Off-line test detection method for pure electric all-in-one controller assembly

Abstract

The invention discloses an off-line test detection method for a pure electric all-in-one controller assembly. The off-line test detection method comprises the following steps: step 1) detecting CAN communication of the pure electric all-in-one controller assembly; 2) detecting a software version number and a hardware version number of the pure electric all-in-one controller assembly; 3) detecting the low-voltage test of the pure electric all-in-one controller assembly; the performance of the pure electric all-in-one controller assembly can be objectively evaluated in the off-line detection stage of the pure electric all-in-one controller assembly, unqualified products are effectively intercepted in combination with the actual situation of the whole vehicle, and the reliability of the products is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicle controller assembly production, and in particular to a method for offline testing of a pure electric all-in-one controller assembly. Background Art

[0002] With the development of new energy vehicles, all-in-one controller assemblies (ECUs) have become widely used in these vehicles due to their compact structure and high level of software and hardware integration. As a crucial component of the vehicle's powertrain, these ECUs primarily consist of modules such as the power control system (OBC) (for DC / DC output and DC / AC output), the central control system (IPU), and a high-voltage DC input. With the increasing number of all-in-one controller assemblies in new energy vehicles, ensuring their reliability has become a critical issue for both the ride and safety of these vehicles.

[0003] The main problems with all-in-one pure electric controller assemblies in vehicles include unstable current output calibration, which can easily lead to failure of the controller to control the motor, thus causing certain safety issues. End-of-line testing of all-in-one pure electric controller assemblies is an effective way to manage these problems. It can conduct targeted and effective end-of-line testing of products. Having reliable and reasonable end-of-line testing methods to monitor product quality will also enhance the market competitiveness of corporate products and the overall strength of the company. However, the existing technology for end-of-line testing of all-in-one pure electric controller assemblies is not comprehensive enough, which can easily lead to control failure when installed in the vehicle, reducing product reliability. Summary of the Invention

[0004] In view of the above-mentioned deficiencies in the prior art, the technical problem to be solved by the present invention is: how to provide a method for offline testing of a pure electric all-in-one controller assembly that can perform more comprehensive testing on the pure electric all-in-one controller assembly, reduce the probability of control failure, and greatly improve product reliability.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions: A method for testing an off-line all-in-one controller assembly for a pure electric vehicle comprises the following steps: Step 1) Check the CAN communication of the all-in-one electric vehicle controller assembly; Step 2) Check the software and hardware version numbers of the all-in-one electric vehicle controller assembly; Step 3) Perform low voltage test on the all-in-one electric controller assembly; Step 4) Check the current calibration of the all-in-one electric controller assembly.

[0006] Preferably, in step 1), according to the CAN communication protocol of the pure electric all-in-one controller assembly, a specific signal therein is used to detect whether the communication between the pure electric all-in-one controller assembly and the test bench is normal.

[0007] Preferably, in step 2), detection is performed based on the signal address location where the software version number and hardware version number of the pure electric all-in-one controller assembly are stored, and the signal address location where the software version number and hardware version number of the pure electric all-in-one controller assembly are stored is obtained in real time through CAN communication or through UDS instructions.

[0008] Preferably, step 3) includes the following steps: Step 3.1) Apply a low voltage to the DC bus of the all-in-one electric controller assembly, wait for a first set time, and then read the value of the corresponding information on the CAN; Step 3.2) Determine the low-voltage status value read on the CAN, where the low-voltage status value includes the DC bus voltage value, DC power supply voltage value, VoltageDiff value, FCT1_VoltVAUX value, FCT1_VoltVCORE value, FCT1_VoltVCCFZ value, the low-voltage value of controller K30 in the pure electric all-in-one controller assembly, the three-phase temperature value of the IGBT in the pure electric all-in-one controller assembly, the temperature value of the pure electric all-in-one controller assembly, the current operating current value of the pure electric all-in-one controller assembly, and the fault code of the current operating current value of the all-in-one controller assembly; Step 3.3) If any value in step 3.2) is not within the standard range, the low-voltage test of the pure electric all-in-one controller assembly is determined to have failed. If all values in step 3.2) are within the standard range, the low-voltage test of the pure electric all-in-one controller assembly is determined to have passed.

