Motor controller offline aging detection method

Abstract

The invention relates to the field of new energy automobile motor controller production, in particular to a motor controller offline aging detection method. Determining a detection time threshold value of off-line aging detection of the motor controller through a calibration test; a plurality of detection threshold values are set; the motor controller to be detected is installed in the detection equipment, multiple parameters of the motor controller are detected in real time within the detection time threshold value to obtain corresponding detection values, the detection values are compared with the corresponding detection threshold values, and whether the motor controller meets the requirement or not is judged. In the offline stage of a motor controller product, offline aging detection is carried out on the motor controller product, that is, when the motor controller is powered on for the first time and current output is carried out, a plurality of key parameters of the motor controller are detected, so that whether the controller has defects or not under the long-time working condition is tested; and early faults caused by product processes and elements are identified and eliminated, so that the working reliability and stability of the motor controller are effectively verified.

Description

Technical Field

[0001] The present invention relates to the field of production of motor controllers for new energy vehicles, and in particular to a method for detecting off-line aging of motor controllers. Background Art

[0002] In the field of new energy vehicles, the motor controller is a core component, and its stability and reliability play a vital role in the normal operation of the entire vehicle system. If the motor controller has defects before it is produced, resulting in unstable and unreliable performance, it will have serious negative effects on driving safety, vehicle performance, and after-sales costs. The specific manifestations are as follows: ① Driving safety: Defects in the motor controller can cause sudden power failures while the vehicle is in motion, resulting in power interruptions or abnormal output, making it impossible for the vehicle to adjust or maintain speed according to the driver's instructions. This can easily lead to rear-end collisions at high speeds. In complex road conditions, the vehicle may be unable to avoid obstacles in time, leading to serious collisions.

[0003] At the same time, defects in the motor controller may also cause the brake coordination function to fail, making it impossible for the vehicle to effectively coordinate energy recovery and mechanical braking during braking, resulting in a significant increase in braking distance and even brake locking, which in turn causes the vehicle to skid, drift, and other uncontrolled conditions, seriously threatening driving safety.

[0004] In addition, an unstable motor controller may transmit erroneous signals to other safety systems of the vehicle, causing key safety devices such as airbags and electronic stability control systems to be triggered incorrectly, or failing to work properly when needed in an emergency. This makes it impossible to provide the necessary safety protection for drivers and passengers at critical moments, greatly increasing the risk of casualties in accidents.

[0005] ② Vehicle Performance: Defects in the motor controller can cause abnormal vehicle power output, destabilizing the motor's torque and speed. This can lead to jerky acceleration and severe jerking, significantly reducing the driving experience and handling, and ultimately impacting the vehicle's reputation and competitiveness in the market. Furthermore, motor controller defects can disrupt energy management, leading to uncontrolled battery charge and discharge. This can cause the battery to overcharge or overdischarge, shortening its lifespan and significantly reducing the vehicle's range, impacting its usability and affordability.

[0006] ③ After-sales and Cost: Motor controller defects can lead to frequent vehicle failures, increasing the number and difficulty of repairs. This not only forces consumers to bear high repair costs and reduces customer satisfaction, but also imposes huge after-sales repair and recall costs on automakers. In the long run, this can damage brand image and affect a company's market position and sales performance.

[0007] In summary, the stability and reliability of motor controllers are crucial to the safe operation and performance of new energy vehicles, as well as the sustainable development of the company. Therefore, motor controllers are typically rigorously tested before they roll off the production line to verify that their performance, reliability, and stability meet requirements, ensuring product quality. Summary of the Invention

[0008] The present invention addresses the shortcomings of the prior art by providing a method for detecting end-of-line aging of motor controllers. This method performs end-of-line aging testing on motor controllers during their final production phase. When the motor controller is first powered on and outputting current, the method tests multiple aging test data points to verify whether the controller has defects after prolonged operation. This method identifies and eliminates early failures caused by product process and components, effectively verifying the operational reliability and stability of the motor controller.

