Hot and cold shock test method for all-in-one driving motor system

Abstract

The invention discloses an all-in-one driving motor system cold and hot shock test method, and belongs to the technical field of automobile safety tests. A driving motor system is installed on a power assembly test bed, debugging is carried out, a communication network between a sample piece and a rack is matched, cold start and hot start are carried out according to test steps, and the two test working conditions are repeated for not less than 300 times. In the initial development stage of a driving motor system, the power assembly test bed is used for checking and verifying the limit cold and hot impact of a motor body, a motor controller and a speed reducer, meanwhile, the reliability and safety of control software at the limit high temperature and the limit low temperature are verified, the test period is shortened, and the product research and development progress is accelerated.

Description

Technical Field

[0001] The invention relates to a thermal shock test method for an all-in-one drive motor system, and belongs to the technical field of automobile motor testing. Background Art

[0002] New energy vehicles are developing rapidly, their market share continues to increase, and drive motor systems are being widely used. Currently, high integration has become the development trend of drive motor systems for electric vehicles. Drive motor systems are complex and varied in application scenarios, environmental and climatic conditions, and road conditions. This has put forward new requirements for the safety and reliability of drive motor systems in special operating conditions.

[0003] In regions with significant temperature differences between north and south, drive motor systems face both low- and high-temperature startup challenges, necessitating safety testing of the motor system in diverse environments. To simulate real-world road conditions and diverse environmental conditions within the laboratory, a test bench system with environmental transformation capabilities was required. Based on this test bench system, a comprehensive set of thermal shock test methods was developed to assess the reliability of the drive motor system throughout its lifecycle and ensure product quality. Summary of the Invention

[0004] In order to conduct safety tests on motor systems in different environments, the present invention provides an all-in-one hot and cold shock test method for a drive motor system. The method comprises the following steps:

[0005] A thermal shock test method for an all-in-one drive motor system is implemented based on the following test bench:

[0006] It includes a host computer and a test bench main control system, which control and connect the load dynamometer and the powertrain. The powertrain is placed in an environmental chamber. The powertrain includes a drive motor system and a reducer. The output end of the reducer is connected to the load dynamometer via a real vehicle half shaft.

[0007] Also included is a battery simulator, which provides electrical energy to the drive motor system;

[0008] Also included is a temperature control system, which provides refrigerant for the drive motor system;

[0009] On the test bench, the test is completed as follows:

[0010] S1, bench debugging, establishing the communication network between the drive motor system sample and the bench;

[0011] S2, set environmental conditions: the starting temperature of the environmental chamber is -40℃, and the starting temperature of the coolant is -20℃;

[0012] S3, setting the low-temperature cold start condition, the steps include:

[0013] First, adjust the speed of the drive motor system to the rated speed;

[0014] Then, the rated speed of the drive motor system is kept unchanged, and its torque is adjusted so that the torque goes from 0 to the positive peak, then from the positive peak to 0, then from 0 to the negative peak, and then from the negative peak to 0, and the above cycle is repeated multiple times;

[0015] S4, keep the speed of the drive motor system unchanged, adjust its torque to the positive peak value, and maintain the state until the motor winding temperature reaches 120°C;

[0016] S5, then adjust the drive motor system torque to 0, and adjust the drive motor system speed to 0;

[0017] S6, changing the environmental conditions, raising the temperature of the environmental chamber from -40°C to 85°C, and the temperature of the coolant from -20°C to 65°C;

[0018] S7, setting a high temperature hot start condition, the steps include:

[0019] First, adjust the speed of the drive motor system to the rated speed;

[0020] Then, the rated speed of the drive motor system is kept unchanged, and its torque is adjusted so that the torque goes from 0 to the positive peak, then from the positive peak to 0, then from 0 to the negative peak, and then from the negative peak to 0, and the above cycle is repeated multiple times;

[0021] S8, then keep the speed of the drive motor system unchanged, adjust its torque to the positive peak value, and maintain the state until the motor winding temperature reaches 120°C;

[0022] S9, then adjust the drive motor system torque to 0, and adjust the drive motor system speed to 0;

[0023] S10, repeat steps S2 to S9 multiple times to complete the test.

[0024] As mentioned above, the host computer and the test bench main control system are connected to the load dynamometer control through a communication harness, and are connected to the power motor system control through a CAN bus; the load dynamometer simulates two wheels to provide a full vehicle road simulation for the powertrain.

[0025] As described above, in the low-temperature cold start condition and the high-temperature hot start condition, the duration of each torque change stage is 0.5s; and the low-temperature cold start cycle condition is set to more than 30 times, and the high-temperature cold start cycle condition is set to more than 10 times.

