A method of wear testing a cooling waterway of a power electronic controller

Abstract

The application relates to the field of power electronic controller product cooling water channel testing, in particular to a wear test method for a cooling water channel of a power electronic controller. The method comprises the following steps: injecting cooling liquid mixed with sand and / or dust into a ring-shaped circulating channel, setting the flow of the cooling liquid and the temperature of a temperature box. The experimental time is calculated according to the cooling liquid flow time and an acceleration factor, and the water pump is controlled according to the experimental time to complete the wear test. The mechanical stress of the internal components of the water channel system under the real existing conditions that the controller cooling water channel is not clean, contains impurities or the cooling liquid contains particulate matters can be simulated, meanwhile, the characteristics that the cooling liquid does not stop flowing immediately when the power electronic controller stops charging and discharging are fully considered, and the four-dimensional acceleration factor is combined, so that the result obtained by the wear test method has higher reliability.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of power electronic controller product cooling waterway testing, in particular to a wear test method of a cooling waterway of a power electronic controller. BACKGROUND

[0002] In a power electronic controller product, a cooling waterway is a core component that bears the heat transfer inside the controller. In the design and development of the cooling waterway, mainly attention is paid to the structural design and heat dissipation performance design of the waterway, as well as the reliability and service life of the waterway, but these are all limited to the ideal case that the cooling waterway is clean and free of impurities. In the actual production and assembly process of the controller, due to the production, transportation and assembly of the cooling waterway system components and in the detection process of the waterway, there may be particulate matter or impurities remaining in the waterway. These particulate matter or impurities may impact the functional surface of the cooling waterway components with a certain hardness during the operation of the power electronic controller, and may also block the cooling waterway, thereby affecting the pressure drop, flowability, sealing performance and service life of the cooling waterway, and ultimately affecting the temperature rise and safety performance of the controller.

[0003] The existing design verification of the cooling waterway mainly includes a circulating pressure pulsation test, a waterway low pressure test and a waterway overpressure test. These tests mainly examine the cycle service life, structural strength, screw connection and sealing performance of the waterway, but if the cooling waterway is not clean, has impurities or the cooling liquid contains particulate matter in the actual use of the power electronic controller or when the power electronic controller is installed in other equipment, the verification method and results of these tests have limitations. SUMMARY

[0004] In order to solve the problem that the existing technology cannot be applied to the case that the cooling waterway is not clean, has impurities or the cooling liquid contains particulate matter, the present application provides a wear test method of a cooling waterway of a power electronic controller. The cooling waterway is fixed in a test system to complete the wear test. In a first aspect, the test system includes a circulating system and a temperature box. The circulating system includes a circulating water pipe and a water pump. The two ends of the circulating water pipe are respectively connected to the two ends of the cooling waterway. The circulating water pipe, the water pump and the cooling waterway constitute an annular circulating channel. The annular circulating channel is filled with cooling liquid. The cooling liquid is driven to circulate in the annular circulating channel by the water pump.

[0005] The circulating system is arranged inside the temperature box. The temperature of the circulating system is changed by controlling the temperature box.

[0006] In a second aspect, the wear test method includes:

[0007] injecting the cooling liquid mixed with the sand and / or dust into the annular circulating channel, setting the flow of the cooling liquid and the temperature of the temperature box;

[0008] calculating the experimental time according to the cooling liquid flow time and the acceleration factor, and controlling the water pump according to the experimental time to complete the wear test;

[0009] The cooling liquid flow time is the sum of the discharge time, the charging time and the standby time in the actual service life of the power electronic controller.

[0010] The acceleration factor is a value calculated based on the proportion of the sand and / or dust, the flow of the cooling liquid, the temperature of the temperature box and the type of the cooling liquid.

[0011] Specifically, the circulating system further comprises a liquid adding pipe and a T-shaped adapter, one end of the T-shaped adapter is connected with the liquid adding pipe, and the other two ends of the T-shaped adapter are connected with the circulating water pipe perpendicularly to the liquid adding pipe.

[0012] The method of the wear test further comprises: injecting the cooling liquid mixed with the sand and / or dust into the annular circulating channel through the liquid adding pipe, ensuring that there is no bubble in the annular circulating channel, and during the experiment, when the liquid level in the cooling water channel drops to a set threshold, liquid adding judgment is performed, which comprises:

[0013] If the reason for the drop in the liquid level is the leakage of the cooling liquid, the cooling liquid mixed with the sand and / or dust is injected into the annular circulating channel through the liquid adding pipe to ensure that there is no bubble in the annular circulating channel.