[0009] Preferably, in step 3.1), the low voltage given on the DC bus of the pure electric all-in-one controller assembly is 60V, and after waiting for 1 second, the value of the corresponding information on the CAN is read.

[0010] Preferably, in step 3.2), it is determined whether the DC bus voltage value read on the CAN is within the range of ±5V of the given voltage, whether the DC power supply voltage value is within the range of ±5V of the given voltage, whether the fluctuation of the VoltageDiff value is within 5V, whether the FCT1_VoltVAUX value is within the range of 4.5V to 5.5V, whether the FCT1_VoltVCORE value is within the range of 1.15V to 1.35V, and whether the FCT1_VoltVCCFZ value is within 14. Determine whether the low voltage value of controller K30 in the pure electric all-in-one controller assembly is within the range of 11V to 12.5V; determine whether the three-phase temperature value of the IGBT in the pure electric all-in-one controller assembly is within the range of 20℃ to 80℃; determine whether the temperature value of the pure electric all-in-one controller assembly is within the range of 20℃ to 105℃; determine whether the current operating current value of the pure electric all-in-one controller assembly is within the range of 0.3A to 0.4A; determine whether the fault code of the pure electric all-in-one controller assembly is 0; In step 3.3), if the result of any item in step 3.2) is no, it is determined that the low-voltage test of the pure electric all-in-one controller assembly has failed. If the results of all items in step 3.2) are yes, it is determined that the low-voltage test of the pure electric all-in-one controller assembly has passed.

[0011] Preferably, step 4) includes the following steps: Step 4.1) Apply a high voltage to the DC bus of the all-in-one electric controller assembly, wait for a second set time, read the voltage value, actual voltage value, and voltage fluctuation value on the CAN, and determine whether the voltage value, actual voltage value, and voltage fluctuation value on the CAN are within their respective set ranges; Step 4.2) The test bench sends UVW phase current calibration and automatic calibration enable signals to the all-in-one pure electric controller assembly, waits for the all-in-one pure electric controller assembly to return a calibration start signal, and then delays for a third set time. It then collects the U, V, and W currents output by the all-in-one pure electric controller assembly and calculates their average values. Step 4.3) Determine whether the average current values of the U, V, and W items output by the all-in-one pure electric controller assembly obtained in step 4.2) are within the standard range; Step 4.4) When the average current value of a certain item exceeds the current setting value, determine whether the difference between the average current value of the current item and the average current values of the other two items is within the setting range; Step 4.5) Write the set current value to the all-in-one pure electric controller assembly, wait for a certain period of time, and then reinitialize; Step 4.6) Repeat steps 2) to 5) for the set number of times, then re-initialize. After a certain period of time, read the feedback signals on the CAN of the all-in-one electric vehicle controller assembly: current calibration status, UVW phase current sensor gain values, UVW phase current sensor offset values, and V phase fault code. Determine whether the current calibration status, UVW phase current sensor gain values, UVW phase current sensor offset values, and V phase fault code are within their respective set ranges. Step 4.7) Reset the enable request signal value. After waiting for a certain period of time, the pure electric all-in-one controller assembly will lower the high voltage. After exiting the mode request, the pure electric all-in-one controller assembly will lower the low voltage.

[0012] Preferably, in step 4.1), a high voltage of 130V is given on the DC bus of the pure electric all-in-one controller assembly. After waiting for 2 seconds, the voltage value, actual voltage value and voltage fluctuation value on the CAN are read, and it is determined whether the voltage value on the CAN is within the range of 120-140V, whether the actual voltage value is within the range of 120-140V, and whether the voltage fluctuation value is within the range of 5V.

[0013] Preferably, in step 4.3), it is determined whether the average current of the U item, the V item, and the W item output by the all-in-one pure electric controller assembly obtained in step 4.2) is within the range of 120-350A; In step 4.4), when the average current value of a certain item exceeds the current setting value, it is determined whether the difference obtained by subtracting the average current value of the other two items from the average current value of the current item is within 3A.