[0009] The purpose of the present invention is to adopt the following scheme to achieve: A motor controller offline aging detection method comprises the following steps: 1) Use a temperature chamber to establish a calibration detection system that can determine whether the motor controller is aging, and use it to test the aging detection data of the motor controller under test; 2) During the calibration test, the calibration test system is used to determine the detection time threshold for the motor controller offline aging test and the aging detection threshold of the motor controller to be tested; 3) In the detection test, the motor controller to be tested is set in the calibration detection system, and an aging detection is performed on the motor controller to be tested within a detection time threshold to determine whether the motor controller to be tested is aged.

[0010] Preferably, the calibration detection system includes a high-voltage DC power supply, a low-voltage DC power supply, a host computer, a current acquisition module and a three-phase inductor, the high-voltage DC power supply serves as the power supply of the motor controller to be tested and is connected to the DC bus of the motor controller to be tested, and the low-voltage DC power supply serves as the working power supply of the motor controller to be tested and is connected to the low-voltage power input terminal of the motor controller to be tested; The three-phase input terminal of the current acquisition module is connected to the three-phase output terminal of the motor controller to be tested, and the three-phase output terminal of the current acquisition module is connected to the three-phase inductor for simulating the load motor; The host computer is connected to the high-voltage DC power supply, the motor controller to be tested and the current acquisition module through the CAN bus, and is used for real-time monitoring and collecting aging detection data of the motor controller to be tested to determine whether the motor controller to be tested is aging.

[0011] Preferably, in step 3), the motor controller to be tested is placed in a calibration detection system, and an aging detection is performed on the motor controller to be tested within a detection time threshold to determine whether the motor controller to be tested is aged, specifically including: 3-1) Place the motor controller to be tested in the temperature chamber of the calibration test system and set the internal temperature of the temperature chamber to within the equipment ambient temperature range; 3-2) Detect the aging test data of the motor controller under test at each moment; 3-3) Based on the aging test data obtained in step 3-2), record the maximum value of the aging test data of the motor controller to be tested; 3-4) Compare the maximum value of the aging detection data of the motor controller under test with the corresponding aging detection threshold value to determine whether the motor controller under test is aged.

[0012] Preferably, the aging detection data includes a U-phase current deviation value, the maximum value of the aging detection data includes a U-phase current deviation maximum value, and the aging detection threshold includes a U-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the U-phase current deviation with the U-phase current deviation threshold value. If the maximum value of the U-phase current deviation is not within the U-phase current deviation threshold range, the motor controller to be tested is aged.

[0013] Preferably, the aging detection data includes a V-phase current deviation value, the maximum value of the aging detection data includes a V-phase current deviation maximum value, and the aging detection threshold includes a V-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the V-phase current deviation with the V-phase current deviation threshold value. If the maximum value of the V-phase current deviation is not within the V-phase current deviation threshold range, the motor controller to be tested is aged.

[0014] Preferably, the aging detection data includes a W-phase current deviation value, the maximum value of the aging detection data includes a W-phase current deviation maximum value, and the aging detection threshold includes a W-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the W-phase current deviation with the W-phase current deviation threshold value. If the maximum value of the W-phase current deviation is not within the W-phase current deviation threshold range, the motor controller to be tested is aged.

[0015] Preferably, the aging detection data includes the cooling water temperature, the maximum value of the aging detection data includes the maximum cooling water temperature, and the aging detection threshold includes the cooling water temperature threshold. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum cooling water temperature with the cooling water temperature threshold. If the maximum cooling water temperature is not within the cooling water temperature threshold range, the motor controller to be tested is aged.

[0016] Preferably, the aging detection data includes cooling flow, the maximum value of the aging detection data includes the maximum cooling flow, and the aging detection threshold includes the cooling flow threshold. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the W-phase current deviation with the W-phase current deviation threshold. If the maximum cooling flow is not within the cooling flow threshold range, the motor controller to be tested is aged.

[0017] Preferably, in step 3-4), determining whether the motor controller to be tested is aged further includes determining whether the host computer receives a fault code from the motor controller to be tested via the CAN bus. If a fault code is received, the motor controller to be tested is aged.

