A test method for a brushless blower for vehicle

Abstract

The application discloses a testing method for a vehicle brushless blower, which comprises a controller, a brushless motor, an impeller and a volute. The input end of the controller is electrically connected with the output end of a power supply. The output end of the controller is electrically connected with the brushless motor. The impeller and the volute are installed inside an air conditioner box HVAC. The testing method comprises the following steps: a dynamic torque sensor and an encoder are arranged on a transmission rod between the rotor of the brushless motor and the impeller and the volute; the brushless motor is started by the controller to drive the impeller to run; the output voltage and current of the power supply and the three-phase instantaneous voltage and current output by the controller are detected; the output torque of the brushless motor is detected by the dynamic torque sensor, and the rotating speed of the brushless motor is detected by the encoder; the output air volume of the air conditioner box HVAC under a specific static pressure after the impeller is installed inside the air conditioner box HVAC is detected; and the controller efficiency, the brushless motor efficiency, the impeller efficiency and the assembly efficiency of the air conditioner box HVAC system are calculated according to the above test results.

Description

Technical Field

[0001] This invention relates to the field of vehicle electronics technology, and in particular to a testing method for a brushless blower for vehicles. Background Technology

[0002] As the automotive industry accelerates its upgrade towards electrification and intelligentization, the performance stability and reliability of automotive brushless blowers, as a core component of the air conditioning system, are crucial to the vehicle's energy consumption, driving experience, and safety. Therefore, it is necessary to conduct performance testing on automotive brushless blowers to ensure their quality.

[0003] In the design and development of heating, ventilation, and air conditioning systems, current focus is primarily on the input voltage and current of the motor in automotive brushless blowers, as well as the airflow and noise levels under different modes (such as face blowing, foot blowing, and defrosting). Because automotive brushless blowers are defined as complete products, the optimization analysis of the impeller, motor performance, and controller is not sufficiently clear during the optimization process. Summary of the Invention

[0004] This invention provides a testing method for automotive brushless blowers to address the problem of unclear optimization analysis of various components of automotive brushless blowers.

[0005] According to one aspect of the present invention, a test method for an automotive brushless blower is provided. The automotive brushless blower includes a controller, a brushless motor, an impeller, and a volute. The input terminal of the controller is electrically connected to the output terminal of a power supply. The output terminal of the controller is electrically connected to the stator coils U, V, and W of the brushless motor. The rotor of the brushless motor and the input terminals of the impeller and volute are mechanically connected via a transmission rod. The impeller and volute are installed inside an HVAC unit.

[0006] The testing methods include:

[0007] The transmission rod between the rotor and the impeller of the brushless motor is lengthened, and a dynamic torque sensor and an encoder are installed on the transmission rod;

[0008] The controller starts the brushless motor and drives the impeller.

[0009] Detect the power supply output voltage and power supply output current;

[0010] The three-phase instantaneous voltage and three-phase instantaneous current output by the controller are detected;

[0011] The output torque of the brushless motor is detected by the dynamic torque sensor, and the speed of the brushless motor is detected by the encoder.

[0012] The output air volume of the HVAC unit under a specific static pressure is detected after the impeller is placed inside the HVAC unit.

[0013] Based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit, the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system are calculated.

[0014] Optionally, the step of calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit includes:

[0015] The efficiency of the controller is calculated based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, and the three-phase instantaneous current.

[0016] The efficiency of the brushless motor is calculated based on the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor;

[0017] The efficiency of the impeller and volute is calculated based on the output torque of the brushless motor, the speed of the brushless motor, and the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit.

[0018] The overall efficiency of the HVAC system is calculated based on the power supply output voltage, the power supply output current, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit.

[0019] Optionally, calculating the efficiency of the controller based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, and the three-phase instantaneous current includes:

[0020] Calculate the input power of the controller based on the power supply output voltage and the power supply output current;

[0021] Calculate the output power of the controller based on the three-phase instantaneous voltage and the three-phase instantaneous current;

[0022] Calculate the efficiency of the controller based on its output power and input power;

[0023] And / or, the step of calculating the efficiency of the brushless motor based on the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor includes:

[0024] The input power of the brushless motor is calculated based on the three-phase instantaneous voltage and the three-phase instantaneous current.

