Method and device for improving vibration resistance of motor controller, equipment and medium

Abstract

The invention discloses a method, device and equipment for improving the vibration resistance of a motor controller and a medium, and belongs to the technical field of vehicles. The method at least comprises the following steps: executing vibration magnitude analysis on the mounting position of any motor controller; if the vibration magnitude of the installation position is higher than the preset vibration magnitude, acquiring a load spectrum according to the installation position and converting the load spectrum into a vibration test condition; enabling the first-order inherent frequency of the motor controller to be far away from a vibration source frequency band through a pre-design measure; dividing subordinate function modules of the motor controller according to the function relation of the motor controller so as to identify high-risk function modules and execute vibration-resistant performance optimization operation; executing a special small V test on each optimized high-risk function module; and if the test result meets the vibration test condition, entering the next development stage. According to the application, the vibration risk point can be recognized in advance in the early stage of project development and risk degradation is carried out, the commercial vehicle vibration test precision is improved, the number of prototype development iterations is reduced, and the development period is effectively shortened.

Description

Technical Field

[0001] Embodiments of the present invention relate to the field of vehicle technology, and in particular to a method, device, equipment, and medium for improving the vibration resistance of a motor controller. Background Art

[0002] At present, the installation layout of drive motor controllers for new energy commercial vehicles is diverse. Depending on the installation location, the vibration conditions corresponding to different locations vary greatly.

[0003] If vibration reliability is tested through design verification (DV) in the middle and late stages of project development according to traditional development methods, the test verification cycle is usually 4 to 6 months, and the risk of test failure is high. Multiple rounds of development iterations are required to pass the verification, which seriously affects the progress of project development.

[0004] At the same time, due to the large differences in the structures of commercial vehicles, even if the motor controllers are arranged at different points in the same position, the vibration conditions they are in will be quite different, which will cause large deviations in the vibration test conditions and ultimately lead to inaccurate test verification. Summary of the Invention

[0005] Embodiments of the present invention provide a method, apparatus, device, and medium for improving the vibration resistance of a motor controller, thereby reducing iterative development cycles and shortening the test verification cycle, while at least improving the accuracy of commercial vehicle vibration tests. This helps alleviate problems such as long development cycles and development delays, and accelerates project development progress.

[0006] In a first aspect, an embodiment of the present invention provides a method for improving the vibration resistance performance of a motor controller, comprising at least:

[0007] performing a vibration level analysis on a mounting location of any motor controller to at least determine a vibration level at the mounting location;

[0008] If the vibration level of the installation position is higher than a preset vibration level, collecting a load spectrum according to the installation position and converting the load spectrum into a vibration test condition;

[0009] By means of pre-design measures, the first-order natural frequency of the motor controller is kept away from the frequency band of the vibration source;

[0010] Dividing the subordinate functional modules of the motor controller according to their functional relationships, and performing vibration resistance analysis on each of the subordinate functional modules to identify high-risk functional modules and perform vibration resistance performance optimization operations on each of the high-risk functional modules;

[0011] Perform a special small V test on each of the optimized high-risk functional modules and conduct deviation analysis on the test results;

[0012] If the test results meet the vibration test conditions, proceed to the next development stage;

[0013] If the test result does not meet the vibration test condition, re-performing the vibration resistance performance optimization operation on each high-risk functional module, then performing the special small V test on each optimized high-risk functional module, and performing the deviation analysis on the test results, until the test result meets the vibration test condition and then entering the next development stage;

[0014] If the vibration level of the installation position is not higher than the preset vibration level, the vibration test conditions are formulated with reference to relevant standards and the next development stage is entered.

[0015] Optionally, at least when the motor controller is arranged on a commercial vehicle engine, a transmission, or a non-elastic body of a commercial vehicle, it is determined that the vibration level of the installation position is higher than the preset vibration level;

[0016] At least when the motor controller is arranged on the elastic body or the cab of a commercial vehicle, it is determined that the vibration level of the installation position is not higher than the preset vibration level.

[0017] Optionally, the collection positions of the load spectrum at least correspond to installation contact points of the motor controller having a vibration level higher than the preset vibration level; and the number of the collection positions is not less than a preset number.

[0018] Optionally, the first-order natural frequency is at least 10 times the frequency band of the vibration source.

[0019] Optionally, the subordinate functional modules include at least a control board, an inverter module, an input component, an output component, a housing and an electrical interface.

[0020] Optionally, when the subordinate functional module is the control board, the inverter module, the input component, the output component and / or the housing, the vibration resistance optimization operation at least includes optimizing the structure and hardware design, material selection and / or production process of the above-mentioned subordinate functional modules to improve the mode and stiffness of the motor controller and enhance the vibration resistance of the motor controller;

[0021] When the subordinate functional module is the electrical interface, the vibration resistance optimization operation at least includes fixing and constraining the wiring harness of the motor controller to avoid excessive shaking of the wiring harness on the vehicle, reduce the possibility of failure of the vehicle wiring harness connection, and enhance the vibration resistance of the motor controller.