[0014] If the reason for the drop in the liquid level is the evaporation of the cooling liquid, deionized water is injected into the annular circulating channel through the liquid adding pipe to ensure that there is no bubble in the annular circulating channel.

[0015] Specifically, the proportion of the sand and / or dust is a value increased on the basis of a standard value set in the main plant, the flow of the cooling liquid, the temperature of the temperature box and the type of the cooling liquid are values adjusted on the basis of the actual operation condition of the power electronic controller, so as to increase the acceleration factor.

[0016] Specifically, the proportion of the sand and / or dust and the flow of the cooling liquid increase the wear efficiency in the acceleration factor, and the temperature of the temperature box and the type of the cooling liquid increase the corrosion efficiency in the acceleration factor.

[0017] Specifically, the calculation method of calculating the experimental time according to the cooling liquid flow time and the acceleration factor is to divide the cooling liquid flow time by the acceleration factor to obtain the experimental time.

[0018] Specifically, the inside of the temperature box is provided with a plurality of the circulating systems, each of which corresponds to one of the cooling water channels, so as to simultaneously perform the wear test on the plurality of cooling water channels at the same temperature.

[0019] Specifically, the test system is in communication connection with an electric control cabinet and an upper computer, when the wear test is performed, the voltage value of the water pump remains constant, after the electric control cabinet receives the flow signal and the time signal of the upper computer, the current of the water pump is controlled according to the flow signal and the time signal, and the actual flow value is returned to the upper computer for display and storage.

[0020] Specifically, the cooling water channel is fixed in the temperature box, and the fixed direction is consistent with the direction of the cooling water channel in actual use;

[0021] When the water pump drives the cooling liquid to circulate in the annular circulating channel, the flow direction is consistent with the flow direction of the cooling liquid in the cooling water channel in actual use.

[0022] Specifically, the method further comprises: according to the model of the cooling water channel and the model of the power electronic controller, searching for a historical use time record, extracting an actual use life, a charging time and a discharging time from the historical use time record, and obtaining a downtime by subtracting the charging time and the discharging time from the actual use life.

[0023] According to the model of the cooling water channel and the model of the power electronic controller, a mapping table is searched to obtain a heat dissipation characteristic, and a ratio of a time during which the cooling liquid keeps flowing in the downtime is confirmed according to the heat dissipation characteristic, so as to obtain the standby time.

[0024] Specifically, the method further comprises: according to the model of the cooling water channel and the model of the power electronic controller, searching for a historical use flow record, extracting a flow fluctuation feature from the historical use flow record, and correcting the flow of the cooling liquid in the acceleration factor according to the flow fluctuation feature.

[0025] The application has the following technical effects:

[0026] The wear test method can simulate the mechanical stress of the internal components of the water channel system under the real existing conditions that the controller cooling water channel is not clean, has impurities or the cooling liquid contains particulate matter, so as to fully verify the reliability and service life of the water channel system.

[0027] The wear test method fully considers the characteristics that the cooling liquid does not immediately stop flowing when the power electronic controller stops charging and discharging, and combines the four-dimensional acceleration factor, so that the result obtained by the wear test method has higher reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] By reading the detailed description below with reference to the accompanying drawings, the above and other objects, features and advantages of the exemplary embodiments of the present application will become readily understood. In the accompanying drawings, several embodiments of the present application are shown in an exemplary and non-limiting manner, and the same or corresponding numbers represent the same or corresponding parts.

[0029] Figure 1 Schematic diagram of the experimental system structure for the wear test of the cooling water channel of the power electronic controller in the embodiment of the present application;

[0030] Figure 2 This is a flow chart of the experimental steps for the wear test of the cooling water channel of the power electronic controller. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application.

[0032] like Figure 1 As shown, the experimental system of this embodiment includes a test sample assembly 10, a test sample assembly 20, a test sample assembly 30, a temperature chamber 40, an electrical control cabinet 50, a communication line 60, and a computer host computer 70. According to the actual test verification requirements, the actual volume of the temperature chamber 40, the number of power modules of the electrical control cabinet 50, and the number of channels of the computer host computer 70, multiple samples can be placed inside the temperature chamber 40 for testing. Only three test sample assemblies are drawn in this figure. The temperature chamber 40 has a certain accommodating space, and the three test sample assemblies are placed in the accommodating space to simulate the ambient temperature of the power electronic controller during its actual service life and the temperature rise caused by the heat generated by the power electronic controller itself.