[0025] Calculate the output power of the brushless motor based on its output torque and speed;

[0026] Calculate the efficiency of the brushless motor based on its output power and input power.

[0027] And / or, the calculation of the efficiency of the impeller and volute based on the output torque of the brushless motor, the rotational speed of the brushless motor, and the output airflow of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit includes:

[0028] Calculate the input power of the impeller and volute based on the output torque and speed of the brushless motor;

[0029] Based on the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit, calculate the output power of the impeller and the volute.

[0030] Calculate the efficiency of the impeller and volute based on the input power and output power of the impeller;

[0031] And / or, the step of calculating the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit includes:

[0032] Calculate the total input power based on the power supply output voltage and the power supply output current;

[0033] Calculate the total output power based on the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit.

[0034] The overall efficiency of the HVAC system is calculated based on the output power and input power of the assembly.

[0035] Optionally, before the step of controlling the brushless motor to start and drive the impeller via the controller, the method further includes:

[0036] Different operating modes are set for the HVAC unit; the operating modes include a full cooling internal circulation mode for blowing on the face, a full heating external circulation mode for blowing on the feet, or a full heating external circulation mode for defrosting.

[0037] Optionally, after calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the method further includes:

[0038] After replacing one component of the automotive brushless blower, the test method is executed again to obtain the adjusted test results; the component is the controller, the brushless motor, the impeller, and the HVAC system; the test results include the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system.

[0039] The component was adjusted and verified based on the test results before and after the adjustment.

[0040] Optionally, after detecting the three-phase instantaneous voltage and three-phase instantaneous current output by the controller, the method further includes:

[0041] Fast Fourier Transform analysis is performed on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, and the three-phase instantaneous current;

[0042] Based on the analysis results of the Fast Fourier Transform, the program of the controller is optimized;

[0043] By analyzing components of a specific order, adjusting the program can help optimize noise performance.

[0044] Optionally, after calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the method further includes:

[0045] Calculate the mechanical power of the brushless motor based on its output torque and speed;

[0046] Based on the test results of the mechanical power, efficiency, and output torque of the brushless motor, the algorithm of the controller is optimized.

[0047] Optionally, the testing method for the automotive brushless blower also includes testing the output torque of the brushless motor using a torque tester and testing the rotational speed using an encoder;

[0048] Before or after calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the following steps are also included:

[0049] Based on the output torque and speed of the brushless motor, the torque at different angles is evaluated.

[0050] Optionally, before or after calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the following method is further included:

[0051] The vibration signal of the HVAC unit is detected, and the driver's comfort is evaluated based on the vibration signal.

[0052] The noise of the brushless motor and the impeller is isolated and detected. Based on the decibel value, order diagram, and Campbell diagram of the brushless motor, and the decibel value, order diagram, and Campbell diagram of the impeller and volute, the noise source of the automotive brushless blower is determined.

[0053] In summary, by testing the output performance of different components of an automotive brushless blower, the efficiency of each part of the blower can be easily calculated. By individually testing the output performance of the controller, brushless motor, impeller, and volute, the efficiency of each component can be accurately calculated, avoiding the masking of performance shortcomings of individual components by testing the whole system, and making the performance status of each component clear at a glance. Because the impact of each component on the overall performance is clearly understood, adjustments can be made to the controller, brushless motor, impeller, or HVAC unit during optimization, avoiding blind optimization and improving optimization efficiency. Furthermore, the embodiments of the present invention facilitate individual verification and improvement of each component; for example, simply replacing the impeller can test its impact on the overall efficiency without modifying other components, simplifying the verification process and reducing testing costs.

[0054] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0055] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0056] Figure 1 This is a schematic diagram of the structure of a vehicle brushless blower being disassembled and tested in an HVAC unit according to an embodiment of the present invention;

[0057] Figure 2 A flowchart illustrating a testing method for a brushless blower for vehicles provided in an embodiment of the present invention;

[0058] Figure 3 This is a schematic diagram of a testing method for a brushless blower for vehicles provided in an embodiment of the present invention. Detailed Implementation

[0059] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0060] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification, claims and accompanying drawings of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such processes, methods, products or devices.