[0022] Optionally, before performing the special small-V test, the motor controller is connected to a dedicated bench for the motor system;

[0023] During the test process of the special small V test, if the system meets the requirements of the preset functional status level; and, after the test, the system fasteners are not loose, and the re-tested system insulation voltage and liquid cooling circuit sealing are normal; and, after returning to normal, the operating voltage of the motor system is set to the rated voltage and the drive motor is controlled to operate according to the preset cooling conditions, if the peak torque, peak power and duration of the drive motor meet the technical requirements specified in the product, then it is determined that the special small V test has passed and the test results meet the vibration test conditions; otherwise, it is determined that the special small V test has failed and the test results do not meet the vibration test conditions.

[0024] In a second aspect, an embodiment of the present invention further provides a device for improving the vibration resistance of a motor controller, comprising at least:

[0025] a vibration level analysis module, configured to perform a vibration level analysis on an installation location of any motor controller to at least determine a vibration level at the installation location;

[0026] a load spectrum acquisition and conversion module, configured to acquire a load spectrum according to the installation position when the vibration level of the installation position is higher than a preset vibration level, and convert the load spectrum into vibration test conditions;

[0027] A natural frequency changing module, configured to make the first-order natural frequency of the motor controller move away from the vibration source frequency range through pre-designed measures;

[0028] a performance optimization module, configured to divide the motor controller's subordinate functional modules according to their functional relationships, and perform a vibration resistance analysis on each of the subordinate functional modules to identify high-risk functional modules and perform a vibration resistance performance optimization operation on each of the high-risk functional modules;

[0029] A special test module is used to perform a special small V test on each of the optimized high-risk functional modules and perform deviation analysis on the test results;

[0030] The first stage transfer module is used to enter the next development stage when the test results meet the vibration test conditions;

[0031] a re-optimization module, configured to, when the test result does not meet the vibration test condition, re-perform the vibration resistance performance optimization operation on each of the high-risk functional modules, further perform the special small V test on each of the optimized high-risk functional modules, and perform the deviation analysis on the test results, until the test result meets the vibration test condition and then enter the next development stage;

[0032] The second stage transition module is used to formulate the vibration test conditions with reference to relevant standards and enter the next development stage when the vibration level of the installation position is not higher than the preset vibration level.

[0033] In a third aspect, an embodiment of the present invention further provides an electronic device comprising a memory and a processor, wherein the memory stores a computer program that can be run on the processor, and when the processor executes the program, the steps of the method for improving the vibration resistance of the motor controller described in any one of the first aspects are implemented.

[0034] In a fourth aspect, an embodiment of the present invention further provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the method for improving the vibration resistance of a motor controller as described in any one of the first aspects.

[0035] The technical solution provided by the embodiment of the present invention is as follows: first, a vibration level analysis is performed on the installation position of any motor controller to at least determine the vibration level of the installation position; further, if the vibration level of the installation position is not higher than the preset vibration level, vibration test conditions are formulated with reference to relevant standards and the next development stage is entered; on the contrary, if the vibration level of the installation position is higher than the preset vibration level, a load spectrum is collected according to the installation position, and the load spectrum is converted into a vibration test condition; further, after the load spectrum is converted into the vibration test condition, the first-order natural frequency of the motor controller is kept away from the vibration source frequency band through pre-designed measures; further, according to the functional relationship of the motor controller, its subordinate functional modules are The system is divided into blocks, and a vibration resistance analysis is performed on each subordinate functional module to identify high-risk functional modules and perform vibration resistance performance optimization operations on each high-risk functional module; further, a special small V test is performed on each optimized high-risk functional module, and a deviation analysis is performed on the test results; finally, if the test results meet the vibration test conditions, the system enters the next development stage. Conversely, if the test results do not meet the vibration test conditions, the system re-performs the vibration resistance optimization operation on each high-risk functional module, and then performs a special small V test on each optimized high-risk functional module, and a deviation analysis is performed on the test results, until the test results meet the vibration test conditions and the system enters the next development stage. In view of this, the embodiment of the present invention can at least identify vibration risk points in advance in the early stage of motor controller project development, and perform risk reduction and optimization on the risk points, thereby improving the accuracy of commercial vehicle vibration tests, reducing the number of prototype development iterations, effectively shortening the development cycle, and helping to reduce the risk of project delays. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0037] Figure 1 This is a flow chart of a method for improving the vibration resistance of a motor controller provided by an embodiment of the present invention;

[0038] Figure 2 This is a schematic diagram of the layout of a motor controller in a new energy heavy-duty truck provided by an embodiment of the present invention;

[0039] Figure 3 This is a natural frequency simulation result diagram of a motor controller provided by an embodiment of the present invention;

[0040] Figure 4 Schematic diagram of connection and fixing points of a motor controller provided by an embodiment of the present invention;

[0041] Figure 5 This is a schematic diagram of module division of a motor controller provided by an embodiment of the present invention;

[0042] Figure 6 This is a schematic diagram of fixing a motor controller wiring harness provided by an embodiment of the present invention;

[0043] Figure 7 1 is a schematic structural diagram of a device for improving the vibration resistance of a motor controller provided by an embodiment of the present invention;

[0044] Figure 8 It is a structural diagram of an electronic device provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0045] To make the objectives, technical solutions, and advantages of this application more clear, this application will be further described in detail below with reference to the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this application.