[0033] Test sample assembly 10 includes test sample 101, water pipe 102, water pipe 103, water pipe 104, water pipe 105, water pump 106, T-type adapter 107, and signal line 108. Test sample assembly 20 includes test sample 201, water pipe 202, water pipe 203, water pipe 204, water pipe 205, water pump 206, T-type adapter 207, and signal line 208. Test sample assembly 30 includes test sample 301, water pipe 302, water pipe 303, water pipe 304, water pipe 305, water pump 306, T-type adapter 307, and signal line 308.

[0034] The test sample assemblies are connected to the electric cabinet 50 through signal lines respectively, and the electric cabinet 50 is connected to the computer 70 through communication line 60. The computer 70 sends flow and time signals to the electric cabinet 50 through the communication line 60. After receiving the signals from the computer 70, the electric cabinet controls the current of the corresponding water pump through the signal line to realize the change of the flow in the water pipe under different time conditions, so as to realize the change of the flow in each test sample assembly with time, wherein the voltage of the water pump 106, the water pump 26 and the water pump 306 is constant. The computer 70 also displays and records the actual time and flow value of each test sample assembly in real time, and saves it in the form of a data file.

[0035] The three test sample assemblies have the same principle and structure. In this embodiment, only the test sample assembly 10 is described. The coolant in the test sample assembly 10 circulates in a clockwise direction according to the actual flow direction of the power electronic controller product. The water inlet of the test sample 101 is connected to the water pipe 102, and the water outlet is connected to the water pipe 105, so as to ensure that the coolant circulates in a clockwise direction from the water inlet to the water outlet. Among the four water pipes connected to the test sample 101, one water pipe is used as a liquid adding pipe, and the other three water pipes are used for circulating the coolant, wherein the water pipe 103 is the liquid adding pipe, and the water pipe 102, the water pipe 104 and the water pipe 105 are the water pipes for circulating the coolant. The T-shaped adapter 107 connects the water pipe 102, the water pipe 103 and the water pipe 104. The water pump 106 is connected to the water pipe 105, the water pipe 104 and the signal line 108.

[0036] As Figure 2As shown, before the test begins, the cooling liquid mixture containing a certain proportion of sand or dust that has been prepared is injected from the water pipe 103, flows through the T-shaped adapter 107 into the circulating loop of the entire test sample assembly 10, and ensures that the entire circulating loop is filled with cooling liquid without leaving air bubbles. After the entire circulating loop is filled with cooling liquid, the test sample 101 is placed vertically to simulate the installation direction of the test sample 101 inside the power electronic controller, and is fixed in the temperature box 40 to prevent shaking during the test. After the test begins, the flow rate and test execution time are input on the computer host 70, and the computer host 70 controls the power module of the electric cabinet 50 through the communication line 60. The power module of the electric cabinet 50 sends instructions to the water pump 106 through the signal line 108 connected to the water pump. After receiving the current signal from the signal line 108, the water pump 106 rotates at a certain speed to drive the cooling liquid to circulate in the clockwise direction in the test sample 101, the water pipe 105, the water pump 106, the water pipe 104, the T-shaped adapter 107, and the water pipe 102. When the cooling liquid containing sand or dust circulates through the water channel of the test sample 101, the sand or dust inside the cooling liquid impacts the functional surfaces of the cooling water channel assembly, such as the heat dissipation needles, the sealing ring, and the heat dissipation base plate, at a certain speed, force, and hardness. If the quality of these functional surfaces is not good, the surfaces may be worn, corroded, or even irreversibly damaged or deformed, and the results of these verifications are used to evaluate the quality and reliability of the internal components of the water channel.

[0037] The entire test sample assembly 10 is fixedly placed inside the temperature box 40, which is used to simulate the ambient temperature during the actual service life of the power electronic controller and the temperature rise due to the heat generated by the power electronic controller itself, so as to more closely match the actual use environment of the cooling water channel during the service life of the power electronic controller after installation and use.