[0061] Figure 1 This is a schematic diagram illustrating the disassembly and testing of a brushless automotive blower in an HVAC (Heating, Ventilation, and Air Conditioning) unit, as provided in an embodiment of the present invention. See also... Figure 1The automotive brushless blower includes a controller 110, a brushless motor 120, an impeller, and a volute 130. The input terminal of the controller 110 is electrically connected to the output terminal of the power supply 100, and the output terminal of the controller 110 is electrically connected to the stator coils U, V, and W of the brushless motor 120. The rotor of the brushless motor 120 and the input terminal of the impeller and volute 130 are mechanically connected through a transmission rod. The impeller and volute 130 are installed inside the air conditioning unit HVAC 140.

[0062] Figure 2 This is a schematic flowchart illustrating a testing method for a brushless automotive blower provided in an embodiment of the present invention. See also... Figure 2 The testing method includes the following steps:

[0063] Step 210: Lengthen the transmission rod between the rotor and impeller of the brushless motor 120 and the volute 130, and install a dynamic torque sensor and encoder on the transmission rod.

[0064] Step 211: Control the brushless motor 120 to start via controller 110, and drive the impeller to run.

[0065] Step 212: Detect the power output voltage and power output current of power supply 100.

[0066] Step 213: Detect the three-phase instantaneous voltage and three-phase instantaneous current output by the controller 110.

[0067] Step 214: Detect the output torque of the brushless motor 120 using a dynamic torque sensor and the rotational speed of the brushless motor 120 using an encoder.

[0068] Step 215: Detect the output air volume of the HVAC140 air conditioning unit under a specific static pressure after the impeller is placed inside the unit.

[0069] Step 216: Based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of brushless motor 120, and output air volume of air conditioning unit HVAC140 under a specific static pressure after the impeller is placed inside HVAC140, calculate the efficiency of controller 110, efficiency of brushless motor 120, efficiency of impeller and volute 130, and overall efficiency of air conditioning unit HVAC140 system.

[0070] The automotive brushless blower is a key component of the automotive air conditioning system. Its core uses a brushless motor 120 to drive an impeller, achieving air delivery and circulation. The controller 110 of the automotive brushless blower is the core component for its precise operation and intelligent control. It is mainly responsible for receiving command signals from the vehicle control system, combining torque and speed information fed back from sensors or encoders, and adjusting the operating status of the brushless motor 120 in real time through a built-in control algorithm. For example, the controller 110 is a brushless direct current motor (BLDC) controller.

[0071] Figure 3 This diagram illustrates a testing method for a brushless automotive blower according to an embodiment of the present invention. During testing, the length of the transmission rod between the rotor, impeller, and volute 130 of the brushless motor 120 is adjusted according to actual needs to accommodate a dynamic torque sensor 311 and an encoder 312 mounted on the transmission rod. The dynamic torque sensor 311 can detect the torque of the output shaft of the brushless motor 120 in real time. The encoder 312 converts the mechanical rotational motion of the brushless motor 120 into an electrical signal using optical principles; this electrical signal can be detected by the testing equipment 313. During testing, the encoder 312 can provide real-time feedback on the speed change of the brushless motor 120. For example, the dynamic torque sensor 311 is a high-precision, fast-response torque tester.

[0072] The power supply output voltage and current can be detected using test equipment 313. To detect the power supply output voltage, simply connect the probe to the output terminal of power supply 100. To detect the power supply output current, a current sensor 310, such as a Hall effect current sensor, is required. The Hall effect current sensor uses the principle of electromagnetic induction to convert the current signal into a corresponding voltage signal, which is then input into test equipment 313 for observation, thus achieving indirect current measurement. For example, test equipment 313 includes a power analyzer capable of detecting current and voltage, a torque and speed measuring instrument capable of measuring rotational speed and torque, an airflow meter capable of measuring air volume, and a vibration detector capable of detecting vibration.

