Performance test structure for three-in-one electric drive system assembly of new energy automobile

Abstract

The invention discloses a new energy automobile three-in-one electric drive system assembly performance test structure, and relates to the technical field of new energy automobiles, and the structure comprises a pedestal, the upper surface of the pedestal is provided with a T-shaped groove, the lower surface of the pedestal is fixedly connected with a test site, and the two ends of the T-shaped groove are respectively provided with an automobile load condition simulation unit. A three-in-one electric drive system assembly is installed in the middle of the T-shaped groove, and the two output ends of the three-in-one electric drive system assembly are in transmission connection with the automobile load working condition simulation unit through the connecting unit. And a sensor unit is mounted on the connecting unit. According to the performance test structure for the three-in-one electric drive system assembly of the new energy automobile, the complex structure of the rack is simplified, operation is convenient, practicability is high, meanwhile, the height and angle of the three-in-one electric drive system assembly can be adjusted through the support unit, three-in-one electric drive system assemblies of different types can be rapidly installed, and the test efficiency is improved. And the adaptability of the three-in-one electric drive system assembly test structure is enhanced.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle technology, and in particular to a performance testing structure for a three-in-one electric drive system assembly in new energy vehicles. Background Technology

[0002] With the increasing penetration rate of the new energy vehicle market, the efficiency, reliability, and dynamic response capabilities of powertrains have become core competitive indicators. In the powertrain field, the "three-in-one" electric drive system assembly integrating the motor, reducer, and inverter has become the market mainstream due to its high integration, lightweight design, and cost advantages. Existing three-in-one electric drive system assemblies primarily rely on complex physical bench tests for performance evaluation. The entire testing process heavily depends on precise mechanical structures (clamps, couplings, drive shafts, dynamometers, and their mounting bases) to transmit power and simulate loads, ensuring measurement accuracy. However, this approach suffers from complex bench structure design, cumbersome installation, and high testing costs. Existing benches typically require the design and manufacture of expensive dedicated mechanical clamps and connectors for each tested model, resulting in numerous non-standard parts, complex inventory management, and high costs. Furthermore, to suppress vibration and ensure testing accuracy, the entire bench (including the base, support structure, and connectors) needs to be designed to be very bulky and rigid, increasing the difficulty and cost of manufacturing, transportation, and installation.

[0003] Furthermore, the system lacks adaptability to performance testing of different types of three-in-one electric drive system assemblies. This is reflected in the fact that the external dimensions, output shaft offset, and height of different types of three-in-one electric drive system assemblies may vary, and the mechanical structure of the test bench, such as the position of the dynamometer and the adjustment range of the support frame, is limited, making it difficult to flexibly adapt to various geometric dimensions.

[0004] Developing a performance testing structure for a three-in-one electric drive system assembly in new energy vehicles, reducing reliance on non-standard parts, solving the problems of complex bench structure design, troublesome installation, and high testing costs, and enhancing the adaptability of the three-in-one electric drive system assembly testing structure, has become a technical challenge that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide a performance testing structure for a three-in-one electric drive system assembly in new energy vehicles, thereby solving the problems listed in the background art.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] This invention discloses a performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle, comprising a frame and a base. The upper surface of the base has a T-shaped groove, and the lower surface of the base is fixedly connected to the test site. Vehicle load condition simulation units are respectively installed at both ends of the T-shaped groove, and a three-in-one electric drive system assembly is installed in the middle of the T-shaped groove. The two output ends of the three-in-one electric drive system assembly are respectively connected to the vehicle load condition simulation unit through a connecting unit.

[0008] A sensor unit is installed on the connection unit.

[0009] Preferably, the vehicle load condition simulation unit includes a left-side three-phase asynchronous motor and a right-side three-phase asynchronous motor, which are respectively fixedly installed on the left and right sides of the T-slot using anchor bolts.

[0010] The output end of the left-side three-phase asynchronous motor is equipped with a first coupling, and the output end of the right-side three-phase asynchronous motor is equipped with a fourth coupling.

[0011] Preferably, the connecting unit includes a left support member and a right support member. The lower ends of the left support member and the right support member are fixedly connected to the T-slot by bolts. A left bearing seat is installed at the upper end of the left support member, and a right bearing seat is installed at the upper end of the right support member.

[0012] A left test drive shaft is installed inside the left bearing housing. One end of the left test drive shaft is connected to the first coupling. A second coupling is installed at the other end of the left test drive shaft. The second coupling is connected to the left half-shaft connector. The left half-shaft connector is connected to one end of the left half-shaft. The other end of the left half-shaft is connected to the three-in-one electric drive system assembly.