[0014] Preferably, in step 4.6), after repeating steps 2) to 5) 4 times, initialize again, wait for a certain period of time, read the feedback signal on the CAN of the pure electric all-in-one controller assembly: current calibration status, UVW phase current sensor gain value, UVW phase current sensor offset value and V phase fault code, and determine whether the current calibration status is 1, whether the UVW phase current sensor gain value is within the range of 0.95-1.05A, whether the UVW phase current sensor offset value is within the range of (-10)-10, and whether the V phase fault code is 0.

[0015] Compared with the existing technology, the present invention can objectively evaluate the performance of the pure electric all-in-one controller assembly during the off-line inspection stage of the pure electric all-in-one controller assembly, and effectively intercept unqualified products based on the actual situation of the vehicle, thereby improving the reliability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Attachment Figure 1 The figure is a flow chart of the off-line testing method for a pure electric all-in-one controller assembly according to the present invention. DETAILED DESCRIPTION

[0017] 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 part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings herein can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0018] Problems often exposed by all-in-one pure electric vehicle controller assemblies that fail to meet end-of-line standards include: sensor feedback values exceeding the range during low-voltage testing, current values falling outside the calibration range or failing calibration, and fault codes appearing during testing. Table 1 lists the indicators that should be tested, along with their corresponding functions, based on the controller assembly model and its performance in the vehicle.

[0019] Table 1: Off-line test indicators for the pure electric all-in-one controller assembly off-line test bench In order to meet the off-line detection requirements of the above-mentioned pure electric all-in-one controller assembly, a pure electric all-in-one controller assembly off-line test method is provided in this specific embodiment, as shown in the attached figure. Figure 1 As shown, the following steps are included: Step 1) Check the CAN communication of the all-in-one electric controller assembly.

[0020] Based on the CAN communication protocol of the all-electric all-in-one controller assembly, specific signals are used to verify whether the all-electric all-in-one controller assembly and the test bench are communicating properly. Specifically, the Counter and Check_Sum signals in the 1A4 frame on the CAN are used to verify and verify whether the all-electric all-in-one controller assembly and the test bench are communicating properly.

[0021] Step 2) Check the software and hardware version numbers of the all-in-one electric vehicle controller assembly.

[0022] Specifically, detection is performed based on the signal address location where the software version number and hardware version number of the pure electric all-in-one controller assembly are stored, and the signal address location where the software version number and hardware version number of the pure electric all-in-one controller assembly are stored is obtained in real time through CAN communication or through UDS instructions.

[0023] Step 3) Perform low voltage test on the all-in-one electric controller assembly.

[0024] Step 3.1) Apply a low voltage to the DC bus of the all-electric all-in-one controller assembly, wait for a first set time, and then read the value of the corresponding information on the CAN. Specifically, apply a low voltage of 60V to the DC bus of the all-electric all-in-one controller assembly, wait for 1 second, and then read the value of the corresponding information on the CAN.

[0025] Step 3.2) Determine the low-voltage status value read on the CAN, where the low-voltage status value includes the DC bus voltage value, DC power supply voltage value, VoltageDiff (voltage difference detection) value, FCT1_VoltVAUX (auxiliary power supply voltage detection) value, FCT1_VoltVCORE (core operating voltage detection) value, FCT1_VoltVCCFZ (frozen state voltage detection) value, the low-voltage value of the controller K30 in the pure electric all-in-one controller assembly, the three-phase temperature value of the IGBT in the pure electric all-in-one controller assembly, the temperature value of the pure electric all-in-one controller assembly, the current operating current value of the pure electric all-in-one controller assembly, and the fault code of the current operating current value of the all-in-one controller assembly. Specifically, determine whether the DC bus voltage value read on CAN is within the given voltage ±5V range, determine whether the DC power supply voltage value is within the given voltage ±5V range, determine whether the fluctuation of VoltageDiff value is within 5V, determine whether the FCT1_VoltVAUX value is within the range of 4.5V to 5.5V, determine whether the FCT1_VoltVCORE value is within the range of 1.15V to 1.35V, determine whether the FCT1_VoltVCCFZ value is within the range of 14.5V to 1 6V, determine whether the low voltage value of controller K30 in the pure electric all-in-one controller assembly is within the range of 11V to 12.5V, determine whether the three-phase temperature value of IGBT in the pure electric all-in-one controller assembly is within the range of 20℃ to 80℃, determine whether the temperature value of the pure electric all-in-one controller assembly is within the range of 20℃ to 105℃, determine whether the current working current value of the pure electric all-in-one controller assembly is within the range of 0.3A to 0.4A, and determine whether the fault code of the pure electric all-in-one controller assembly is 0.