[0073] In an automotive brushless blower, the controller 110 outputs three-phase instantaneous voltage and three-phase instantaneous current to match the stator voltage requirements of the brushless motor 120. The rotation of the brushless motor 120 drives the impeller to operate efficiently, meeting the automotive air conditioning system's requirements for different airflow and air pressure. For example, when detecting the three-phase instantaneous current of the controller 110, three current sensors 310 are used to connect the three-phase output instantaneous current signals of the controller 110 to the test equipment 313 for observation.

[0074] In summary, this invention, by testing the output performance of different components of an automotive brushless blower, can calculate the efficiency of each part of the blower. By individually testing the output performance of the controller 110, brushless motor 120, impeller and volute 130, and HVAC unit 140, the efficiency of each component can be accurately calculated, avoiding the masking of individual component performance shortcomings by testing the whole system, and making the performance status of each component clear at a glance. Because the impact of each component on the overall performance is clearly understood, adjustments can be made to the controller 110, brushless motor 120, impeller and volute 130, or HVAC unit 140 during the optimization process, avoiding blind optimization and improving optimization efficiency. Furthermore, this invention facilitates individual verification and improvement of each component; for example, simply replacing the impeller and volute 130 can test its impact on the overall efficiency without modifying other components, simplifying the verification process and reducing testing costs.

[0075] Based on the above embodiments, optionally, step 216, calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, includes:

[0076] Calculate the efficiency of controller 110 based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, and three-phase instantaneous current.

[0077] Optionally, calculating the efficiency of controller 110 based on power supply output voltage, power supply output current, three-phase instantaneous voltage, and three-phase instantaneous current includes: calculating the input power of controller 110 based on power supply output voltage and power supply output current; calculating the output power of controller 110 based on three-phase instantaneous voltage and three-phase instantaneous current; and calculating the efficiency of controller 110 based on the output power and input power of controller 110.

[0078] For example, the input power (denoted as P1) of controller 110 is calculated using the formula: P1 = U1 × I1. Where U1 is the power supply output voltage, and I1 is the power supply output current. For example, if the input voltage of a vehicle brushless blower controller 110 is 12V and the input current is 5A, then its input power is: P1 = 12V × 5A = 60W. The output power of controller 110 (denoted as P2), which is the power it outputs to a three-phase motor, is calculated using the formula: P2 = U2 × I2. Where U2 is the three-phase instantaneous voltage vector, calculated using the formula: U2 = (u... u u v u w )T I2 is the three-phase instantaneous current vector, and its calculation formula is: I2=(i u i v i w ) T The efficiency of controller 110 (denoted as n1) is calculated using the following formula: When controller 110 is working, part of the input electrical energy is converted and output to controller 110 (i.e., output power P2), while the other part is consumed due to internal losses (such as switching losses and resistive losses of devices). Higher efficiency means less loss and more efficient energy utilization.

[0079] Based on the above embodiments, optionally, step 216, calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, includes:

[0080] Calculate the efficiency of brushless motor 120 based on the three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of brushless motor 120.

[0081] Optionally, calculating the efficiency of the brushless motor 120 based on the three-phase instantaneous voltage, three-phase instantaneous current, output torque, and speed of the brushless motor 120 includes: calculating the input power of the brushless motor 120 based on the three-phase instantaneous voltage and three-phase instantaneous current; calculating the output power of the brushless motor 120 based on the output torque and speed of the brushless motor 120; and calculating the efficiency of the brushless motor 120 based on the output power and input power of the brushless motor 120.

[0082] For example, the input power of the brushless motor 120 is the output power P2 of the controller 110. The output power of the brushless motor 120 (denoted as P3) is calculated using the following formula: In the formula, T is the output torque of the brushless motor 120, and N is the rotational speed of the brushless motor 120. Using a unit conversion factor, the rotational speed is converted from revolutions per minute to radians per second. I2 is the three-phase instantaneous current vector. For example, assuming the brushless motor 120 has an output torque of 0.65 N·m and a rotational speed of 3000 r / min, the output power is: P3 = 0.65 N·m × 3000 r / min × 0.1047 ≈ 204 W. The efficiency of the brushless motor 120 (denoted as n2) is calculated using the following formula:

[0083] Based on the above embodiments, optionally, step 216, calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, includes:

[0084] The efficiency of the impeller and volute 130 is calculated based on the output torque of the brushless motor 120, the speed of the brushless motor 120, and the output air volume of the air conditioning unit 140 HVAC 140 under a specific static pressure after the impeller is placed inside the air conditioning unit 140 HVAC.

