Modular range extender rack test system based on industrial PC control

Abstract

The modularized range extender rack test system based on the industrial PC control comprises modularized rack upper computer software, a battery simulator, a fuel supply system and a low-voltage power supply system, and the modularized range extender rack test system based on the industrial PC control comprises a modularized rack upper computer software, a battery simulator, a fuel supply system and a low-voltage power supply system. The range extender rack test system has the functions of data display, data collection and equipment control. Meanwhile, the functions of the measurement and control equipment can be self-defined, various data acquisition sensors, control IOs and sub-equipment with various communication protocols are integrated into a channel form by analyzing the characteristics of the measurement and control equipment, and the channels are used for acquiring data, outputting commands and controlling equipment operation, so that the difficulty of building the rack test system is simplified, and the test efficiency is improved. And meanwhile, the manufacturing of the equipment is more transparent, so that the hindrance to the cost and the progress in the whole project implementation process is reduced, and the monopoly of equipment manufacturers is reduced at the same time.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicle range extenders, and in particular to a modular range extender bench test system based on industrial PC control. Background Art

[0002] In recent years, new energy vehicles have been booming, and the trend of electrification of vehicle power has become increasingly prominent. Among them, extended-range electric vehicles, as a hybrid technology closest to pure electric vehicles, add an internal combustion engine and a generator to the pure electric vehicle. When driving short distances, it is in pure electric mode. When the mileage is longer, the range extender starts to work and generates electricity by consuming fuel to supplement the electric energy required for vehicle driving or charge the power battery.

[0003] Compared with traditional fuel vehicles, extended-range electric vehicles have the advantages of energy saving and fuel saving; compared with pure electric vehicles, they solve the problem of range anxiety. In the environment where new energy vehicles such as fuel cells are less mature and more expensive, extended-range electric vehicles will be the key direction of industrial development for a long time in the future.

[0004] Defects and shortcomings of the existing technology:

[0005] With the continuous changes in test regulations and test objectives, test methods and test processes are becoming more and more complex and changeable. Existing test platforms need to connect to more third-party equipment and add new functions to meet test needs. It is often necessary to find original equipment manufacturers to improve or integrate software systems again, resulting in the inability to quickly build a test platform and requiring additional capital investment. Summary of the invention

[0006] The present invention proposes a modular range extender bench test system based on industrial PC control, which can solve the problem.

[0007] To achieve the above object, the present invention adopts the following technical solutions:

[0008] A modular range extender bench test system based on industrial PC control, including modular bench host computer software, the modular bench host computer software including a building module, the building module including a channel library building unit and a control library building unit, the channel library building unit uses data acquisition sensors, control IO and sub-devices with communication protocols to integrate into the form of channels, and collects data and outputs commands through the above channels to control the operation of the equipment, and then combines the equipment's own requirements, the requirements of the test product, the requirements of the test items, and the auxiliary requirements outside the test;

[0009] The control library establishment unit establishes its own required actions according to the channel library unit and the input and output action composition of the channel library unit.

[0010] Furthermore, the modular test bench host computer software also includes an action library setting module, which combines action library units by operating the channel library establishment units, including phased actions and global monitoring actions and adjustment actions from the beginning to the end of the test, thereby forming independent operating modes during the equipment operation process.

[0011] Furthermore, the modular bench host computer software also includes an advanced data management module, which meets the data storage requirements by setting the acquisition channel, acquisition method, and storage method of the acquisition result of the channel library establishment unit, and stores these data in the database, which is convenient for classification call and statistical analysis at any time.

[0012] Furthermore, it also includes a battery simulator for simulating the power battery pack of the entire vehicle, which is connected to the generator system through a high-voltage line to store the electrical energy fed back by the generator system.

[0013] Furthermore, it also includes a fuel supply system, which simulates the fuel tank of the entire vehicle, provides the fuel required for engine combustion and performs measurements.

[0014] Furthermore, it also includes a low-voltage power supply system, which simulates the battery of the entire vehicle and provides the electrical appliances with the low-voltage electricity required for operation.

[0015] It can be seen from the above technical solution that the modular range extender bench test system based on industrial PC control of the present invention has built a range extender bench test system that can display data, collect data, and control equipment according to different test requirements. At the same time, it can customize the measurement and control equipment functions, and by analyzing the characteristics of the measurement and control equipment, various data acquisition sensors, control IO, and sub-devices with various communication protocols are integrated into the form of channels, and these channels are used to collect data and output commands to control the operation of the equipment, which simplifies the difficulty of building the bench test system, and also makes the manufacturing of the equipment more transparent, so as to reduce the obstacles to cost and progress during the implementation of the entire project, and at the same time reduce the monopoly of equipment manufacturers.

[0016] Specifically, its advantages are as follows:

[0017] 1) Based on real-time technology development, it can truly achieve almost complete synchronous collection of measured data;

[0018] 2) Ability to ensure the real-time and reliability of collected data and the security of system operation;

[0019] 3) Excellent dynamic response characteristics, able to meet various transient test requirements, with response time reaching millisecond level;

[0020] 4) It has a friendly user interface and powerful test program editing capabilities;

[0021] 5) The database has multiple driver interfaces (supports secondary development) and has strong third-party device integration capabilities;

[0022] 6) Can be seamlessly connected to the laboratory management system and provide real-time docking protocols;

[0023] 7) Separating the control process makes it easy to change the process at any time, greatly improving the flexibility of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is the principle diagram of the test bench of the present invention;

[0025] Figure 2 The figure is a flow chart of the experimental method of the present invention. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments.