[0046] The terms used in the examples of this application are for the purpose of describing specific embodiments only and are not intended to limit this application. The singular forms "a," "the," and "the" used in the examples of this application and the appended claims are also intended to include plural forms, and unless the context clearly indicates otherwise, "a plurality" generally includes at least two.

[0047] It should be understood that the term "and / or" as used herein simply describes a relationship between associated objects, indicating that three possible relationships exist. For example, "A and / or B" can represent: A exists alone, A and B exist simultaneously, or B exists alone. Furthermore, the character " / " in this document generally indicates that the associated objects are in an "or" relationship.

[0048] It should be understood that although the terms first, second, third, etc. may be used to describe in the embodiments of the present application, these descriptions should not be limited to these terms. These terms are only used to distinguish the descriptions. For example, without departing from the scope of the embodiments of the present application, the first may also be referred to as the second, and similarly, the second may also be referred to as the first.

[0049] As used herein, the words "if" and "if" may be interpreted as "at the time of" or "when" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrases "if it is determined" or "if (stated condition or event) is detected" may be interpreted as "when it is determined" or "in response to the determination" or "when detecting (stated condition or event)" or "in response to detecting (stated condition or event)," depending on the context.

[0050] It should also be noted that the terms "include," "comprises," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a product or device comprising a series of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such product or device. In the absence of further limitations, an element defined by the phrase "comprises a..." does not exclude the presence of other identical elements in the product or device comprising the element.

[0051] It should be noted in particular that any symbols and / or numbers in the specification that are not marked in the accompanying drawings are not drawing marks.

[0052] As mentioned in the background technology, existing commercial vehicles have technical problems such as low vibration test accuracy, multiple iterative development rounds, and long test verification cycles. After careful research, the inventors found that the reason for the above technical problems is that the drive motor control of new energy passenger vehicles is almost entirely arranged in the passenger vehicle elastomer. The test conditions refer to ISO16750-3 or GB / T28046-3 Environmental conditions and tests for electrical and electronic equipment of road vehicles Part 3: Mechanical load 4.1.2.4 Test IV Passenger vehicle elastomer (body), which has good vibration conditions and low vibration failure risk.

[0053] However, in new energy commercial vehicles, the installation layout of the drive motor controller is diverse. The vibration levels corresponding to different installation locations vary greatly. There are four typical installation locations:

[0054] (1) Arranged on the engine and transmission of commercial vehicles, the test conditions refer to ISO16750-3 or GB / T28046-34.1.2.6 Test VI Commercial Vehicle Cab;

[0055] (2) Arranged on commercial vehicle elastomers, the test conditions refer to ISO16750-3 or GB / T28046-3 4.1.2.7 Test VII Commercial Vehicle Elastomers;

[0056] (3) For commercial vehicle cab layout, the test conditions refer to ISO16750-3 or GB / T28046-3 4.1.2.8 Test VIII Commercial Vehicle Cab;

[0057] (4) For the arrangement of non-elastic bodies of commercial vehicles, the test conditions shall refer to ISO16750-3 or GB / T28046-3 4.1.2.9 Test IX for non-elastic bodies of commercial vehicles.

[0058] Among them, for the scheme arranged in commercial vehicle engines, transmissions and commercial vehicle non-elastic bodies, the vibration test conditions are relatively harsh and the risk of vibration failure is high.

[0059] If vibration reliability is designed and verified in the middle and late stages of project development according to traditional development methods, the test verification cycle is usually 4 to 6 months, with a high risk of test failure, multiple rounds of development iterations, and problems that affect project development progress.

[0060] At the same time, commercial vehicles have large structural differences. Even if the motor controller is arranged at different points in the same position, such as on the upper, lower, left and right sides of the non-elastic body of the commercial vehicle, the vibration levels will vary greatly. This makes it very easy for the vibration test conditions determined only with reference to ISO16750-3 or GB / T28046-3 standards to deviate, which in turn leads to technical problems such as inaccurate test verification.

[0061] In view of this, the inventors intend to identify vibration risk points in advance in the early stage of motor controller project development, and perform risk downgrade and optimization on the risk points, so as to improve the accuracy of commercial vehicle vibration tests, reduce the number of prototype development iterations, effectively shorten the development cycle, and help reduce the risk of project delays. The following is a detailed explanation in conjunction with embodiments or implementation methods.

[0062] Figure 1This is a flowchart of a method for improving the vibration resistance of a motor controller provided by an embodiment of the present invention. This embodiment is at least applicable to the design and testing scenarios of motor controllers for commercial vehicles. The method for improving the vibration resistance of a motor controller can be, but is not limited to, executed by the device for improving the vibration resistance of a motor controller in an embodiment of the present invention as the execution subject, and the execution subject can be implemented in software and / or hardware. Figure 1 As shown, the method for improving the vibration resistance of the motor controller includes at least the following steps:

[0063] S1. Perform a vibration level analysis on the installation location of any motor controller to at least determine the vibration level of the installation location.

[0064] Among them, taking new energy commercial vehicles as an example, the installation location of the motor controller can be but is not limited to the aforementioned commercial vehicle engine, transmission, commercial vehicle non-elastic body, commercial vehicle elastomer or commercial vehicle cab.