[0026] In step 3.3), if any value in step 3.2) is outside the standard range, the low-voltage test for the all-electric all-in-one controller assembly is deemed to have failed. If all values in step 3.2) are within the standard range, the low-voltage test for the all-electric all-in-one controller assembly is deemed to have passed. Specifically, if any value in step 3.2) is negative, the low-voltage test for the all-electric all-in-one controller assembly is deemed to have failed. If all values in step 3.2) are positive, the low-voltage test for the all-electric all-in-one controller assembly is deemed to have passed.

[0027] Step 4) Check the current calibration of the all-in-one electric controller assembly.

[0028] Step 4.1) Apply a high voltage to the DC bus of the all-in-one electric controller assembly, wait for a second set time, read the voltage value, actual voltage value, and voltage fluctuation value on the CAN, and determine whether the voltage value, actual voltage value, and voltage fluctuation value on the CAN are within their respective set ranges; specifically, apply a high voltage of 130V to the DC bus of the all-in-one electric controller assembly, wait for 2 seconds, read the voltage value, actual voltage value, and voltage fluctuation value on the CAN, and determine whether the voltage value on the CAN is within the range of 120-140V, determine whether the actual voltage value is within the range of 120-140V, and determine whether the voltage fluctuation value is within the range of 5V.

[0029] Step 4.2) The test bench sends UVW phase current calibration and automatic calibration enable signals to the all-in-one pure electric controller assembly, waits for the all-in-one pure electric controller assembly to return a calibration start signal, and then delays for a third set time. The U, V, and W currents output by the all-in-one pure electric controller assembly are collected and the average value is calculated; specifically, the third set time is 3 seconds.

[0030] Step 4.3) Determine whether the average current of the U item, V item, and W item output by the pure electric all-in-one controller assembly obtained in step 4.2) is within the standard range; specifically, determine whether the average current of the U item, V item, and W item output by the pure electric all-in-one controller assembly obtained in step 4.2) is within the range of 120-350A.

[0031] Step 4.4) Determine whether the difference between the average current value of a certain item and the average current values of the other two items is within the set range after the average current value of the current item exceeds the set current value; specifically, determine whether the difference between the average current value of a certain item and the average current value of the other two items is within 3A after the average current value of the current item exceeds the set current value.

[0032] Step 4.5) Write the set current value into the all-in-one pure electric controller assembly, wait for a certain period of time (the time here can be reasonably selected according to the actual situation), and then reinitialize; Step 4.6) Repeat steps 2) to 5) for a set number of times, initialize again, wait for a certain period of time (the time here can be reasonably selected according to actual conditions), read the feedback signal on the CAN of the pure electric multi-in-one controller assembly: current calibration status, UVW phase current sensor gain value, UVW phase current sensor offset value and V phase fault code, and determine whether the current calibration status, UVW phase current sensor gain value, UVW phase current sensor offset value and V phase fault code are within their respective set ranges; specifically, repeat steps 2) to 5) 4 times, initialize again, wait for a certain period of time, read the feedback signal on the CAN of the pure electric multi-in-one controller assembly: current calibration status, UVW phase current sensor gain value, UVW phase current sensor offset value and V phase fault code, and determine whether the current calibration status is 1, whether the UVW phase current sensor gain value is within the range of 0.95-1.05A, whether the UVW phase current sensor offset value is within the range of (-10)-10, and whether the V phase fault code is 0.