[0018] The present invention has the following beneficial effects: A motor controller offline aging detection method comprises the following steps: 1) Use a temperature chamber to establish a calibration detection system that can determine whether the motor controller is aging, and use it to test the aging detection data of the motor controller under test; 2) During the calibration test, the calibration test system is used to determine the detection time threshold for the motor controller offline aging test and the aging detection threshold of the motor controller to be tested; 3) In the detection test, the motor controller to be tested is set in the calibration detection system, and an aging detection is performed on the motor controller to be tested within a detection time threshold to determine whether the motor controller to be tested is aged.

[0019] The present invention performs real-time detection and judgment on the aging detection data of the motor controller to be tested within the detection time threshold, thereby testing whether the motor controller to be tested off the production line has defects under long-term operation. It can effectively identify and eliminate early failures caused by product processes and components, and further effectively verify the working reliability and stability of the motor controller to be tested.

[0020] Preferably, the calibration detection system includes a high-voltage DC power supply, a low-voltage DC power supply, a host computer, a current acquisition module and a three-phase inductor, the high-voltage DC power supply serves as the power supply of the motor controller to be tested and is connected to the DC bus of the motor controller to be tested, and the low-voltage DC power supply serves as the working power supply of the motor controller to be tested and is connected to the low-voltage power input terminal of the motor controller to be tested; The three-phase input terminal of the current acquisition module is connected to the three-phase output terminal of the motor controller to be tested, and the three-phase output terminal of the current acquisition module is connected to the three-phase inductor for simulating the load motor; The host computer is connected to the high-voltage DC power supply, the motor controller to be tested and the current acquisition module through the CAN bus, and is used for real-time monitoring and collecting aging detection data of the motor controller to be tested to determine whether the motor controller to be tested is aging.

[0021] The detection equipment of the present invention simulates the inductance characteristics of the motor by setting a three-phase inductor to simulate the load of the motor controller, effectively saving electricity, while avoiding mechanical loss, heat generation and other problems during the operation of the real motor, and simplifying the testing process.

[0022] Preferably, in step 3), the motor controller to be tested is placed in a calibration detection system, and an aging detection is performed on the motor controller to be tested within a detection time threshold to determine whether the motor controller to be tested is aged, specifically including: 3-1) Place the motor controller to be tested in the temperature chamber of the calibration test system and set the internal temperature of the temperature chamber to within the equipment ambient temperature range; 3-2) Detect the aging test data of the motor controller under test at each moment; 3-3) Based on the aging test data obtained in step 3-2), record the maximum value of the aging test data of the motor controller to be tested; 3-4) Compare the maximum value of the aging detection data of the motor controller under test with the corresponding aging detection threshold value to determine whether the motor controller under test is aged.

[0023] The present invention simulates the actual operating environment of the motor controller so that the obtained aging detection data can better reflect the status of the motor controller in actual operation, avoiding the problem of inaccurate detection results due to the large difference between the detection environment and the actual operating environment. By detecting the aging detection data of the motor controller to be tested at various moments and recording the maximum value of the aging detection data of the motor controller to be tested, the performance changes of the motor controller at different time stages are fully understood, reflecting the extreme cases of performance degradation or problems of the motor controller during the aging process, thereby ensuring the effectiveness and reliability of the detection.

[0024] Preferably, the aging detection data includes a U-phase current deviation value, the maximum value of the aging detection data includes a U-phase current deviation maximum value, and the aging detection threshold includes a U-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the U-phase current deviation with the U-phase current deviation threshold value. If the maximum value of the U-phase current deviation is not within the U-phase current deviation threshold range, the motor controller to be tested is aged.

[0025] Preferably, the aging detection data includes a V-phase current deviation value, the maximum value of the aging detection data includes a V-phase current deviation maximum value, and the aging detection threshold includes a V-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the V-phase current deviation with the V-phase current deviation threshold value. If the maximum value of the V-phase current deviation is not within the V-phase current deviation threshold range, the motor controller to be tested is aged.

[0026] Preferably, the aging detection data includes a W-phase current deviation value, the maximum value of the aging detection data includes a W-phase current deviation maximum value, and the aging detection threshold includes a W-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the W-phase current deviation with the W-phase current deviation threshold value. If the maximum value of the W-phase current deviation is not within the W-phase current deviation threshold range, the motor controller to be tested is aged.