[0065] In a specific embodiment, optionally, at least when the motor controller is arranged on a commercial vehicle engine, a transmission or a non-elastic body of a commercial vehicle, the vibration level of the installation position is determined to be higher than a preset vibration level; at least when the motor controller is arranged on a commercial vehicle elastomer or a commercial vehicle cab, the vibration level of the installation position is determined to be not higher than a preset vibration level (in this case, the test conditions can be formulated directly with reference to the standards ISO16750-3 or GB / T28046-3, and vibration load spectrum collection is not performed).

[0066] For example, Figure 2 This is a schematic diagram of the layout of a motor controller in a new energy heavy truck provided by an embodiment of the present invention, see Figure 2 The motor controller of new energy heavy-duty trucks is arranged on the electric drive axle, that is, the non-elastic body (unsprung) of commercial vehicles. The electric drive axle system consists of a drive axle, a transmission, a motor and a motor controller. At this time, it can be determined that the vibration level corresponding to the installation position of the motor controller is higher than the preset vibration level.

[0067] S2. If the vibration level at the installation location is higher than the preset vibration level, a load spectrum is collected according to the installation location, and the load spectrum is converted into a vibration test condition.

[0068] The term "load spectrum" refers to a collection of graphs, tables, matrices, and other probabilistic eigenvalues ​​derived from mathematically and statistically processing the time history of the load experienced by the motor controller. These graphs represent the relationship between load magnitude and frequency of occurrence. The load spectrum acquisition process can include, for example, obtaining load sample data; testing the stability of the load sample data; eliminating invalid amplitudes; statistically counting load cycles; and estimating the overall load distribution. This will not be elaborated further.

[0069] In another specific embodiment, optionally, the collection positions of the load spectrum correspond to at least the installation contact points of the motor controller where the vibration level is higher than the preset vibration level; and the number of collection positions is not less than a preset number (the preset number can be 3, for example).

[0070] In another specific embodiment, the basic method of converting the vibration load spectrum collected from the actual vehicle into the vibration test conditions can be specifically as follows:

[0071] 1. Data Collection: Acceleration sensors are installed at key locations on the vehicle (such as the motor controller installation location) to collect vibration data from the vehicle under different road conditions and operating conditions, such as rocky roads, twisted roads, cobblestone roads, washboard roads, and fish-scale pit roads.

[0072] 2. Data analysis and processing: After preliminary processing of the collected data to remove noise and detect outliers, the Fourier transform method is used to identify key vibration frequencies and their corresponding acceleration levels. The duration and intensity distribution of vibration events are then determined based on time history analysis.

[0073] 3. Application of the damage equivalence principle: Based on the fatigue characteristics of materials, the damage equivalence principle is used to convert random vibration input under actual use conditions into equivalent stress or acceleration spectra used in laboratory tests;

[0074] 4. Develop vibration test specifications: Based on the above analysis results, combined with the vehicle's design requirements and service life goals, develop a vibration test plan with parameters such as frequency range, acceleration level, scan rate, dwell time in each frequency band, and total test cycle.

[0075] S3. Take pre-design measures to make the first-order natural frequency of the motor controller away from the frequency range of the vibration source.

[0076] Among them, the pre-design measures can be local potting, adding connection points, etc.; the vibration source frequency range can be the vibration frequency range caused by the vehicle driving on a rough road.

[0077] In another specific embodiment, the stiffness of the motor controller can be increased through system design and local potting to ensure that its first-order natural frequency is far away from the vibration frequency range caused by the vehicle driving on rough roads (e.g., 8 Hz to 40 Hz); Figure 3 FIG. 1 is a natural frequency simulation result diagram of a motor controller provided by an embodiment of the present invention, such as Figure 3 As shown in Figure 2, the first-order natural frequency of the motor controller is 950.26 Hz.

[0078] In yet another specific embodiment, optionally, the first-order natural frequency is at least 10 times the frequency band of the vibration source.

[0079] In addition, the motor controller connection can be further optimized by increasing the number of connection points between the motor controller and the electric drive axle and increasing the stiffness at the connection points to ensure that its first-order natural frequency is far away from the vibration frequency range caused by the vehicle when driving on rough roads; Figure 4 Schematic diagram of the connection points of a motor controller provided by an embodiment of the present invention. Figure 4 As shown in the figure, the circled points are the connection and fixing points of the motor controller.

[0080] S4. Divide the subordinate functional modules of the motor controller according to their functional relationships, and perform vibration resistance analysis on each subordinate functional module to identify high-risk functional modules and perform vibration resistance performance optimization operations on each high-risk functional module.

[0081] Among them, the subordinate functional modules can be divided according to the functions of each component in the motor controller; optionally, the subordinate functional modules at least include a control board, an inverter module, an input component, an output component, a housing and an electrical interface. Figure 5 This is a schematic diagram of the module division of a motor controller provided by an embodiment of the present invention, see Figure 5 The motor controller can be divided into the control board (i.e., the circuit board (PCB), inverter module (e.g., containing IGBT power devices, busbar capacitors, driver board, etc.), input components, output components, housing, and electrical interfaces. Furthermore, vibration tolerance analysis is performed on each of these functional modules to identify high-risk functional modules; for example, functional modules at high risk of vibration failure may specifically be the control board and inverter module.