[0027] like Figure 1 and Figure 2 As shown, the modular range extender bench test system based on industrial PC control described in this embodiment includes:

[0028] A modular bench host computer software is set up, including an establishment module, which includes a channel library establishment unit and a control library establishment unit. The channel library establishment unit integrates data acquisition sensors, control IO and sub-devices with communication protocols into a channel form, and collects data and outputs commands through the above channels to control the operation of the equipment, and then combines the equipment's own requirements, the requirements of the test product, the requirements of the test items, and the auxiliary requirements outside the test;

[0029] The control library establishment unit establishes its own required actions according to the channel library unit and the input and output action composition of the channel library unit.

[0030] It also includes an action library setting module, which combines action library units by operating channel library establishment units, including phased actions and global monitoring actions and adjustment actions from the beginning to the end of the test, thereby forming independent operating modes during the operation of the equipment.

[0031] It also includes an advanced data management module, which meets the requirements of data storage by setting the acquisition channel, acquisition method, and storage method of the acquisition results of the channel library establishment unit, and stores these data in the database for easy classification, call, and statistical analysis at any time.

[0032] It also includes an alarm monitoring module, which is used to set various allowable limits for each channel according to the channel library establishment unit and the control library establishment unit, including process limits, warning limits and severe warning limits, and set various behaviors that exceed the limits to achieve various control actions, thereby ensuring the safety of people, products and the equipment itself.

[0033] It also includes a black box module, which is used to enable the black box according to the conditions set by the alarm monitoring module. When the equipment meets the conditions during operation, the black box function is automatically started to store data for the pre-set channels, thereby providing a data basis for finding and holding accountable the causes of subsequent problems.

[0034] It also includes a display module, which includes a custom interface module. The custom interface module can make various data forms and various data control methods into unified standards according to the test requirements, allowing the tester to create an interface of appropriate size and drag and drop the data display and data control blocks required by themselves, thereby realizing the entire test operation. The display module also includes an image segmentation module. The image segmentation module is used to divide the displayed image into several specific areas with unique properties and propose the technology and process of pipe points. It is a key step from image processing to image analysis, and is mainly divided into the following categories: threshold-based segmentation method, region-based segmentation method, edge-based segmentation method, and segmentation method based on specific theories.

[0035] The battery simulator is used to simulate the vehicle's power battery pack. It is connected to the generator system through a high-voltage line and stores the electrical energy fed back by the generator system.

[0036] The fuel supply system simulates the vehicle's fuel tank and can provide and measure the fuel required for engine combustion.

[0037] The low-voltage power supply system simulates the vehicle battery and provides electrical appliances with the low-voltage electricity they need for operation.

[0038] The cooling system simulates the heat dissipation of the entire vehicle to ensure that the engine, motor and electronic control system can operate at an appropriate temperature.

[0039] See also Figure 2, taking the range extender reliability test as an actual case, the tester conducts qualified inspection (including weight inspection, insulation test, voltage resistance test, etc.) on the range extender sample under test before the test. After the sample is qualified, the test bench is built according to the above method and the test equipment and sensors required for the test are connected, and the host computer and the low-voltage wiring harness are connected by CAN communication. Set up channels in the host computer software: set up temperature and pressure measurement channels for sensors; set up preparation, operation, stop, fault alarm, alarm reset and control parameter channels for control hardware; set up CAN message receiving and sending channels for the range extender sample under test. Set up alarm monitoring according to the boundary conditions required by the test outline and the safety instructions for equipment use. After running-in and initial performance testing, edit the automatic test script according to the test conditions, and run the script to start the range extender reliability test. Stop the test and evaluate it after the expected test duration is reached or a serious fault occurs, and issue a test report.

[0040] In summary, the embodiments of the present invention pay particular attention to the modular block structure, especially the design of the building module, which integrates the data acquisition sensors, control IO and sub-devices with communication protocols into the form of channels, and collects data and outputs commands through the above channels, thereby separating the control process flow and simplifying the difficulty of construction.

[0041] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A modular range extender bench test system based on industrial PC control, including modular bench host computer software, characterized in that: The modular bench host computer software includes an establishment module, which includes a channel library establishment unit and a control library establishment unit. The channel library establishment unit uses data acquisition sensors, control IO and sub-devices with communication protocols to integrate into the form of channels, and collects data and outputs commands through the above channels to control the operation of the equipment, and then combines the equipment's own requirements, the requirements of the test product, the requirements of the test items, and the auxiliary requirements outside the test; The control library establishment unit establishes its own required actions according to the channel library unit and the input and output action composition of the channel library unit.

2. The modular range extender bench test system based on industrial PC control according to claim 1 is characterized in that: The modular test bench host computer software also includes an action library setting module, which combines action library units by operating the channel library establishment units, including phased actions and global monitoring actions and adjustment actions from the beginning to the end of the test, thereby forming independent operating modes during the equipment operation process.

3. The modular range extender bench test system based on industrial PC control according to claim 2 is characterized in that: The modular bench host computer software also includes an advanced data management module, which meets the data storage requirements by setting the acquisition channel, acquisition method, and storage method of the acquisition result of the channel library establishment unit, and stores these data in the database for easy classification and statistical analysis at any time.

4. The modular range extender bench test system based on industrial PC control according to claim 1 is characterized in that: It also includes a battery simulator, which is used to simulate the vehicle's power battery pack, which is connected to the generator system through a high-voltage line to store the electrical energy fed back by the generator system.

5. The modular range extender bench test system based on industrial PC control according to claim 1 is characterized in that: It also includes a fuel supply system that simulates the vehicle's fuel tank, provides the fuel required for engine combustion and performs measurements.

6. The modular range extender bench test system based on industrial PC control according to claim 1 is characterized in that: It also includes a low-voltage power supply system, which simulates the battery of the entire vehicle and provides the electrical appliances with the low-voltage electricity required for operation.

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