[0027] Preferably, the aging detection data includes the cooling water temperature, the maximum value of the aging detection data includes the maximum cooling water temperature, and the aging detection threshold includes the cooling water temperature threshold. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum cooling water temperature with the cooling water temperature threshold. If the maximum cooling water temperature is not within the cooling water temperature threshold range, the motor controller to be tested is aged.

[0028] Preferably, the aging detection data includes cooling flow, the maximum value of the aging detection data includes the maximum cooling flow, and the aging detection threshold includes the cooling flow threshold. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the W-phase current deviation with the W-phase current deviation threshold. If the maximum cooling flow is not within the cooling flow threshold range, the motor controller to be tested is aged.

[0029] The present invention sets multiple aging detection thresholds to cover the key performance indicators in the operation of the motor controller, independently evaluates different aging detection data of the motor controller, avoids misjudgment caused by a single indicator, comprehensively and accurately evaluates the performance of the motor controller, and effectively ensures the comprehensiveness and accuracy of the test results.

[0030] Preferably, in step 3-4), determining whether the motor controller to be tested is aged further includes determining whether the host computer receives a fault code from the motor controller to be tested via the CAN bus. If a fault code is received, the motor controller to be tested is aged.

[0031] The present invention judges the overall operating status and fault condition of the motor controller based on whether a fault code appears within a detection time threshold, and further comprehensively evaluates the performance and reliability of the motor controller to be tested to ensure that it meets design requirements and actual application needs.

[0032] Glossary Incubator: An incubator is a device that can artificially control and maintain a specific temperature environment. It can also be called a constant temperature box, incubator, etc. It is often used in experiments, production or storage processes that require stable temperature conditions.

[0033] Power supply: In this application, the power supply of the motor controller actually refers to the key energy source that provides power to the motor. It provides driving energy for the motor to generate mechanical movement.

[0034] Working power supply: In this application, the working power supply of the motor controller is actually the key part to ensure the normal operation of the motor controller. The control circuit of the motor controller provides the necessary power so that the microprocessor can run the control algorithm normally and accurately control the motor's speed, torque and other parameters.

[0035] End-of-line aging testing: In this application, it refers to a testing method in which the product (motor controller) is placed in a system that simulates the actual operating environment at the end of production to check whether the product has defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Schematic diagram of the detection equipment of the present invention. DETAILED DESCRIPTION

[0037] like Figure 1 As shown, a motor controller offline aging detection method is characterized by comprising the following steps: 1) Use a temperature chamber to establish a calibration detection system that can determine whether the motor controller is aging, and use it to test the aging detection data of the motor controller under test; The calibration detection system includes a high-voltage DC power supply, a low-voltage DC power supply, a host computer, a current acquisition module and a three-phase inductor, wherein the high-voltage DC power supply serves as a power supply for the motor controller to be tested and is connected to the DC bus of the motor controller to be tested, and the low-voltage DC power supply serves as a working power supply for the motor controller to be tested and is connected to the low-voltage power input terminal of the motor controller to be tested; The three-phase input terminal of the current acquisition module is connected to the three-phase output terminal of the motor controller to be tested, and the three-phase output terminal of the current acquisition module is connected to the three-phase inductor for simulating the load motor; The host computer is connected to the high-voltage DC power supply, the motor controller to be tested and the current acquisition module through the CAN bus, and is used for real-time monitoring and collecting aging detection data of the motor controller to be tested to determine whether the motor controller to be tested is aging.

[0038] Specifically, the host computer sends control signals via the CAN bus, thereby driving the high-voltage DC power supply. Once operational, the high-voltage DC power supply prompts the motor controller to output three-phase currents: U, V, and W. The current acquisition module is connected to the three-phase output terminals of the motor controller under test. The current acquisition card independently acquires the U, V, and W phase currents and transmits the acquired three-phase current data to the host computer. The host computer performs logical processing on this data, calculating the deviation between the acquired value and the theoretical value or set value. This deviation is then compared with a pre-set three-phase current deviation threshold to assess the current output performance of the motor controller.