[0082] In another specific embodiment, optionally, when the subordinate functional module is a control board, an inverter module, an input component, an output component and / or a housing, the vibration resistance performance optimization operation at least includes optimizing the structure and hardware design, material selection and / or production process of the above-mentioned subordinate functional modules to improve the mode and stiffness of the motor controller and enhance the vibration resistance of the motor controller; when the subordinate functional module is an electrical interface, the vibration resistance performance optimization operation at least includes fixing and constraining the wiring harness of the motor controller ( Figure 6 This is a schematic diagram of fixing a motor controller wiring harness provided by an embodiment of the present invention. Figure 6 The circled part is the wiring harness fixing and tightening point) to prevent the wiring harness from shaking too much on the vehicle, reduce the possibility of vehicle wiring harness connection failure, and enhance the vibration resistance of the motor controller.

[0083] S5. Perform a special small V test on each high-risk functional module after optimization, and conduct deviation analysis on the test results.

[0084] Among them, the special small V test can refer to a special test that can verify the function, performance, reliability, safety performance, etc. of each component of the motor controller.

[0085] In another specific embodiment, optionally, before performing the special small-V test, the motor controller is connected to a dedicated bench for the motor system;

[0086] During the special small V test, if the system meets the requirements of the preset functional status level; and, after the test, the system fasteners are not loose, and the re-tested system insulation voltage and liquid cooling circuit sealing are normal; and, after returning to normal, the operating voltage of the motor system is set to the rated voltage and the drive motor is controlled according to the preset cooling conditions. If the peak torque, peak power and duration of the drive motor meet the technical requirements specified in the product, then the special small V test is judged to have passed and the test results meet the vibration test conditions. Otherwise, the special small V test is judged to have failed and the test results do not meet the vibration test conditions.

[0087] Specifically, the preset functional status level may refer to level A.

[0088] For example, the functional status classification may be as follows:

[0089] Level A: During and after the test, all functions of the device or system are consistent with the design requirements;

[0090] Level B: All functions of the device or system are consistent with the design requirements during the test, however, one or more exceeds the specified allowable error; after the test, it can automatically recover to the specified range;

[0091] Level C: During the test, one or more functions of the device or system do not meet the design requirements, but normal operation is automatically restored after the test;

[0092] Level D: During the test, one or more functions of the device or system do not meet the design requirements, and the device or system needs to be reactivated after the test;

[0093] Level E: During the test, one or more functions of the device or system do not meet the design requirements and the device or system does not return to normal operation after the test. The device or system needs to be repaired or replaced.

[0094] S6. If the test results meet the vibration test conditions, proceed to the next development stage.

[0095] S7. If the test results do not meet the vibration test conditions, re-perform the vibration resistance optimization operation on each high-risk functional module, and then perform a special small V test on each optimized high-risk functional module, and perform deviation analysis on the test results until the test results meet the vibration test conditions and enter the next development stage.

[0096] S8. If the vibration level at the installation location is not higher than the preset vibration level, determine the vibration test conditions with reference to relevant standards and proceed to the next development stage.

[0097] The relevant standards may include but are not limited to the aforementioned standards ISO16750-3 or GB / T28046-3.

[0098] The technical solution provided in this embodiment is as follows: first, a vibration level analysis is performed on the installation position of any motor controller to at least determine the vibration level of the installation position; further, if the vibration level of the installation position is not higher than the preset vibration level, vibration test conditions are formulated with reference to relevant standards and the next development stage is entered; on the contrary, if the vibration level of the installation position is higher than the preset vibration level, a load spectrum is collected according to the installation position and the load spectrum is converted into vibration test conditions; further, after the load spectrum is converted into vibration test conditions, the first-order natural frequency of the motor controller is kept away from the vibration source frequency band through pre-designed measures; further, according to the functional relationship of the motor controller, its subordinate functional modules are The system is divided and vibration resistance analysis is performed on each subordinate functional module to identify high-risk functional modules and perform vibration resistance performance optimization operations on each high-risk functional module; further, a special small V test is performed on each optimized high-risk functional module, and a deviation analysis is performed on the test results; finally, if the test results meet the vibration test conditions, the system enters the next development stage; on the contrary, if the test results do not meet the vibration test conditions, the vibration resistance optimization operation is performed on each high-risk functional module again, and then a special small V test is performed on each optimized high-risk functional module, and a deviation analysis is performed on the test results, until the test results meet the vibration test conditions and the system enters the next development stage. In view of this, this embodiment can at least identify vibration risk points in advance in the early stage of motor controller project development, and perform risk reduction and optimization on risk points, thereby improving the accuracy of commercial vehicle vibration tests, reducing the number of prototype development iterations, effectively shortening the development cycle, and helping to reduce the risk of project delays.