[0085] Optionally, the efficiency of the impeller and volute 130 is calculated based on the output torque of the brushless motor 120, the rotational speed of the brushless motor 120, and the output airflow of the air conditioning unit 140 under a specific static pressure after the impeller is placed inside the air conditioning unit 140. This includes: calculating the input power of the impeller and volute 130 based on the output torque and rotational speed of the brushless motor 120; calculating the output power of the impeller and volute 130 based on the output airflow of the air conditioning unit 140 under a specific static pressure after the impeller is placed inside the air conditioning unit 140; and calculating the efficiency of the impeller and volute 130 based on the input power and output power.

[0086] For example, the input power of the impeller and volute 130 is the output power P3 of the brushless motor 120. The output power of the impeller and volute 130 (denoted as P4) is calculated using the following formula: In the formula, Q1 is the output air volume of the HVAC140 air conditioning unit, and Ps is the static pressure set before the test. The efficiency of the impeller and volute 130 (denoted as n3) is calculated using the following formula:

[0087] Based on the above embodiments, optionally, step 216, calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC 140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC 140 system under a specific static pressure after the impeller is placed inside the HVAC 140, includes:

[0088] Calculate the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, and the output air volume of the HVAC140 air conditioning unit under a specific static pressure after the impeller is placed inside the HVAC140 air conditioning unit.

[0089] Optionally, the overall efficiency of the HVAC140 system is calculated based on the power supply output voltage, power supply output current, and the output air volume of the HVAC140 under a specific static pressure after the impeller is placed inside the HVAC140 air conditioning unit. This includes: calculating the overall input power based on the power supply output voltage and power supply output current; calculating the overall output power based on the output air volume of the HVAC140 under a specific static pressure after the impeller is placed inside the HVAC140 air conditioning unit; and calculating the overall efficiency of the HVAC140 system based on the overall output power and overall input power.

[0090] For example, the assembly input power is the input power P1 of the controller 110, and the assembly output power is the output power P4 of the impeller and volute 130. The assembly efficiency (denoted as n4) of the HVAC140 air conditioning unit system is calculated using the following formula: Overall efficiency is a core indicator for evaluating the quality of a blower design. For example, if a blower has an input power P1 = 350W and P4 = 120W, then n4 = 34%, meaning that 66% of the energy is lost in the controller 110, brushless motor 120, impeller and volute 130, and HVAC unit 140. A higher overall efficiency in the HVAC unit 140 system results in lower energy consumption and less cooling pressure.

[0091] Optionally, before the brushless motor 120 is started by the controller 110 and the impeller is driven to run, the following steps are also included:

[0092] Different operating modes can be set for the HVAC140 air conditioning unit; the operating modes include full cooling internal circulation mode for blowing on the face, full heating external circulation mode for blowing on the feet, or full heating external circulation mode for defrosting.

[0093] This invention allows for testing of automotive brushless blowers under different operating modes, thereby enhancing the comprehensiveness of the testing. Specifically, Table 1 is a record table for testing automotive brushless blowers provided by this invention.

[0094] Table 1

[0095]

[0096] In the testing of automotive brushless blowers, a table recording the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed, and output air volume under different modes serves as a data carrier for evaluating the performance of the brushless blower and verifying whether it meets design requirements under various operating conditions. This table can intuitively record the test results of the embodiments of the present invention. With the help of Table 1, problems of the brushless blower in specific modes can be quickly located, providing data support for design optimization.

[0097] Optionally, after calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, the following is also included:

[0098] After replacing one component of the automotive brushless blower, the test method was repeated to obtain the adjusted test results. The component is the controller 110, brushless motor 120, impeller and volute 130, and air conditioning unit (HVAC) 140. The test results include the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the air conditioning unit (HVAC) 140 system.

[0099] The component was adjusted and verified based on the test results before and after the adjustment.