[0038] The duration of the sand or dust containing cooling liquid wear test in the water channel will affect the verification results of the water channel assembly and the cost of the test. In this embodiment, the test time is calculated based on the cooling liquid flow time and the acceleration factor, and the water pump is controlled based on the test time to complete the wear test. The discharge time and the charging time during the actual service life of the power electronic controller need to be considered, and after the power electronic controller stops charging and discharging, the cooling liquid will not immediately stop flowing in the control strategy of the power electronic controller, so a certain proportion of standby time during the actual service life in the actual use environment is also considered. Therefore, the cooling liquid flow time is the sum of the discharge time, the charging time, and the standby time during the actual service life of the power electronic controller. For the purpose of accelerating the test, the acceleration factor in this embodiment is a value calculated based on the proportion of sand and / or dust, the flow rate of the cooling liquid, the temperature of the temperature box, and the type of the cooling liquid.

[0039] In the embodiment, when the liquid level in the cooling water channel drops to a set threshold during the experiment, liquid addition determination is performed, which includes:

[0040] If the reason for the drop in the liquid level is leakage of the cooling liquid, the cooling liquid mixed with the sand and / or dust is injected into the annular circulation channel through the liquid addition pipe to make the annular circulation channel free of bubbles;

[0041] If the reason for the drop in the liquid level is evaporation of the cooling liquid, deionized water is injected into the annular circulation channel through the liquid addition pipe to make the annular circulation channel free of bubbles.

[0042] In the embodiment, specifically, the proportion of the sand and / or dust is a value obtained by increasing a standard value set in the main plant, and the flow rate of the cooling liquid, the temperature of the temperature tank, and the type of the cooling liquid are values adjusted on the basis of actual operation conditions of the power electronic controller to obtain a greater acceleration factor.

[0043] The failure mechanism of the water channel wear test is wear, and the test acceleration factor is proportional to the particulate matter concentration of the sand or dust in the test process and is exponentially related to the flow rate of the cooling liquid in the test process. The environmental temperature and the type of the cooling liquid in the test process have a failure mechanism of corrosion on the water channel, and the acceleration factor in the test process is proportional to the particulate matter concentration and the flow rate of the cooling liquid, in addition to the same relationship as described above, and the type of the cooling liquid directly affects the service life of the water channel through its chemical corrosion performance. In the embodiment, the proportion of the sand and / or dust and the flow rate of the cooling liquid increase the wear efficiency in the acceleration factor, and the temperature of the temperature tank and the type of the cooling liquid increase the corrosion efficiency in the acceleration factor. Specifically, the calculation method for calculating the experimental time according to the cooling liquid flow time and the acceleration factor is to divide the cooling liquid flow time by the acceleration factor to obtain the experimental time.

[0044] In the embodiment, when the standby time parameter of the cooling water channel wear test needs to be determined, the system accesses the equipment history database according to the model of the currently measured cooling water channel and the model of the matched power electronic controller to retrieve the actual operation record of the model combination. The database stores a large number of operation logs of devices of the same model accumulated under real working conditions, and by analyzing these logs, key time parameters such as actual service life, charging time, and discharging time can be obtained. By subtracting the charging time and the discharging time from the actual service life, the downtime of the device can be obtained. According to the model of the cooling water channel and the model of the power electronic controller, the heat dissipation characteristics are obtained by looking up the mapping table, and the ratio of the time during which the cooling liquid keeps flowing in the downtime is confirmed according to the heat dissipation characteristics, to obtain the standby time, avoiding human estimation deviation.

[0045] In the embodiment, the flow parameter in the acceleration factor is also based on the cooling water channel and the controller model to call the flow monitoring record in the historical operation database. The record contains the instantaneous flow data of the equipment under different working conditions. The flow fluctuation characteristics are extracted by a signal processing algorithm. The characteristics are quantified as dynamic correction coefficients. The basic flow value in the acceleration factor is weighted and corrected by a correction formula.

[0046] Obviously, the above-described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0047] It should be understood that when the claims, the specification, and the drawings of the present application use the terms "first", "second", etc., they are only used to distinguish different objects, and are not used to describe a specific sequence. The terms "include" and "contain" used in the specification and claims of the present application indicate the presence of the described features, whole, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, whole, steps, operations, elements, components and / or sets thereof.