[0013] A right test drive shaft is installed inside the right bearing housing. One end of the right test drive shaft is connected to the fourth coupling. A third coupling is installed at the other end of the right test drive shaft. The third coupling is connected to the right half-shaft connector. The right half-shaft connector is connected to one end of the right half-shaft. The other end of the right half-shaft is connected to the three-in-one electric drive system assembly.

[0014] Preferably, the sensor unit includes a left torque-speed sensor and a right torque-speed sensor, the left torque-speed sensor being installed in the middle of the left test drive shaft, and the right torque-speed sensor being installed in the middle of the right test drive shaft.

[0015] Preferably, it further includes a support unit, the support unit including a first suspension bracket, a second suspension bracket and a third suspension bracket, the first suspension bracket, the second suspension bracket and the third suspension bracket are arranged in an isosceles triangle, and the second suspension bracket and the third suspension bracket are symmetrically installed about the first suspension bracket, the lower end of the first suspension bracket is connected to an adjustable support frame, and the second suspension bracket and the third suspension bracket are installed on the T-slot;

[0016] The upper ends of the first suspension bracket, the second suspension bracket, and the third suspension bracket are connected to the three-in-one electric drive system assembly.

[0017] Preferably, the adjustable support frame includes a transition fixture, an upper connecting plate, a support column, and a lower connecting plate. The lower connecting plate is fixed to the base by a pressure plate. The support column is welded to the lower connecting plate, and a threaded lifting rod is installed inside the support column. The top of the lifting rod is fixedly connected to the lower surface of the upper connecting plate.

[0018] The upper connecting plate has a stepped mating surface, and the upper plate of the upper connecting plate is machined with four 90° equally distributed symmetrical positioning protrusions.

[0019] The transition fixture adopts an adjustable tilting base structure. The base of the transition fixture is machined with four 90° equally distributed symmetrical positioning keyways, which are precisely matched with the positioning convex keys.

[0020] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0021] 1) The performance testing structure for the three-in-one electric drive system assembly of the present invention can complete a series of test items on existing benches, such as assembly efficiency test, peak power torque duration test, continuous performance test, and torque control accuracy test. It simplifies the complex structure of the bench, is easy to operate, and is highly practical. At the same time, the height and angle of the three-in-one electric drive system assembly can be adjusted through the support unit, and different types of three-in-one electric drive system assemblies can be quickly installed, which enhances the adaptability of the three-in-one electric drive system assembly testing structure.

[0022] 2) The three-in-one electric drive system assembly has a wide adaptability in performance testing structure. It can be equipped with a frequency converter to control the speed and torque of a three-phase asynchronous motor. It is also equipped with communication equipment, providing CAN communication to transmit the speed and torque of the three-phase asynchronous motor in real time and receive commands from the control system. When the three-in-one electric drive system assembly is powered on and the drive system is working, the frequency converter can rectify the AC power generated by the three-phase asynchronous motor in the generator state into DC power, and feed it back to the battery system through the DC bus to realize the recovery of regenerative energy. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings.

[0024] Figure 1 This is a front view schematic diagram of a performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle according to the present invention;

[0025] Figure 2 This is a top view schematic diagram of a performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle according to the present invention;

[0026] Figure 3 This is a three-dimensional schematic diagram of a performance testing structure for a three-in-one electric drive system assembly for new energy vehicles according to the present invention;

[0027] Figure 4 This is a schematic diagram of the adjustable support frame structure of the present invention.

[0028] Explanation of reference numerals in the attached drawings: 1. Base; 2. Left support; 3. Left three-phase asynchronous motor; 4. First coupling; 5. Left test drive shaft; 6. Left torque and speed sensor; 7. Left bearing housing; 8. Second coupling; 9. Left half-shaft connector; 10. Left half-shaft; 11. Three-in-one electric drive system assembly; 12. First suspension bracket; 13. Adjustable support frame; 131. Transition fixture; 132. Upper connecting plate; 133. Support column; 134. Lower connecting plate; 14. Right half-shaft; 15. Right torque and speed sensor; 16. Right test drive shaft; 17. Fourth coupling; 18. Right three-phase asynchronous motor; 19. Right support; 20. Right bearing housing; 21. Third coupling; 22. Right half-shaft connector; 23. Second suspension bracket; 24. Third suspension bracket. Detailed Implementation

[0029] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0030] like Figure 1-4 As shown, a performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle includes a base 1. The upper surface of the base 1 has a T-slot for stable installation of the testing structure. The lower surface of the base 1 is fixedly connected to the test site. Vehicle load condition simulation units are installed at both ends of the T-slot to simulate the load conditions of the vehicle during actual operation. A three-in-one electric drive system assembly 11 is installed in the middle of the T-slot. The two output ends of the three-in-one electric drive system assembly 11 are respectively connected to the vehicle load condition simulation unit through a connecting unit.