[0100] Specifically, in the inspection of automotive blowers, if torque and speed tests confirm a problem with the brushless motor 120, such as insufficient torque output or abnormal speed fluctuations, only the brushless motor 120 needs to be replaced; the entire brushless blower does not need to be replaced. This can control maintenance costs and avoid wasting valuable resources.

[0101] Optionally, after detecting the three-phase instantaneous voltage and three-phase instantaneous current output by the controller 110, the following is also included:

[0102] Fast Fourier Transform analysis was performed on the power supply output voltage, power supply output current, three-phase instantaneous voltage, and three-phase instantaneous current.

[0103] Based on the analysis results of the Fast Fourier Transform, the program of controller 110 is optimized.

[0104] By analyzing components of a specific order, adjusting the program can help optimize noise performance.

[0105] The Fast Fourier Transform (FFT) converts the power supply output voltage and current signals in the time domain into frequency domain signals, which is beneficial for observing abnormal frequencies and helping to optimize the controller 110 program design. The controller 110 program is the core of regulating the operation of the brushless motor 120, and its algorithm logic directly determines the output characteristics of the power supply output voltage and current. Harmonic data and frequency fluctuation patterns obtained through FFT analysis can provide clear directions for program optimization. For example, if there are significant amplitude differences in the FFT results of the three-phase instantaneous currents, it indicates a deviation in the three-phase balance control logic of the program. This can be addressed by optimizing the current closed-loop adjustment parameters to make the three-phase output more balanced.

[0106] Optionally, after calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, the following is also included:

[0107] Calculate the mechanical power of brushless motor 120 based on its output torque and speed.

[0108] Based on the test results of the mechanical power, efficiency, and output torque of the brushless motor 120, the algorithm of the controller 110 is optimized.

[0109] The algorithms of controller 110, such as speed closed-loop control and torque compensation strategies, determine the output of brushless motor 120. The test results of the mechanical power, efficiency, and output torque of brushless motor 120 provide multi-dimensional quantitative references for optimizing the controller 110's algorithm. For example, if the test finds that the actual mechanical power of brushless motor 120 is lower than the target value in a certain operating mode, it indicates a deviation in the speed command output of controller 110's algorithm. This can be addressed by optimizing the pulse width modulation duty cycle adjustment logic to improve the power output of brushless motor 120 in that mode and ensure effective airflow. If the test shows that the efficiency is too low in a certain torque range, it indicates that the current distribution of controller 110's algorithm under that operating condition is unreasonable. This can be addressed by optimizing the vector control algorithm to reduce ineffective energy consumption and improve efficiency. If the torque test shows that the torque of brushless motor 120 fluctuates too much when changing operating modes, such as switching from blowing mode to defrosting mode, during the jump from 0.56 N·m to 0.73 N·m, it indicates that the torque compensation of the algorithm is lagging. By adding feedforward control parameters, changes in the operating mode can be predicted in advance and the output current can be adjusted, thereby reducing torque fluctuation and improving operational stability.

[0110] Based on the above embodiments, optionally, the testing method for the automotive brushless blower also includes testing the output torque of the brushless motor 120 using a torque tester and testing the rotational speed using an encoder.

[0111] Before or after calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, the following is also included:

[0112] Based on the output torque and speed of the brushless motor 120, the torque at different angles is evaluated.

[0113] Specifically, during the rotation of the brushless motor 120, the output torque does not remain constant due to the continuous changes in the magnetic field distribution and the relative positions of the stator windings and rotor magnetic poles. Instead, it exhibits a certain periodic fluctuation with the rotation angle. For example, during one rotation of the rotor, the torque may reach a peak in some angular ranges and a trough in others; this fluctuation characteristic is called torque pulsation. Evaluating the torque at different angles aims to capture this pulsation pattern and determine the actual output torque value of the brushless motor 120 at each specific angle. For example, if testing the brushless motor 120 at a speed of 2000 r / min reveals significant torque pulsation within the mechanical angle range of 30°-60°, causing noticeable noise during blower operation, adjustments can be made to the brushless motor 120 and the current regulation algorithm of the controller 110 can be optimized to reduce the torque pulsation amplitude within this angular range, thereby reducing the operating noise of the blower.