[0026] Compared with other test methods, the present invention has the following main advantages:

[0027] The present invention simultaneously performs thermal shock tests on the motor body, motor controller, reducer and other control units, which is an all-in-one system test;

[0028] If the present invention sets the test number to be no less than 300 times, it is equivalent to conducting 100,000 cold and hot start tests on the vehicle during its life cycle.

[0029] Compared with using a complete vehicle to perform cold and hot starting of a real vehicle, the present invention can be completed on a test bench system without the need for a driver, thereby improving the safety of the test;

[0030] The present invention can be carried out on the test bench 24 hours a day, greatly shortening the test cycle and accelerating the progress of product development;

[0031] Compared with conducting cold and hot start tests on a real vehicle, the present invention saves a lot of manpower, material resources and financial resources;

[0032] The present invention conducts extreme thermal shock tests on both software and hardware, and verifies the reliability and safety of the control software under extreme high and low temperatures. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a structural diagram of the all-in-one drive motor system test bench of the present invention;

[0034] Figure 2 It is a flow chart of the present invention;

[0035] Figure 3 This is a diagram showing the temperature change settings for the environmental chamber and water cooling system of the present invention;

[0036] Figure 4 This is the torque setting diagram for the cold and hot starting operating conditions of the present invention. DETAILED DESCRIPTION

[0037] The present invention is described in detail below with reference to the accompanying drawings and embodiments. However, those skilled in the art should know that the following embodiments are not the only limitations on the technical solutions of the present invention, and any equivalent transformations or modifications made within the spirit of the technical solutions of the present invention should be deemed to fall within the scope of protection of the present invention.

[0038] Figure 1 The present invention provides an all-in-one drive motor system test bench. In this embodiment, the all-in-one drive motor system test bench includes: a host computer and a bench main control system 1, a load dynamometer 2, a drive motor system 3, a reducer 4, a battery simulator 5, a temperature control system 6, a half-axle 7, various wiring harnesses (including a communication wiring harness 8, a CAN bus 9, and a high-voltage power line 10), a temperature control pipeline 11, and an environmental chamber 12.

[0039] The host computer and the test bench main control system 1 control the load dynamometer 2 through the communication harness 8 and control the powertrain through the CAN bus 9.

[0040] The drive motor system 3 and reducer 4 form the powertrain, which is installed on a test bench. An environmental chamber 12 provides the required environmental conditions for the entire powertrain test. The output of the powertrain reducer is connected to the test bench's two load dynamometers 2 via a real vehicle half-axle 7. The load dynamometers 2 simulate two wheels, providing full vehicle road simulation for the powertrain.

[0041] The battery simulator 5 is connected to the drive motor system 3 via a high-voltage power line 10 to provide electrical energy to the drive motor system 3 and absorb the electrical energy generated by the drive motor system 3.

[0042] The temperature control system 6 is connected to the drive motor system 3 through the temperature control pipeline 11 to provide it with refrigerant and control its internal temperature.

[0043] During the test, the host computer and the test bench main control system 1 control the load dynamometer 2 and powertrain via a communication harness and CAN bus, ensuring the entire powertrain operates according to the test procedures. The battery simulator 5 provides power to the drive motor system 3, and the temperature control system 6 provides temperature control for the test environment.

[0044] The test object of the present invention is an all-in-one drive motor system (including a motor body, a motor controller, and a reducer). During the test, the test bench is debugged to the optimal state. Figure 2 Complete the following test steps in the order shown:

[0045] S1, bench debugging, establishing a communication network between the sample and the bench: Install the all-in-one drive motor system on the powertrain test bench, connect the high-voltage wiring harness and the low-voltage wiring harness, and establish communication between the drive motor system and the bench through the CAN protocol.

[0046] S2, set the environmental conditions: set the starting temperature of the environmental chamber to -40℃ and the starting temperature of the coolant to -20℃. Figure 3 shown.

[0047] S3, set the low temperature cold start condition, such as Figure 4 As shown, the steps include:

[0048] Step 3.1: Adjust the speed of the drive motor system to the rated speed;

[0049] Step 3.2: Keep the speed of the drive motor system constant and adjust its torque so that the torque changes from 0 to the positive peak value in 0.5s;

[0050] Step 3.3: Keep the speed of the drive motor system constant and adjust its torque so that the torque changes from the positive peak to 0 in 0.5s.

[0051] Step 3.4: Keep the speed of the drive motor system unchanged and adjust its torque so that the torque changes from 0 to the negative peak in 0.5s;

[0052] Step 3.5: Keep the speed of the drive motor system unchanged, and then adjust its torque so that the torque changes from the negative peak to 0 in 0.5s.

[0053] Repeat steps 3.2 to 3.5 at least 30 times.

[0054] S4, maintain the motion state of the sample: keep the speed of the drive motor system unchanged, adjust its torque to the positive peak, and then maintain the state until the motor winding temperature reaches 120℃.