[0099] Figure 7 This is a schematic diagram of the structure of a device for improving the vibration resistance of a motor controller provided by an embodiment of the present invention. This embodiment is at least applicable to the design and testing scenarios of motor controllers for commercial vehicles. The device for improving the vibration resistance of the motor controller can be implemented in software and / or hardware. Figure 7 As shown, the device for improving the vibration resistance of the motor controller includes at least:

[0100] a vibration level analysis module 110 for performing a vibration level analysis on an installation location of any motor controller to at least determine a vibration level at the installation location;

[0101] A load spectrum acquisition and conversion module 120 is configured to acquire a load spectrum according to the installation location when the vibration level at the installation location is higher than a preset vibration level, and convert the load spectrum into vibration test conditions;

[0102] The natural frequency changing module 130 is used to make the first-order natural frequency of the motor controller away from the vibration source frequency range through pre-designed measures;

[0103] a performance optimization module 140 for dividing the motor controller's subordinate functional modules according to their functional relationships, and performing a vibration resistance analysis on each subordinate functional module to identify high-risk functional modules and perform a vibration resistance performance optimization operation on each high-risk functional module;

[0104] The special test module 150 is used to perform a special small V test on each high-risk functional module after optimization and perform deviation analysis on the test results;

[0105] The first stage is transferred to module 160, which is used to enter the next development stage when the test results meet the vibration test conditions;

[0106] The re-optimization module 170 is used to re-perform the vibration resistance optimization operation on each high-risk functional module when the test results do not meet the vibration test conditions, and then perform a special small V test on each optimized high-risk functional module and perform deviation analysis on the test results until the test results meet the vibration test conditions and enter the next development stage;

[0107] The second stage transitions to module 180 , which is used to formulate vibration test conditions with reference to relevant standards and enter the next development stage when the vibration level at the installation location is not higher than the preset vibration level.

[0108] Optionally, the vibration magnitude analysis module 110 is specifically configured to:

[0109] At least when the motor controller is arranged on a commercial vehicle engine, a transmission, or a non-elastic body of a commercial vehicle, it is determined that the vibration level of the installation location is higher than a preset vibration level;

[0110] At least when the motor controller is arranged on the elastic body or the cab of the commercial vehicle, it is determined that the vibration level of the installation position is not higher than the preset vibration level.

[0111] Optionally, the collection positions of the load spectrum at least correspond to installation contact points of the motor controller where the vibration level is higher than a preset vibration level; and the number of the collection positions is not less than a preset number.

[0112] Optionally, the first-order natural frequency is at least 10 times the frequency band of the vibration source.

[0113] Optionally, the subordinate functional modules include at least a control board, an inverter module, an input component, an output component, a housing and an electrical interface.

[0114] Optionally, when the subordinate functional modules are a control board, an inverter module, an input component, an output component and / or a housing, the vibration resistance performance optimization operation at least includes optimizing the structure and hardware design, material selection and / or production process of the above-mentioned subordinate functional modules to improve the mode and stiffness of the motor controller and enhance the vibration resistance performance of the motor controller;

[0115] When the subordinate functional module is an electrical interface, the vibration resistance optimization operation at least includes fixing and constraining the wiring harness of the motor controller to avoid excessive shaking of the wiring harness on the vehicle, reduce the possibility of failure of the vehicle wiring harness connection, and enhance the vibration resistance of the motor controller.

[0116] Optionally, before performing the special small-V test, the motor controller is connected to a dedicated test bench for the motor system;

[0117] The special test module 150 is specifically used for:

[0118] During the special small V test, if the system meets the requirements of the preset functional status level; and, after the test, the system fasteners are not loose, and the re-tested system insulation voltage and liquid cooling circuit sealing are normal; and, after returning to normal, the operating voltage of the motor system is set to the rated voltage and the drive motor is controlled according to the preset cooling conditions. If the peak torque, peak power and duration of the drive motor meet the technical requirements specified in the product, then the special small V test is judged to have passed and the test results meet the vibration test conditions. Otherwise, the special small V test is judged to have failed and the test results do not meet the vibration test conditions.

[0119] The technical solution provided in this embodiment is as follows: first, a vibration level analysis module is used to perform vibration level analysis on the installation position of any motor controller to at least determine the vibration level of the installation position; further, when the vibration level of the installation position is not higher than the preset vibration level, the second-stage transfer module is used to refer to relevant standards to formulate vibration test conditions and enter the next development stage; on the contrary, when the vibration level of the installation position is higher than the preset vibration level, the load spectrum is collected according to the installation position by the load spectrum acquisition and conversion module, and the load spectrum is converted into vibration test conditions; further, after the load spectrum is converted into vibration test conditions, the natural frequency change module is used to make the first-order natural frequency of the motor controller away from the vibration source frequency band through pre-designed measures; further, the performance optimization module is used to optimize the performance of the motor controller according to the vibration level of the motor controller. The functional relationship divides its subordinate functional modules, and performs vibration resistance analysis on each subordinate functional module to identify high-risk functional modules and perform vibration resistance performance optimization operations on each high-risk functional module. Furthermore, a special small V test is performed on each optimized high-risk functional module through a special test module, and a deviation analysis is performed on the test results. Finally, when the test results meet the vibration test conditions, the module is transferred to the next development stage through the first stage. Conversely, when the test results do not meet the vibration test conditions, the vibration resistance optimization operation is re-performed on each high-risk functional module through the re-optimization module, and then a special small V test is performed on each optimized high-risk functional module, and a deviation analysis is performed on the test results until the test results meet the vibration test conditions and enter the next development stage. In view of this, this embodiment can at least identify vibration risk points in advance in the early stage of motor controller project development, and perform risk reduction and optimization on risk points, thereby improving the accuracy of commercial vehicle vibration tests, reducing the number of prototype development iterations, effectively shortening the development cycle, and helping to reduce the risk of project delays.

