In-loop test device and method of motor controller based on Hall signal

Abstract

The invention provides an in-loop test device and method of a motor controller based on Hall signals, and belongs to the technical field of automobile detection. The motor simulation test device is electrically connected with the to-be-tested motor controller, the configuration parameters of the to-be-tested motor are loaded, the motor driving signal sent by the motor controller is detected, and the motion state information of the driving motor under the current condition is simulated under the condition that the motor driving signal is detected. Hall feedback signals are simulated and generated and fed back to the motor controller, a hardware loop is formed, in-loop testing is achieved, whether functional logic of the motor controller is correct or not is verified, any actual upstream and downstream devices are not needed to be matched for testing in the whole testing process, the testing passivity is lower, the testing limit is smaller, and the testing efficiency is higher; and the state change of the motor under the extreme working condition can be directly simulated, the test coverage is wider, the adaptability is better, and the development period of the motor controller is shortened.

Description

Technical Field

[0001] This invention relates to the field of automotive testing technology, specifically to an in-loop testing device and method for motor controllers based on Hall signals. Background Technology

[0002] Car windows, sunroofs, and power seats are usually equipped with drive motors, and these drive motors are equipped with motor controllers. The motor controllers output control commands to the drive motors to control their operating status. Therefore, ensuring the performance of the motor controllers is crucial to ensuring that the relevant functions on the car work properly.

[0003] Currently, there are motor controllers on the market that utilize Hall signals from the drive motor for control. During their development and testing, testing typically waits for upstream and downstream component suppliers to prepare crucial components such as windows, motors, seats, and sunroofs before proceeding to verify the correctness of their functional logic. This testing method is highly susceptible to problems due to the characteristics of the motor under test (DUT) connected to the controller, as well as potential program errors or misoperations during testing. This can easily lead to aging and damage to the DUT, or even prolonged stalling and burnout. Furthermore, the passive nature of waiting for all upstream and downstream components to be in place before testing and verification during motor controller development and testing imposes significant limitations, impacting testing efficiency and consequently affecting the product development cycle. Furthermore, some extreme operating conditions are difficult to manufacture on normal components during testing. If extreme operating condition testing is required, some normal components need to be damaged or a different design needs to be made before re-verification. This makes it difficult to verify extreme operating conditions, resulting in a small test coverage, further reducing test limitations and efficiency, and failing to meet the development needs of rapid design and verification of motor controllers. Therefore, the industry needs to provide an in-loop test device that can test motor controllers without requiring actual upstream and downstream components to cooperate in testing and can meet the requirements of extreme operating condition testing. Summary of the Invention

[0004] To address the aforementioned problems in existing technologies, this paper aims to provide an in-loop testing device and method for motor controllers based on Hall signals. A motor simulation testing device is connected to the motor controller under test. After the motor controller sends a motor drive signal, the motor simulation testing device generates a Hall feedback signal corresponding to the current condition. This Hall feedback signal contains the motor's speed and direction information under the current condition, and the generated Hall feedback signal is fed back to the motor controller, forming a hardware loop. This satisfies the in-loop testing requirements of the motor controller. Furthermore, no actual upstream or downstream components are involved in the testing process, reducing test passivity, minimizing test limitations, and increasing test efficiency. It can also directly simulate state changes under extreme operating conditions, providing better test coverage and better meeting the testing needs for rapid design verification of motor controllers.

[0005] The specific technical solution is as follows: An in-loop testing device for a motor controller based on Hall signals, used to test a motor controller that acquires Hall feedback signals, has the following features: The motor simulation test device is electrically connected to the motor controller that acquires Hall feedback signals. It is used to load the configuration parameters of the motor, and after the loading is completed, it continuously detects the motor drive signal output by the motor controller. Based on the configuration parameters, the motor drive signal, and the Hall feedback signal of the motor under the current condition when there is an injection event, it simulates the Hall feedback signal of the motor and feeds it back to the motor controller. The power supply is electrically connected to the motor simulation test device to provide power for its operation.

[0006] The aforementioned in-loop testing device for a motor controller based on Hall signals further includes a host computer that is communicatively connected to a motor simulation testing device. The host computer is used to load the motor's configuration parameters into the motor simulation testing device, modify the motor's configuration parameters, inject events into the calculation process of the simulated Hall feedback signal, and receive and display the updated motor motion status under the current conditions from the motor simulation testing device.

[0007] The aforementioned in-loop testing device for a motor controller based on Hall signals further includes an external button for injecting events into the calculation process of the simulated Hall feedback signal.

[0008] The aforementioned in-loop testing device for a motor controller based on Hall signals includes a screen that displays the configuration parameters of the loaded motor and updates the current motion status information in real time.