[0055] S5, adjust the motion state of the sample: first adjust the torque of the drive motor system to 0, and then adjust the speed of the drive motor system to 0.

[0056] S6, environmental condition change: increase the environmental box temperature from -40℃ to 85℃, and the coolant temperature from -20℃ to 65℃. Figure 3 shown.

[0057] S7, set the high temperature hot start condition, such as Figure 4 As shown:

[0058] Step 7.1: Adjust the speed of the drive motor system to the rated speed;

[0059] Step 7.2: Keep the speed of the drive motor system constant and adjust its torque so that the torque changes from 0 to the positive peak value in 0.5s;

[0060] Step 7.3: Keep the speed of the drive motor system constant and adjust its torque so that the torque changes from the positive peak to 0 in 0.5s.

[0061] Step 7.4: Keep the speed of the drive motor system constant and adjust its torque so that the torque changes from 0 to the negative peak in 0.5s;

[0062] Step 7.5: Keep the speed of the drive motor system unchanged, and then adjust its torque so that the torque changes from the negative peak to 0 in 0.5s.

[0063] Repeat steps 7.2 to 7.5 at least 10 times.

[0064] S8, then maintain the sample's motion state: keep the drive motor system's speed unchanged, adjust its torque to the positive peak value, and then maintain the state until the motor winding temperature reaches 120°C.

[0065] S9, then adjust the motion state of the sample: first adjust the torque of the drive motor system to 0, and then adjust the speed of the drive motor system to 0.

[0066] S10, repeat S2-S9 at least 300 times.

[0067] After the operating test, the drive motor system was removed from the test bench for disassembly analysis, focusing on the damage to the motor components during alternating cycles of positive and negative peak torques in high and low temperature environments. This invention subjected the motor system to a cold and hot dual shock cycle test, equivalent to 100,000 cold and hot start tests over the vehicle's lifecycle, verifying its reliability and safety in extreme high and low temperature environments.

Claims

1. A thermal shock test method for an all-in-one drive motor system, characterized in that: This is based on the following test bench: It includes a host computer and a test bench main control system, which control and connect the load dynamometer and the powertrain. The powertrain is placed in an environmental chamber. The powertrain includes a drive motor system and a reducer. The output end of the reducer is connected to the load dynamometer via a real vehicle half shaft. Also included is a battery simulator, which provides electrical energy to the drive motor system; Also included is a temperature control system, which provides refrigerant for the drive motor system; On the test bench, the test is completed as follows: S1, bench debugging, establishing the communication network between the drive motor system sample and the bench; S2, set environmental conditions: the starting temperature of the environmental chamber is -40℃, and the starting temperature of the coolant is -20℃; S3, setting the low-temperature cold start condition, the steps include: First, adjust the speed of the drive motor system to the rated speed; Then, the rated speed of the drive motor system is kept unchanged, and its torque is adjusted so that the torque goes from 0 to the positive peak, then from the positive peak to 0, then from 0 to the negative peak, and then from the negative peak to 0, and the above cycle is repeated multiple times; S4, keep the speed of the drive motor system unchanged, adjust its torque to the positive peak value, and maintain the state until the motor winding temperature reaches 120°C; S5, then adjust the drive motor system torque to 0, and adjust the drive motor system speed to 0; S6, changing the environmental conditions, raising the temperature of the environmental chamber from -40°C to 85°C, and the temperature of the coolant from -20°C to 65°C; S7, setting a high temperature hot start condition, the steps include: First, adjust the speed of the drive motor system to the rated speed; Then, the rated speed of the drive motor system is kept unchanged, and its torque is adjusted so that the torque goes from 0 to the positive peak, then from the positive peak to 0, then from 0 to the negative peak, and then from the negative peak to 0, and the above cycle is repeated multiple times; S8, then keep the speed of the drive motor system unchanged, adjust its torque to the positive peak value, and maintain the state until the motor winding temperature reaches 120°C; S9, then adjust the drive motor system torque to 0, and adjust the drive motor system speed to 0; S10, repeat steps S2 to S9 multiple times to complete the test.

2. The thermal shock test method for an all-in-one drive motor system according to claim 1, characterized in that: The host computer and the test bench main control system are connected to the load dynamometer control via a communication harness, and are connected to the power motor system control via a CAN bus; the load dynamometer simulates two wheels to provide a full vehicle road simulation for the powertrain.

3. The thermal shock test method for an all-in-one drive motor system according to claim 1, characterized in that: In low-temperature cold start conditions and high-temperature hot start conditions, the duration of each torque change phase is 0.5s; The low-temperature cold start cycle condition is set to more than 30 times, and the high-temperature cold start cycle condition is set to more than 10 times.

Images