[0031] A sensor unit is installed on the connection unit.

[0032] Specifically, the vehicle load condition simulation unit includes a left three-phase asynchronous motor 3 and a right three-phase asynchronous motor 18, which are respectively fixedly installed on the left and right sides of the T-slot by anchor bolts;

[0033] The output end of the left-side three-phase asynchronous motor 3 is equipped with a first coupling 4, and the output end of the right-side three-phase asynchronous motor 18 is equipped with a fourth coupling 17.

[0034] Specifically, the connecting unit includes a left support member 2 and a right support member 19. The lower ends of the left support member 2 and the right support member 19 are fixedly connected to the T-slot by bolts. A left bearing seat 7 is installed on the upper end of the left support member 2, and a right bearing seat 20 is installed on the upper end of the right support member 19.

[0035] A left test drive shaft 5 is installed inside the left bearing housing 7. One end of the left test drive shaft 5 is connected to the first coupling 4. A second coupling 8 is installed at the other end of the left test drive shaft 5. The second coupling 8 is connected to the left half-shaft connector 9. The left half-shaft connector 9 is connected to one end of the left half-shaft 10. The other end of the left half-shaft 10 is connected to the three-in-one electric drive system assembly 11.

[0036] A right test drive shaft 16 is installed inside the right bearing housing 20. One end of the right test drive shaft 16 is connected to the fourth coupling 17. The other end of the right test drive shaft 16 is equipped with a third coupling 21. The third coupling 21 is connected to the right half-shaft connector 22. The right half-shaft connector 22 is connected to one end of the right half-shaft 14. The other end of the right half-shaft 14 is connected to the three-in-one electric drive system assembly 11.

[0037] Specifically, the sensor unit includes a left torque and speed sensor 6 and a right torque and speed sensor 15. The left torque and speed sensor 6 is installed in the middle of the left test drive shaft 5 and is used to measure the torque and speed of the input shaft of the three-phase asynchronous motor 3. The right torque and speed sensor 15 is installed in the middle of the right test drive shaft 16 and is used to measure the torque and speed of the input shaft of the three-phase asynchronous motor 18.

[0038] Specifically, it also includes a support unit, which includes a first suspension bracket 12, a second suspension bracket 23, and a third suspension bracket 24. The first suspension bracket 12, the second suspension bracket 23, and the third suspension bracket 24 are arranged in an isosceles triangle, and the second suspension bracket 23 and the third suspension bracket 24 are symmetrically installed about the first suspension bracket 12. The lower end of the first suspension bracket 12 is connected to an adjustable support frame 13, and the second suspension bracket 23 and the third suspension bracket 24 are installed on the T-slot.

[0039] The upper ends of the first suspension bracket 12, the second suspension bracket 23 and the third suspension bracket 24 are connected to the three-in-one electric drive system assembly 11;

[0040] The adjustable support frame 13 includes a transition tooling 131, an upper connecting plate 132, a support column 133, and a lower connecting plate 134. The lower connecting plate 134 is fixed to the base 1 by a pressure plate. The support column 133 is welded to the lower connecting plate 134. A threaded lifting rod is installed inside the support column 133. The lifting is driven by rotating the rod or by an external handwheel. A locking nut is provided to prevent backing out. The top of the lifting rod is fixedly connected to the lower surface of the upper connecting plate 132.

[0041] The upper connecting plate 132 has a stepped mating surface, and the upper plate of the upper connecting plate 132 is machined with four 90° equally distributed symmetrical positioning protrusions.

[0042] The transition fixture 131 adopts an adjustable tilting base structure. The base of the transition fixture 131 is machined with four 90° equally distributed symmetrical positioning keyways. The positioning keyways are precisely matched with the positioning convex key to ensure the positioning accuracy of the suspension bracket 12 installed on the transition fixture 131. At the same time, the transition fixture 131 drives the screw to rotate by rotating the handwheel.

[0043] The height and angle of the three-in-one electric drive system assembly can be adjusted by the bracket unit, which allows for quick installation of different types of three-in-one electric drive system assemblies and enhances the adaptability of the three-in-one electric drive system assembly test structure.