[0120] This embodiment provides an electronic device, Figure 8 This is a schematic diagram of the structure of an electronic device provided by an embodiment of the present invention. Figure 8The electronic device 1000 includes a processor 1001 and a memory 1002. The memory 1002 stores computer-readable instructions. When the computer-readable instructions are executed by the processor 1001, the steps in any one of the above methods for improving the vibration resistance of the motor controller are executed. Through the above technical solution, the processor 1001 and the memory 1002 are interconnected and communicate with each other through a communication bus and / or other forms of connection mechanisms (not shown). The memory 1002 stores a computer program executable by the processor. When the electronic device 1000 is running, the processor 1001 executes the computer program to execute the method for improving the vibration resistance of the motor controller in any optional implementation of the above embodiment to at least achieve the following functions: perform vibration level analysis on the installation position of any motor controller to at least determine the vibration level of the installation position; if the vibration level of the installation position is not higher than the preset vibration level, formulate vibration test conditions with reference to relevant standards and enter the next development stage; on the contrary, if the vibration level of the installation position is higher than the preset vibration level, collect the load spectrum according to the installation position and convert the load spectrum into vibration test conditions; in After converting the load spectrum into vibration test conditions, pre-design measures are taken to make the first-order natural frequency of the motor controller away from the vibration source frequency segment; the subordinate functional modules of the motor controller are divided according to their functional relationships, and vibration resistance analysis is performed on each subordinate functional module to identify high-risk functional modules and perform vibration resistance performance optimization operations on each high-risk functional module; a special small V test is performed on each high-risk functional module after optimization, and a deviation analysis is performed on the test results; if the test results meet the vibration test conditions, the next development stage is entered; conversely, if the test results do not meet the vibration test conditions, the vibration resistance performance optimization operation is performed on each high-risk functional module again, and then a special small V test is performed on each high-risk functional module after optimization, and a deviation analysis is performed on the test results, until the test results meet the vibration test conditions and the next development stage is entered.

[0121] The present embodiment provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements a method for improving the vibration resistance of a motor controller as provided in all the inventive embodiments of the present application: performing a vibration level analysis on the installation position of any motor controller to at least determine the vibration level of the installation position; if the vibration level of the installation position is not higher than the preset vibration level, then formulating vibration test conditions with reference to relevant standards and entering the next development stage; on the contrary, if the vibration level of the installation position is higher than the preset vibration level, then collecting a load spectrum according to the installation position and converting the load spectrum into a vibration test condition; after converting the load spectrum into the vibration test condition, pre-designing measures are taken to keep the first-order natural frequency of the motor controller away from the vibration source. frequency segment; divide the subordinate functional modules of the motor controller according to its functional relationship, and perform vibration resistance analysis on each subordinate functional module to identify high-risk functional modules and perform vibration resistance performance optimization operations on each high-risk functional module; perform special small V tests on each high-risk functional module after optimization, and perform deviation analysis on the test results; if the test results meet the vibration test conditions, enter the next development stage; on the contrary, if the test results do not meet the vibration test conditions, re-execute vibration resistance performance optimization operations on each high-risk functional module, and then perform special small V tests on each high-risk functional module after optimization, and perform deviation analysis on the test results, until the test results meet the vibration test conditions and enter the next development stage.

[0122] Any combination of one or more computer-readable media may be employed. A computer-readable medium may be a computer-readable signal medium or a computer-readable storage medium. A computer-readable storage medium may be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples (a non-exhaustive list) of computer-readable storage media include: an electrical connection having one or more conductors, a portable computer disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), optical fiber, a portable compact disk read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination thereof. In this document, a computer-readable storage medium may be any tangible medium containing or storing a program that may be used by or in conjunction with an instruction execution system, apparatus, or device.

[0123] A computer-readable signal medium may include a data signal propagated in baseband or as part of a carrier wave, which carries computer-readable program code. Such a propagated data signal may take a variety of forms, including, but not limited to, electromagnetic signals, optical signals, or any suitable combination thereof. A computer-readable signal medium may also be any computer-readable medium other than a computer-readable storage medium that can transmit, propagate, or transport a program for use by or in conjunction with an instruction execution system, apparatus, or device.

