initialization, the maximum allowable torque of the rear motor is the first preset torque, the minimum allowable torque of the rear motor is the second preset torque, the rear motor torque compensation enable is disabled, and the rear motor maximum torque gradient is the preset gradient; The control console connects the ignition circuit of the all-in-one oil-cooled electric drive assembly; Collect three-phase current data within a period of time, and calculate the current fluctuation value of each phase within this period of time based on the maximum and minimum values ​​of each phase current data; If the three-phase current fluctuation value is less than or equal to the preset current, it is determined that the three-phase current fluctuation value is qualified.

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