[0044] Working principle: When the three-in-one electric drive system assembly 11 is powered on, it drives the left half shaft 10 and the right half shaft 14 to rotate. The left half shaft 10 and the right half shaft 14 are connected to the three-phase asynchronous motors at both ends through a coupling, a torque and speed sensor, and the three-phase asynchronous motors at both ends. The three-phase asynchronous motors at both ends are used to simulate the load conditions of the car in actual operation, thereby completing the performance test of the three-in-one electric drive system assembly.

[0045] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0046] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle, comprising a base (1), wherein a T-slot is formed on the upper surface of the base (1), and the lower surface of the base (1) is fixedly connected to the test site, characterized in that: The two ends of the T-slot are respectively equipped with vehicle load condition simulation units, and the middle of the T-slot is equipped with a three-in-one electric drive system assembly (11). The two output ends of the three-in-one electric drive system assembly (11) are respectively connected to the vehicle load condition simulation unit through a connection unit. A sensor unit is installed on the connection unit.

2. The performance testing structure for a three-in-one electric drive system assembly of new energy vehicles according to claim 1, characterized in that: The vehicle load simulation unit includes a left three-phase asynchronous motor (3) and a right three-phase asynchronous motor (18), which are respectively fixedly installed on the left and right sides of the T-slot by anchor bolts; The output end of the left three-phase asynchronous motor (3) is equipped with a first coupling (4), and the output end of the right three-phase asynchronous motor (18) is equipped with a fourth coupling (17).

3. The performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle according to claim 2, characterized in that: The connecting unit includes a left support member (2) and a right support member (19). The lower ends of the left support member (2) and the right support member (19) are fixedly connected to the T-slot by bolts. A left bearing seat (7) is installed on the upper end of the left support member (2), and a right bearing seat (20) is installed on the upper end of the right support member (19). The left bearing housing (7) is equipped with a left test drive shaft (5). One end of the left test drive shaft (5) is connected to the first coupling (4). The other end of the left test drive shaft (5) is equipped with a second coupling (8). The second coupling (8) is connected to the left half shaft connector (9). The left half shaft connector (9) is connected to one end of the left half shaft (10). The other end of the left half shaft (10) is connected to the three-in-one electric drive system assembly (11). The right bearing housing (20) is equipped with a right test drive shaft (16). One end of the right test drive shaft (16) is connected to the fourth coupling (17). The other end of the right test drive shaft (16) is equipped with a third coupling (21). The third coupling (21) is connected to the right half-shaft connector (22). The right half-shaft connector (22) is connected to one end of the right half-shaft (14). The other end of the right half-shaft (14) is connected to the three-in-one electric drive system assembly (11).

4. The performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle according to claim 3, characterized in that: The sensor unit includes a left torque-speed sensor (6) and a right torque-speed sensor (15). The left torque-speed sensor (6) is installed in the middle of the left test drive shaft (5), and the right torque-speed sensor (15) is installed in the middle of the right test drive shaft (16).

5. The performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle according to claim 1, characterized in that: It also includes a support unit, which includes a first suspension bracket (12), a second suspension bracket (23) and a third suspension bracket (24). The first suspension bracket (12), the second suspension bracket (23) and the third suspension bracket (24) are arranged in an isosceles triangle, and the second suspension bracket (23) and the third suspension bracket (24) are symmetrically installed about the first suspension bracket (12). The lower end of the first suspension bracket (12) is connected to an adjustable support frame (13), and the second suspension bracket (23) and the third suspension bracket (24) are installed on the T-slot. The upper ends of the first suspension bracket (12), the second suspension bracket (23) and the third suspension bracket (24) are connected to the three-in-one electric drive system assembly (11).

6. The performance testing structure for a three-in-one electric drive system assembly of a new energy vehicle according to claim 5, characterized in that: The adjustable support frame (13) includes a transition fixture (131), an upper connecting plate (132), a support column (133), and a lower connecting plate (134). The lower connecting plate (134) is fixed to the base (1) by a pressure plate. The support column (133) is welded to the lower connecting plate (134), and a threaded lifting rod is installed inside the support column (133). The top of the lifting rod is fixedly connected to the lower surface of the upper connecting plate (132). The upper connecting plate (132) has a stepped mating surface, and the upper plate of the upper connecting plate (132) is machined with four 90° equally distributed symmetrical positioning protrusions. The transition fixture (131) adopts an adjustable tilting base structure. The base of the transition fixture (131) is machined with four 90° equally distributed symmetrical positioning keyways. The positioning keyways are precisely matched with the positioning convex keys.

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