[0033] Step 4.7) Reset the enable request signal value. After a certain period of time (this period can be selected based on actual conditions), the all-electric all-in-one controller assembly switches to high voltage. After the mode exit request, the all-electric all-in-one controller assembly switches to low voltage. Specifically, reset the enable request and other signal values. After a certain period of time, the high voltage is set to 24V. After the controller mode exit request is sent as 0, the low voltage is switched to low voltage, shutting down the power supply to K30 and K15.

[0034] Compared with the existing technology, the present invention can objectively evaluate the performance of the pure electric all-in-one controller assembly during the off-line inspection stage of the pure electric all-in-one controller assembly, and effectively intercept unqualified products based on the actual situation of the vehicle, thereby improving the reliability of the product.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit the technical solutions. Those skilled in the art should understand that modifications or equivalent replacements of the technical solutions of the present invention that do not depart from the purpose and scope of the technical solutions of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A method for testing an off-line all-in-one controller assembly for a pure electric vehicle, characterized in that: The following steps are involved: Step 1) Check the CAN communication of the all-in-one electric vehicle controller assembly; Step 2) Check the software and hardware version numbers of the all-in-one electric vehicle controller assembly; Step 3) Perform low voltage test on the all-in-one electric controller assembly; Step 4) Check the current calibration of the all-in-one electric controller assembly.

2. The off-line testing method for a pure electric all-in-one controller assembly according to claim 1 is characterized in that: In step 1), according to the CAN communication protocol of the pure electric all-in-one controller assembly, a specific signal therein is used to detect whether the communication between the pure electric all-in-one controller assembly and the test bench is normal.

3. The off-line testing method for a pure electric all-in-one controller assembly according to claim 1 is characterized in that: In step 2), detection is performed based on the signal address location where the software version number and hardware version number of the pure electric all-in-one controller assembly are stored, and the signal address location where the software version number and hardware version number of the pure electric all-in-one controller assembly are stored is obtained in real time through CAN communication or through UDS instructions.

4. The off-line testing method for a pure electric all-in-one controller assembly according to claim 1, characterized in that: Step 3) includes the following steps: Step 3.1) Apply a low voltage to the DC bus of the all-in-one electric controller assembly, wait for a first set time, and then read the value of the corresponding information on the CAN; Step 3.2) Determine the low-voltage status value read on the CAN, where the low-voltage status value includes the DC bus voltage value, DC power supply voltage value, VoltageDiff value, FCT1_VoltVAUX value, FCT1_VoltVCORE value, FCT1_VoltVCCFZ value, the low-voltage value of controller K30 in the pure electric all-in-one controller assembly, the three-phase temperature value of the IGBT in the pure electric all-in-one controller assembly, the temperature value of the pure electric all-in-one controller assembly, the current operating current value of the pure electric all-in-one controller assembly, and the fault code of the current operating current value of the all-in-one controller assembly; Step 3.3) If any value in step 3.2) is not within the standard range, the low-voltage test of the pure electric all-in-one controller assembly is determined to have failed. If all values in step 3.2) are within the standard range, the low-voltage test of the pure electric all-in-one controller assembly is determined to have passed.

5. The off-line testing method for a pure electric all-in-one controller assembly according to claim 4 is characterized in that: In step 3.1), the low voltage given on the DC bus of the pure electric all-in-one controller assembly is 60V. After waiting for 1 second, the value of the corresponding information on the CAN is read.