[0039] A three-phase inductor is connected to the current output of the motor controller to simulate the motor's load characteristics. As an energy storage element, the inductor has unique electrical properties, allowing energy to be exchanged between the inductor and the power supply without being substantially consumed. This means that by using a three-phase inductor as the load, the present invention can effectively avoid the high-power energy consumption associated with real motor operation, thereby saving electricity. At the same time, it can avoid complex conditions such as mechanical loss and heat generation that occur during real motor operation, greatly simplifying the test process and improving test efficiency and stability.

[0040] 2) During the calibration test, the calibration test system is used to determine the detection time threshold for the motor controller offline aging test and the aging detection threshold of the motor controller to be tested; Based on the calibration test results, a detection time threshold for the motor controller offline aging test is determined, ensuring that potential defects are effectively exposed during the motor controller offline aging test while also taking into account test efficiency. In the embodiment of the present invention, the detection time threshold is 4 hours. If this time is exceeded, the test efficiency is low and no further problems are exposed.

[0041] The aging detection thresholds include the U-phase current deviation threshold, the V-phase current deviation threshold, the W-phase current deviation threshold, the cooling water temperature threshold, and the cooling flow rate threshold. Typically, the U-phase current deviation threshold, the V-phase current deviation threshold, and the W-phase current deviation threshold are set according to industry standards to ensure that the product complies with relevant standards and meets market access conditions. In an embodiment of the present invention, the U-phase current deviation threshold is 3% of the rated / peak current of the corresponding motor U-phase, the V-phase current deviation threshold is 3% of the rated / peak current of the corresponding motor V-phase, and the W-phase current deviation threshold is 3% of the rated / peak current of the corresponding motor W-phase; 3) During the test, the motor controller to be tested is placed in the calibration test system, and within the test time threshold, an aging test is performed on the motor controller to determine whether the motor controller to be tested is aged. Specifically, the following steps are performed: 3-1) Place the motor controller to be tested in the temperature chamber of the calibration test system and set the internal temperature of the temperature chamber to within the equipment ambient temperature range; During the end-of-line aging test of a motor controller, placing the motor controller under test in an incubator for testing can more realistically simulate the operating conditions of the motor controller in actual application scenarios such as vehicles, making the test results more valuable for reference. The present invention monitors the incubator temperature in real time to ensure that the incubator temperature remains within the set equipment ambient temperature range throughout the entire test time threshold, thereby more accurately reflecting the reliability and stability of the motor controller in actual use. In this embodiment of the present invention, the equipment ambient temperature range is 85±5°C.

[0042] 3-2) Detect the aging test data of the motor controller under test at each moment; Aging test data includes the U-phase current deviation value, V-phase current deviation value, W-phase current deviation value, cooling water temperature, and cooling flow rate. The U-phase current deviation value, V-phase current deviation value, and W-phase current deviation value refer to the difference between the actual measured values ​​and the theoretical values ​​or set values ​​of the motor controller's U-phase current, V-phase current, and W-phase current; the cooling water temperature specifically refers to the cooling water temperature of the motor controller; and the cooling flow rate specifically refers to the cooling flow rate of the motor controller.

[0043] 3-3) Based on the aging test data obtained in step 3-2), record the maximum value of the aging test data of the motor controller to be tested; Within a detection time threshold, the aging detection data of the motor controller under test at each moment are compared to obtain a maximum aging detection data. The maximum aging detection data includes a maximum U-phase current deviation, a maximum V-phase current deviation, a maximum W-phase current deviation, a maximum cooling water temperature, and a maximum cooling flow rate.

[0044] 3-4) Compare the maximum value of the aging detection data of the motor controller to be tested with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged. The specific method is as follows: 3-4-1) Compare the maximum U-phase current deviation with the U-phase current deviation threshold. If the maximum U-phase current deviation is not within the U-phase current deviation threshold (i.e., 3% of the motor's U-phase rated / peak current), the motor controller under test is aging.

[0045] 3-4-2) Compare the maximum V-phase current deviation with the V-phase current deviation threshold. If the maximum V-phase current deviation is not within the V-phase current deviation threshold (i.e., 3% of the motor's V-phase rated / peak current), the motor controller under test is aging.