[0114] Optionally, before or after calculating the efficiency of the controller 110, the efficiency of the brushless motor 120, the efficiency of the impeller and volute 130, and the overall efficiency of the HVAC140 system based on the power supply output voltage, power supply output current, three-phase instantaneous voltage, three-phase instantaneous current, output torque and speed of the brushless motor 120, and the output air volume of the HVAC140 system under a specific static pressure after the impeller is placed inside the HVAC140, the following may be included:

[0115] Vibration signals from the HVAC140 air conditioning unit are detected, and driver comfort is assessed based on these signals.

[0116] The noise of the brushless motor 120 and the impeller is isolated and detected. Based on the decibel value, order diagram, and Campbell diagram of the brushless motor 120 and the decibel value, order diagram, and Campbell diagram of the impeller, the noise source of the automotive brushless blower is determined.

[0117] In automotive brushless blower systems, detecting impeller vibration can ensure passenger comfort by controlling the vibration source. The operating noise of an automotive brushless blower is typically the result of the combined effects of mechanical vibration and electromagnetic noise from the brushless motor 120, airflow disturbance from the impeller, and blade vortices. Directly detecting the overall noise makes it difficult to distinguish the proportions of these two sources. The core of isolation testing is to physically reduce noise transmission between the two components, allowing their respective noise characteristics to be presented more independently. Then, by comparing decibel values, order diagrams, and Campbell's diagrams, the primary noise source can be identified. For example, if the decibel value of the brushless motor 120 is more than 10 decibels higher than that of the impeller, the noise mainly comes from the brushless motor 120; otherwise, the impeller noise is dominant.

[0118] Noise isolation is achieved by extending the transmission rod. The brushless motor 120 drives the impeller to rotate via the transmission rod. A short transmission rod would directly transmit the vibration of the brushless motor 120 to the impeller, causing the noise from both to superimpose and interfere with each other. Extending the transmission rod reduces the transmission of vibration from the brushless motor 120 to the impeller, while also reducing the reverse transmission of airflow noise from the impeller rotation to the brushless motor 120.

[0119] Specifically, noise detection is performed in an anechoic chamber using one or more microphones. The microphones are placed close to the brushless motor 120 (e.g., at a set distance from the housing) and the impeller (e.g., near the air outlet), respectively, and their real-time decibel values ​​are collected. For example, if the noise level near the brushless motor 120 is 65 decibels and near the impeller is 58 decibels, and the decibel difference remains stable after extending the transmission rod, it indicates that the motor is the primary noise source. Tests are performed before and after extending the transmission rod. If the noise correlation between the brushless motor 120 and the impeller decreases after isolation, it indicates effective isolation, and the decibel value at this point better reflects the true noise level of each component. By identifying the noise source, targeted optimization solutions can be developed. If the brushless motor 120 accounts for a high proportion of noise, electromagnetic noise can be reduced by improving the bearing precision of the brushless motor 120 and optimizing the magnetic circuit design; if the impeller is the primary sound source, the blades can be streamlined or a guide structure can be added to reduce airflow disturbance.

[0120] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0121] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A test method for a brushless blower for vehicles, characterized in that, The automotive brushless blower includes a controller, a brushless motor, an impeller, and a volute; the input terminal of the controller is electrically connected to the output terminal of the power supply; the output terminal of the controller is electrically connected to the stator coils U, V, and W of the brushless motor; the rotor of the brushless motor and the input terminals of the impeller and volute are mechanically connected via a transmission rod; the impeller is installed inside the HVAC unit. The testing method includes: The transmission rod between the rotor of the brushless motor and the impeller and volute is lengthened, and a dynamic torque sensor and encoder are installed on the transmission rod; The controller starts the brushless motor and drives the impeller. Detect the power supply output voltage and power supply output current; The three-phase instantaneous voltage and three-phase instantaneous current output by the controller are detected; The output torque of the brushless motor is detected by the dynamic torque sensor, and the speed of the brushless motor is detected by the encoder. The output air volume of the HVAC unit under a specific static pressure is detected after the impeller is placed inside the HVAC unit. Based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit, calculate the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system. The step of calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit includes: The efficiency of the controller is calculated based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, and the three-phase instantaneous current. The efficiency of the brushless motor is calculated based on the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor; The efficiency of the impeller and volute is calculated based on the output torque of the brushless motor, the speed of the brushless motor, and the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit. The overall efficiency of the HVAC system is calculated based on the power supply output voltage, the power supply output current, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit.