6. The off-line testing method for a pure electric all-in-one controller assembly according to claim 4 is characterized in that: In step 3.2), determine whether the DC bus voltage value read on the CAN is within the given voltage ±5V range, determine whether the DC power supply voltage value is within the given voltage ±5V range, determine whether the fluctuation of the VoltageDiff value is within 5V, determine whether the FCT1_VoltVAUX value is within the range of 4.5V to 5.5V, determine whether the FCT1_VoltVCORE value is within the range of 1.15V to 1.35V, and determine whether the FCT1_VoltVCCFZ value is within 14.5V. to 16V, determine whether the low voltage value of controller K30 in the pure electric all-in-one controller assembly is within the range of 11V to 12.5V, determine whether the three-phase temperature value of the IGBT in the pure electric all-in-one controller assembly is within the range of 20℃ to 80℃, determine whether the temperature value of the pure electric all-in-one controller assembly is within the range of 20℃ to 105℃, determine whether the current operating current value of the pure electric all-in-one controller assembly is within the range of 0.3A to 0.4A, and determine whether the fault code of the pure electric all-in-one controller assembly is 0; In step 3.3), if the result of any item in step 3.2) is no, it is determined that the low-voltage test of the pure electric all-in-one controller assembly has failed. If the results of all items in step 3.2) are yes, it is determined that the low-voltage test of the pure electric all-in-one controller assembly has passed.

7. The off-line testing method for a pure electric all-in-one controller assembly according to claim 1, characterized in that: Step 4) includes the following steps: Step 4.1) Apply a high voltage to the DC bus of the all-in-one electric controller assembly, wait for a second set time, read the voltage value, actual voltage value, and voltage fluctuation value on the CAN, and determine whether the voltage value, actual voltage value, and voltage fluctuation value on the CAN are within their respective set ranges; Step 4.2) The test bench sends UVW phase current calibration and automatic calibration enable signals to the all-in-one pure electric controller assembly, waits for the all-in-one pure electric controller assembly to return a calibration start signal, and then delays for a third set time. It then collects the U, V, and W currents output by the all-in-one pure electric controller assembly and calculates their average values. Step 4.3) Determine whether the average current values of the U, V, and W items output by the all-in-one pure electric controller assembly obtained in step 4.2) are within the standard range; Step 4.4) When the average current value of a certain item exceeds the current setting value, determine whether the difference between the average current value of the current item and the average current values of the other two items is within the setting range; Step 4.5) Write the set current value to the all-in-one pure electric controller assembly, wait for a certain period of time, and then reinitialize; Step 4.6) Repeat steps 2) to 5) for the set number of times, then re-initialize. After a certain period of time, read the feedback signals on the CAN of the all-in-one electric vehicle controller assembly: current calibration status, UVW phase current sensor gain values, UVW phase current sensor offset values, and V phase fault code. Determine whether the current calibration status, UVW phase current sensor gain values, UVW phase current sensor offset values, and V phase fault code are within their respective set ranges. Step 4.7) Reset the enable request signal value. After waiting for a certain period of time, the pure electric all-in-one controller assembly will lower the high voltage. After exiting the mode request, the pure electric all-in-one controller assembly will lower the low voltage.

8. The off-line testing method for a pure electric all-in-one controller assembly according to claim 7, characterized in that: In step 4.1), apply a high voltage of 130V to the DC bus of the all-in-one electric controller assembly. After waiting for 2 seconds, read the voltage value, actual voltage value, and voltage fluctuation value on the CAN. Determine whether the voltage value on the CAN is within the range of 120-140V, whether the actual voltage value is within the range of 120-140V, and whether the voltage fluctuation value is within the range of 5V.

9. The off-line testing method for a pure electric all-in-one controller assembly according to claim 7, characterized in that: In step 4.3), determine whether the average current of the U, V, and W items output by the all-in-one pure electric controller assembly obtained in step 4.2) is within the range of 120-350A; In step 4.4), when the average current value of a certain item exceeds the current setting value, it is determined whether the difference obtained by subtracting the average current value of the other two items from the average current value of the current item is within 3A.

10. The off-line testing method for a pure electric all-in-one controller assembly according to claim 7, characterized in that: In step 4.6), repeat steps 2) to 5) 4 times, initialize again, wait for a certain period of time, read the feedback signal on the CAN of the pure electric multi-in-one controller assembly: current calibration status, UVW phase current sensor gain value, UVW phase current sensor offset value and V phase fault code, and determine whether the current calibration status is 1, whether the UVW phase current sensor gain value is within the range of 0.95-1.05A, whether the UVW phase current sensor offset value is within the range of (-10)-10, and whether the V phase fault code is 0.

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