[0046] 3-4-3) Compare the maximum W-phase current deviation with the W-phase current deviation threshold. If the maximum W-phase current deviation is not within the W-phase current deviation threshold (i.e., 3% of the motor's W-phase rated / peak current), the motor controller under test is aging.

[0047] The three-phase current output deviation of a motor controller is a key indicator of its control accuracy. Keeping the three-phase current deviation within a reasonable range ensures accurate current regulation and stable motor operation. Ideally, the motor controller should output highly balanced three-phase current. Imbalanced three-phase current significantly increases motor losses and reduces efficiency. Excessively large deviations can also lead to unstable motor operation, increased vibration, and increased noise, severely impacting motor performance and service life.

[0048] Therefore, the present invention detects the U-phase current deviation value, the V-phase current deviation value, and the W-phase current deviation value, and compares them with the corresponding U-phase current threshold value, the V-phase current threshold value, and the W-phase current threshold value, respectively, to ensure that the output current of the motor controller is smooth, the operation is stable, and it meets the standards.

[0049] 3-4-4) Compare the maximum cooling water temperature with the cooling water temperature threshold. If the maximum cooling water temperature is not within the cooling water temperature threshold, the motor controller under test is aged.

[0050] 3-4-5) Compare the maximum W-phase current deviation with the W-phase current deviation threshold. If the maximum cooling flow rate is not within the cooling flow rate threshold, the motor controller under test is aged.

[0051] The motor controller will generate a large amount of heat during operation, and it needs to rely on the cooling system to dissipate the heat in time. The cooling water temperature directly reflects the heat dissipation of the motor controller, and sufficient cooling flow is the key to ensuring the effective heat dissipation of the motor controller. The present invention detects the cooling water temperature and cooling flow of the motor controller in real time, and ensures that the detected cooling water temperature and cooling flow are respectively within the set water temperature range threshold and flow range threshold, so as to monitor the heat dissipation effect and ensure the heat dissipation efficiency, while effectively protecting the stability of the heat dissipation system in the motor controller, timely discovering system faults, and evaluating the system operation status, to ensure that the heat dissipation system of the motor controller to be tested meets the design requirements and ensure the consistency of product quality and performance. In the embodiment of the present invention, the cooling water temperature threshold is 60±5℃, and the cooling flow threshold is 8±1L / min.

[0052] 3-4-6) Determining whether the motor controller under test is aging also includes checking whether the host computer receives a fault code sent by the motor controller under test through the CAN bus. If a fault code is received, the motor controller under test is aging.

[0053] A fault code is a specific code generated by the motor controller when it detects an anomaly or fault. It indicates the type, location, and severity of the fault. The motor controller communicates with the host computer via the CAN bus. During CAN bus communication, the motor controller regularly transmits status information (such as operating status and parameter values). Upon detecting a fault, the motor controller immediately transmits the fault code to the host computer. This means that no matter where the fault occurs within the motor controller, the fault code is promptly fed back to the host computer. The present invention continuously monitors for fault codes during the detection cycle to further determine whether the motor controller under test is aging.

[0054] In summary, if any one of the criteria 3-4-1) through 3-4-6) is met during the end-of-line aging test of a motor controller, the motor controller under test is considered aged. Conversely, if none of the criteria 3-4-1) through 3-4-6) are met, the motor controller under test is considered not aged.

[0055] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications made to the present invention by those skilled in the art without departing from the spirit of the present invention shall fall within the scope of protection of the present invention.

Claims

1. A motor controller offline aging detection method, characterized in that: The following steps are involved: 1) Use a temperature chamber to establish a calibration detection system that can determine whether the motor controller is aging, and use it to test the aging detection data of the motor controller under test; 2) During the calibration test, the calibration test system is used to determine the detection time threshold for the motor controller offline aging test and the aging detection threshold of the motor controller to be tested; 3) In the detection test, the motor controller to be tested is set in the calibration detection system, and an aging detection is performed on the motor controller to be tested within a detection time threshold to determine whether the motor controller to be tested is aged.