[0124] Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

[0125] Computer program code for performing the operations of the present invention may be written in one or more programming languages, or a combination thereof, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, as well as conventional procedural programming languages ​​such as "C" or similar programming languages. The program code may be executed entirely on the user's computer, partially on the user's computer, as a stand-alone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the case of a remote computer, the remote computer may be connected to the user's computer via any type of network, including a local area network (LAN) or a wide area network (WAN), or may be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0126] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for improving the vibration resistance of a motor controller, characterized in that: At least: performing a vibration level analysis on a mounting location of any motor controller to at least determine a vibration level at the mounting location; If the vibration level of the installation position is higher than a preset vibration level, collecting a load spectrum according to the installation position and converting the load spectrum into a vibration test condition; By means of pre-design measures, the first-order natural frequency of the motor controller is kept away from the frequency band of the vibration source; Dividing the subordinate functional modules of the motor controller according to their functional relationships, and performing vibration resistance analysis on each of the subordinate functional modules to identify high-risk functional modules and perform vibration resistance performance optimization operations on each of the high-risk functional modules; Perform a special small V test on each of the optimized high-risk functional modules and conduct deviation analysis on the test results; If the test results meet the vibration test conditions, proceed to the next development stage; If the test result does not meet the vibration test condition, re-performing the vibration resistance performance optimization operation on each high-risk functional module, then performing the special small V test on each optimized high-risk functional module, and performing the deviation analysis on the test results, until the test result meets the vibration test condition and then entering the next development stage; If the vibration level of the installation position is not higher than the preset vibration level, the vibration test conditions are formulated with reference to relevant standards and the next development stage is entered.

2. The method for improving the vibration resistance of a motor controller according to claim 1, characterized in that: At least when the motor controller is arranged on a commercial vehicle engine, a transmission, or a non-elastic body of a commercial vehicle, it is determined that the vibration level of the installation position is higher than the preset vibration level; At least when the motor controller is arranged on the elastic body or the cab of a commercial vehicle, it is determined that the vibration level of the installation position is not higher than the preset vibration level.

3. The method for improving the vibration resistance of a motor controller according to claim 1, characterized in that: The collection positions of the load spectrum at least correspond to the installation contact points of the motor controller where the vibration level is higher than the preset vibration level; and the number of the collection positions is not less than a preset number.

4. The method for improving the vibration resistance of a motor controller according to claim 1, characterized in that: The first-order natural frequency is at least 10 times the frequency band of the vibration source.

5. The method for improving the vibration resistance of a motor controller according to claim 1, characterized in that: The subordinate functional modules at least include a control board, an inverter module, an input component, an output component, a housing and an electrical interface.

6. The method for improving the vibration resistance of a motor controller according to claim 5, characterized in that: When the subordinate functional module is the control board, the inverter module, the input component, the output component and / or the housing, the vibration resistance optimization operation at least includes optimizing the structure and hardware design, material selection and / or production process of the above-mentioned subordinate functional modules to improve the mode and stiffness of the motor controller and enhance the vibration resistance of the motor controller; When the subordinate functional module is the electrical interface, the vibration resistance optimization operation at least includes fixing and constraining the wiring harness of the motor controller to avoid excessive shaking of the wiring harness on the vehicle, reduce the possibility of failure of the vehicle wiring harness connection, and enhance the vibration resistance of the motor controller.

7. The method for improving the vibration resistance of a motor controller according to claim 1, characterized in that: Before performing the special small V test, the motor controller is connected to a dedicated test bench for the motor system; During the test process of the special small V test, if the system meets the requirements of the preset functional status level; and, after the test, the system fasteners are not loose, and the re-tested system insulation voltage and liquid cooling circuit sealing are normal; and, after returning to normal, the operating voltage of the motor system is set to the rated voltage and the drive motor is controlled to operate according to the preset cooling conditions, if the peak torque, peak power and duration of the drive motor meet the technical requirements specified in the product, then it is determined that the special small V test has passed and the test results meet the vibration test conditions; otherwise, it is determined that the special small V test has failed and the test results do not meet the vibration test conditions.

8. A device for improving the vibration resistance of a motor controller, characterized in that: At least: a vibration level analysis module, configured to perform a vibration level analysis on an installation location of any motor controller to at least determine a vibration level at the installation location; a load spectrum acquisition and conversion module, configured to acquire a load spectrum according to the installation position when the vibration level of the installation position is higher than a preset vibration level, and convert the load spectrum into vibration test conditions; A natural frequency changing module, configured to make the first-order natural frequency of the motor controller move away from the vibration source frequency band through pre-designed measures; a performance optimization module, configured to divide the motor controller's subordinate functional modules according to their functional relationships, and perform a vibration resistance analysis on each of the subordinate functional modules to identify high-risk functional modules and perform a vibration resistance performance optimization operation on each of the high-risk functional modules; A special test module is used to perform a special small V test on each of the optimized high-risk functional modules and perform deviation analysis on the test results; The first stage transfer module is used to enter the next development stage when the test results meet the vibration test conditions; a re-optimization module, configured to, when the test result does not meet the vibration test condition, re-perform the vibration resistance performance optimization operation on each of the high-risk functional modules, further perform the special small V test on each of the optimized high-risk functional modules, and perform the deviation analysis on the test results, until the test result meets the vibration test condition and then enter the next development stage; The second stage transition module is used to formulate the vibration test conditions with reference to relevant standards and enter the next development stage when the vibration level of the installation position is not higher than the preset vibration level.

9. An electronic device comprising a memory and a processor, wherein the memory stores a computer program that can be run on the processor, wherein: When the processor executes the program, the steps of the method for improving the vibration resistance performance of the motor controller according to any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for improving the vibration resistance performance of a motor controller according to any one of claims 1 to 7 are implemented.

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