[0009] A loop-in-the-loop testing method for a Hall-signal-based motor controller, using the aforementioned loop-in-the-loop testing device for a Hall-signal-based motor controller, includes the following steps: Step S1: Start the testing device; When the device is powered on, the motor simulation test device loads the configuration parameters of the motor and continuously detects the motor drive signal output by the motor controller under test. If the motor drive signal is detected, proceed to step S2; otherwise, return to continue detecting the motor drive signal. Step S2, simulate motor feedback signal; If an event is injected, the motor simulation test device simulates the motor's motion state under the current condition based on the loaded motor's configuration parameters and motor drive signals, and generates a Hall feedback signal under the current condition, feeding the Hall feedback signal back to the feedback structure of the motor controller under test. If an event is injected, the motor simulation test device simulates the motor's motion state under the current condition based on the loaded motor's configuration parameters, motor drive signals, and the injected event, and generates a Hall feedback signal under the current condition, feeding the Hall feedback signal back to the feedback structure of the motor controller under test. Step S3: Update and upload your exercise status; After receiving the Hall feedback signal, the motor controller under test controls the motor simulation test device to update and upload the motor motion status under the current conditions in real time.

[0010] The above-mentioned loop-in-the-loop testing method for a motor controller based on Hall signals, wherein in step S1, the loaded motor configuration parameters include default configuration parameters and modified configuration parameters, and the modified configuration parameters are the configuration parameters after modifying the default configuration parameters.

[0011] The above-mentioned loop-in-the-loop testing method for a motor controller based on Hall signals includes, in the default configuration parameters or modified configuration parameters, the device information of the drive motor, the motor running direction, the motor running speed, the Hall pulse width, the number of motor magnetic poles, the device movement stroke, and the Hall disturbance data during start / stop.

[0012] The above-mentioned in-loop testing method for a motor controller based on Hall signals includes Hall feedback signals including Hall speed signals and Hall direction signals. The Hall speed signal is a pulse signal and is related to the pulse period and the number of magnetic pole pairs. The Hall direction signal is a digital level signal and is determined by the rotation direction of the drive motor.

[0013] The above-mentioned in-loop testing method for a motor controller based on Hall signals includes injected events such as stall, hand clamping, Hall speed loss, Hall direction error, overtravel, and self-position modification.

[0014] The positive effects of the above technical solution are: The aforementioned Hall effect-based motor controller in-loop testing device and method, by setting up a motor simulation test device and electrically connecting it to the motor controller under test, pre-loads the configuration parameters of the motor under test, and combines the configuration parameters with the motor drive signal when it is detected, and calculates and simulates the motor's motion state under the current condition when an event is injected, and simulates the generation of Hall effect feedback signals to feed back to the motor controller, realizes in-loop testing, meets the verification requirements for the correctness of the logic of the motor controller's functionality, and does not require any actual upstream or downstream components to cooperate with the test, effectively reducing the passivity of the test, reducing test limitations, improving test efficiency, and simulating state changes under extreme working conditions, improving test coverage, better meeting the test requirements for rapid design verification of motor controllers, and shortening the development cycle of motor controllers. Attached Figure Description

[0015] Figure 1 This is a structural diagram of an embodiment of an in-loop testing device for a motor controller based on Hall signals according to the present invention; Figure 2 This is a schematic diagram of the operation of an in-loop testing device for a motor controller based on Hall signals according to the present invention; Figure 3 This is a schematic diagram of an in-loop testing device for a motor controller based on Hall signals according to the present invention when an event is injected during the testing process; Figure 4 This is a schematic diagram of an in-loop testing method for a motor controller based on Hall signals according to the present invention; Figure 5 The relationship between Hall speed and Hall direction in the Hall feedback signal under normal conditions and the motor drive signal is presented in the loop-in testing method of a motor controller based on Hall signals according to the present invention. Figure 6 The present invention relates the Hall speed and Hall direction in the Hall feedback signal and the motor drive signal respectively when a stall event is injected in an in-loop test method for a motor controller based on Hall signals. Figure 7 The present invention relates the Hall speed in the Hall feedback signal during overtravel event injection and the Hall speed in the Hall feedback signal under normal conditions to the motor drive signal in an in-loop test method for a Hall signal-based motor controller.

[0016] In the attached diagram: 1. Motor controller; 2. Motor simulation test device; 21. External buttons; 22. Screen; 3. Power supply; 4. Host computer. Detailed Implementation

[0017] To make the technical means, creative features, objectives, and effects of this invention easier to understand, the following embodiments are provided in conjunction with the appendix. Figure 1 To be continued Figure 7 The technical solutions provided by this invention are described in detail, but the following content is not intended to limit this invention.