2. A motor controller offline aging detection method according to claim 1, characterized in that: The calibration detection system includes a high-voltage DC power supply, a low-voltage DC power supply, a host computer, a current acquisition module and a three-phase inductor, wherein the high-voltage DC power supply serves as a power supply for the motor controller to be tested and is connected to the DC bus of the motor controller to be tested, and the low-voltage DC power supply serves as a working power supply for the motor controller to be tested and is connected to the low-voltage power input terminal of the motor controller to be tested; The three-phase input terminal of the current acquisition module is connected to the three-phase output terminal of the motor controller to be tested, and the three-phase output terminal of the current acquisition module is connected to the three-phase inductor for simulating the load motor; The host computer is connected to the high-voltage DC power supply, the motor controller to be tested and the current acquisition module through the CAN bus, and is used for real-time monitoring and collecting aging detection data of the motor controller to be tested to determine whether the motor controller to be tested is aging.

3. The motor controller offline aging detection method according to claim 1, characterized in that: In step 3), the motor controller to be tested is set in the calibration detection system, and an aging detection is performed on the motor controller to be tested within a detection time threshold to determine whether the motor controller to be tested is aged. Specifically, the following steps are performed: 3-1) Place the motor controller to be tested in the temperature chamber of the calibration test system and set the internal temperature of the temperature chamber to within the equipment ambient temperature range; 3-2) Detect the aging test data of the motor controller under test at each moment; 3-3) Based on the aging test data obtained in step 3-2), record the maximum value of the aging test data of the motor controller to be tested; 3-4) Compare the maximum value of the aging detection data of the motor controller under test with the corresponding aging detection threshold value to determine whether the motor controller under test is aged.

4. A motor controller offline aging detection method according to claim 3, characterized in that: The aging detection data includes a U-phase current deviation value, the maximum value of the aging detection data includes a U-phase current deviation maximum value, and the aging detection threshold includes a U-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the U-phase current deviation with the U-phase current deviation threshold value. If the maximum value of the U-phase current deviation is not within the U-phase current deviation threshold range, the motor controller to be tested is aged.

5. The motor controller offline aging detection method according to claim 3, characterized in that: The aging detection data includes a V-phase current deviation value, the maximum value of the aging detection data includes a V-phase current deviation maximum value, and the aging detection threshold includes a V-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged. Specifically, the comparison includes numerically comparing the maximum value of the V-phase current deviation with the V-phase current deviation threshold value. If the maximum value of the V-phase current deviation is not within the V-phase current deviation threshold range, the motor controller to be tested is aged.

6. The motor controller offline aging detection method according to claim 3, characterized in that: The aging detection data includes a W-phase current deviation value, the maximum value of the aging detection data includes a W-phase current deviation maximum value, and the aging detection threshold includes a W-phase current deviation threshold value. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold value to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum value of the W-phase current deviation with the W-phase current deviation threshold value. If the maximum value of the W-phase current deviation is not within the W-phase current deviation threshold range, the motor controller to be tested is aged.

7. The motor controller offline aging detection method according to claim 3, characterized in that: The aging detection data includes the cooling water temperature, the maximum value of the aging detection data includes the maximum cooling water temperature, and the aging detection threshold includes the cooling water temperature threshold. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold to determine whether the motor controller to be tested is aged, specifically including numerically comparing the maximum cooling water temperature with the cooling water temperature threshold. If the maximum cooling water temperature is not within the cooling water temperature threshold range, the motor controller to be tested is aged.

8. The motor controller offline aging detection method according to claim 3, characterized in that: The aging detection data includes a cooling flow rate, the maximum value of the aging detection data includes a maximum cooling flow rate, and the aging detection threshold includes a cooling flow rate threshold. In step 3-4), the aging detection data of the motor controller to be tested is numerically compared with the corresponding aging detection threshold to determine whether the motor controller to be tested is aged. Specifically, the comparison includes numerically comparing the maximum value of the W-phase current deviation with the W-phase current deviation threshold. If the maximum cooling flow rate is not within the cooling flow rate threshold range, the motor controller to be tested is aged.

9. The motor controller offline aging detection method according to claim 3, characterized in that: In step 3-4), determining whether the motor controller to be tested is aged also includes determining whether the host computer receives a fault code sent by the motor controller to be tested via the CAN bus. If a fault code is received, the motor controller to be tested is aged.

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