2. The test method for a brushless automotive blower according to claim 1, characterized in that, The step of calculating the efficiency of the controller based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, and the three-phase instantaneous current includes: Calculate the input power of the controller based on the power supply output voltage and the power supply output current; Calculate the output power of the controller based on the three-phase instantaneous voltage and the three-phase instantaneous current; Calculate the efficiency of the controller based on its output power and input power; And / or, the step of calculating the efficiency of the brushless motor based on the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor includes: The input power of the brushless motor is calculated based on the three-phase instantaneous voltage and the three-phase instantaneous current. Calculate the output power of the brushless motor based on its output torque and speed; Calculate the efficiency of the brushless motor based on its output power and input power. And / or, the calculation of the efficiency of the impeller and volute based on the output torque of the brushless motor, the rotational speed of the brushless motor, and the output airflow of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit includes: Calculate the input power of the impeller and volute based on the output torque and speed of the brushless motor; Based on the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit, calculate the output power of the impeller and the volute. Calculate the efficiency of the impeller and volute based on their input and output power. And / or, the step of calculating the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit includes: Calculate the total input power based on the power supply output voltage and the power supply output current; Calculate the total output power based on the output air volume of the HVAC unit under a specific static pressure after the impeller is placed inside the HVAC unit. The overall efficiency of the HVAC system is calculated based on the output power and input power of the assembly.

3. The test method for a brushless automotive blower according to claim 1, characterized in that, Before the step of controlling the brushless motor to start and drive the impeller via the controller, the method further includes: Different operating modes are set for the HVAC unit; the operating modes include a full cooling internal circulation mode for blowing on the face, a full heating external circulation mode for blowing on the feet, or a full heating external circulation mode for defrosting.

4. The test method for a brushless automotive blower according to claim 1, characterized in that, After calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the following further includes: After replacing one component of the automotive brushless blower, the test method is executed again to obtain the adjusted test results; the component is the controller, the brushless motor, the impeller, and the HVAC system; the test results include the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system. The component was adjusted and verified based on the test results before and after the adjustment.

5. The test method for a brushless automotive blower according to claim 1, characterized in that, After detecting the three-phase instantaneous voltage and three-phase instantaneous current output by the controller, the method further includes: Fast Fourier Transform analysis is performed on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, and the three-phase instantaneous current; Based on the analysis results of the Fast Fourier Transform, the program of the controller is optimized; By analyzing components of a specific order, adjusting the program can help optimize noise performance.

6. The test method for a brushless automotive blower according to claim 1, characterized in that, After calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the following further includes: Calculate the mechanical power of the brushless motor based on its output torque and speed; Based on the test results of the mechanical power, efficiency, and output torque of the brushless motor, the algorithm of the controller is optimized.

7. The test method for a brushless automotive blower according to claim 1, characterized in that, The output torque of the brushless motor was tested using a torque tester, and the rotational speed was tested using an encoder. Before or after calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the following steps are also included: Based on the output torque and speed of the brushless motor, the torque at different angles is evaluated.

8. The test method for a brushless automotive blower according to claim 1, characterized in that, Before or after calculating the efficiency of the controller, the efficiency of the brushless motor, the efficiency of the impeller and volute, and the overall efficiency of the HVAC system based on the power supply output voltage, the power supply output current, the three-phase instantaneous voltage, the three-phase instantaneous current, the output torque and speed of the brushless motor, and the output air volume of the HVAC system under a specific static pressure after the impeller is placed inside the HVAC unit, the following steps are also included: The vibration signal of the HVAC unit is detected, and the driver's comfort is evaluated based on the vibration signal. The noise of the brushless motor and the impeller is isolated and detected. Based on the decibel value, order diagram, and Campbell diagram of the brushless motor, and the decibel value, order diagram, and Campbell diagram of the impeller and volute, the noise source of the automotive brushless blower is determined.

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