Claims

1. A wear test method for a cooling water channel of a power electronic controller, wherein the cooling water channel is fixed in a test system to perform the wear test, characterized in that: The test system includes a circulation system and a temperature box. The circulation system includes a circulating water pipe and a water pump. The two ends of the circulating water pipe are respectively connected to the two ends of the cooling water channel. The circulating water pipe, the water pump and the cooling water channel form an annular circulation channel. The annular circulation channel is filled with coolant. The coolant is driven by the water pump to circulate in the annular circulation channel. The circulation system is arranged inside the temperature box, and the temperature of the circulation system is changed by controlling the temperature box; The wear test method includes: Injecting a coolant mixed with molding sand and / or dust into the annular circulation channel, and setting the flow rate of the coolant and the temperature of the temperature box; Calculating the test time according to the coolant flow time and the acceleration factor, and controlling the water pump according to the test time to complete the wear test; The coolant flow time is the sum of the discharge time, the charge time and the standby time in the actual service life of the power electronic controller; The acceleration factor is a value calculated based on the ratio of the molding sand and / or dust, the flow rate of the coolant, the temperature of the temperature box, and the type of the coolant; The ratio of the molding sand and / or dust is a value obtained by increasing the standard value set by the main engine manufacturer, and the flow rate of the coolant, the temperature of the temperature box, and the type of the coolant are values ​​adjusted based on the actual operating conditions of the power electronic controller to increase the acceleration factor. The method for calculating the experimental time based on the coolant flow time and the acceleration factor is to divide the coolant flow time by the acceleration factor to obtain the experimental time.

2. The method according to claim 1, characterized in that The circulation system further includes a liquid adding pipe and a T-shaped adapter, one end of the T-shaped adapter is connected to the liquid adding pipe, and the other two ends of the T-shaped adapter are perpendicular to the liquid adding pipe and connected to the circulating water pipe; The wear test method further includes: injecting the coolant mixed with molding sand and / or dust into the annular circulation channel through the liquid adding pipe to eliminate bubbles in the annular circulation channel; and performing a liquid addition judgment when the liquid level in the cooling water channel drops to a set threshold during the test, the liquid addition judgment including: If the reason for the drop in the liquid level is a coolant leakage, the coolant mixed with molding sand and / or dust is injected into the annular circulation channel through the liquid adding pipe to remove air bubbles from the annular circulation channel; If the reason for the drop in the liquid level is the evaporation of the coolant, deionized water is fed into the annular circulation channel through the liquid adding pipe to remove air bubbles from the annular circulation channel.

3. The method according to claim 1, characterized in that The ratio of the molding sand and / or dust and the flow rate of the coolant increase the wear efficiency in the acceleration factor, and the temperature of the temperature box and the type of the coolant increase the corrosion efficiency in the acceleration factor.

4. The method according to claim 1, wherein A plurality of the circulation systems are provided inside the temperature box, each of the circulation systems corresponds to one of the cooling water channels, and wear tests are performed on the plurality of cooling water channels at the same temperature at the same time.

5. The method according to claim 1, wherein The test system is communicatively connected to the electrical control cabinet and the host computer. When the wear test is performed, the voltage value of the water pump remains constant. After the electrical control cabinet receives the flow signal and time signal from the host computer, it controls the current of the water pump according to the flow signal and the time signal, and returns the actual flow value to the host computer for display and storage.

6. The method according to claim 1, characterized in that The cooling water channel is fixed in the temperature box, and the fixing direction is consistent with the direction of the cooling water channel in actual use; When the water pump drives the coolant to circulate in the annular circulation channel, the flow direction is consistent with the flow direction of the coolant in the cooling water channel during actual use.

7. The method according to claim 1, characterized in that The method further includes: searching for historical usage time records based on the model of the cooling water channel and the model of the power electronic controller, extracting actual service life, charging time and discharging time from the historical usage time records, and obtaining downtime by subtracting the charging time and the discharging time from the actual service life; A mapping table is searched according to the model of the cooling water channel and the model of the power electronic controller to obtain heat dissipation characteristics, and a ratio of the time during which the coolant keeps flowing during the downtime is determined according to the heat dissipation characteristics to obtain the standby time.

8. The method according to claim 1, characterized in that The method further includes searching for historical flow records based on the model of the cooling water channel and the model of the power electronic controller, extracting flow fluctuation characteristics from the historical flow records, and correcting the flow of the coolant in the acceleration factor based on the flow fluctuation characteristics.

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