[0018] Figure 1 This is a structural diagram of an embodiment of an in-loop testing device for a motor controller based on Hall signals according to the present invention; Figure 2 This is a schematic diagram illustrating the operation of an in-loop testing device for a motor controller based on Hall signals according to the present invention. Figure 1 and Figure 2 As shown, the Hall-signal-based motor controller in-loop testing device provided in this embodiment is used to test the motor controller 1 that acquires Hall feedback signals. It utilizes the Hall feedback signals generated by the Hall sensors installed in the motor during motor operation to represent the motor's motion state. The Hall feedback signals are used to determine whether the motor controller 1 under test meets the design requirements. Specifically, the Hall-signal-based motor controller 1 in-loop testing device provided in this embodiment includes: a motor simulation testing device 2 and a power supply 3. An optional host computer 4 can also be configured to modify the motor's configuration parameters and display the updated motor motion state, facilitating testing operations for the testing personnel.

[0019] Figure 3 This is a schematic diagram illustrating an in-loop testing device for a Hall-signal-based motor controller according to the present invention during an event injection process. Figures 1 to 3As shown, the motor simulation test device 2 is electrically connected to the motor controller 1, which acquires Hall feedback signals. This allows the motor controller 1 to send motor drive signals to the motor simulation test device 2, controlling its operation. The motor simulation test device 2 loads the motor's configuration parameters and continuously monitors the motor drive signal output by the motor controller 1 after the parameters are loaded. If a motor drive signal is detected, the motor simulation test device 2 operates and simulates the motor's operating state under the current conditions based on the configuration parameters, the motor drive signal, and, in the event of an injection event, the injected event. It then generates corresponding Hall feedback signals and feeds them back to the motor controller 1, achieving in-loop testing. This completes the test without the involvement of any actual upstream or downstream components, eliminating the need to wait for the development and manufacturing of these components. This reduces test passivity, reduces test limitations, increases efficiency, and shortens the test cycle. Furthermore, by changing the motor's configuration parameters, it enables simulation testing of different operating conditions for different products, providing better test coverage and better meeting the rapid design and verification testing needs of the motor controller 1. It is worth noting that the motor controller 1 under test has a built-in feedback structure to receive the Hall feedback signal, thereby verifying whether the functional logic of the motor controller 1 under test is correct and meeting the test requirements.

[0020] Specifically, power supply 3 is electrically connected to motor simulation test device 2, and power supply 3 supplies power to motor simulation test device 2 to ensure that motor simulation test device 2 can operate normally during the test and meet the test requirements.

[0021] More specifically, the motor simulation test device 2 is also communicatively connected to a host computer 4. Preferably, the host computer 4 can be a computer, tablet, or other human-computer interaction device, facilitating the tester's access to and modification of information. Furthermore, the host computer 4 is used to load the motor's configuration parameters into the motor simulation test device 2, enabling the tester to load these parameters. The host computer 4 also allows modification of the motor's configuration parameters, allowing the tester to simulate different operating conditions for different products. Additionally, when event injection is required, the host computer 4 injects events into the calculation process of the simulated Hall feedback signal. After the motor simulation test device 2 updates the current motor motion state, the host computer 4 receives and displays this updated state, allowing the tester to easily access the test results. It is worth noting that the host computer 4 and the motor simulation test device 2 are connected through a communication interface, which can transmit signals in real time. This ensures that the motor simulation test device 2 can transmit the current motor motion status to the host computer 4. In addition, the host computer 4 can also send the motor configuration parameters to the motor simulation test device 2 through the communication interface. At the same time, the host computer 4 can also inject events into the motor simulation test device 2 through the communication interface, thus meeting the interactive communication requirements.

[0022] More specifically, the motor simulation test device 2 also includes an external button 21. In this case, the external button 21 is used to inject events into the calculation process of the simulated Hall feedback signal. That is, when it is necessary to inject events during the test, the tester can press the external button 21 to inject time into the calculation process of the simulated Hall feedback signal, thereby facilitating the injection of events during the test and making the test more convenient.

[0023] More specifically, the motor simulation test device 2 also includes a screen 22, which provides a human-machine interface. At this time, the configuration parameters of the loaded motor are displayed on the screen 22, and the current motion status information is updated in real time, which also makes it easier for testers to obtain the test situation and facilitates the test.

[0024] In addition, this embodiment also provides an in-loop testing method for a motor controller 1 based on Hall signals, which uses the aforementioned in-loop testing device for a motor controller 1 based on Hall signals. Figure 4 This is a schematic diagram of an in-loop testing method for a motor controller based on Hall signals according to the present invention; Figure 5 This invention relates to an in-loop testing method for a Hall-signal-based motor controller, specifically the relationship between the Hall speed and Hall direction in the Hall feedback signal under normal conditions and the motor drive signal. For example... Figure 4 and Figure 5As shown, the in-loop testing method for the motor controller 1 based on Hall signals specifically includes the following steps: Step S1: Start the testing device; When the device is powered on, the motor simulation test device 2 loads the motor's configuration parameters. If the configuration parameters have not been modified, the default configuration parameters are loaded. If the configuration parameters have been modified, the modified configuration parameters are loaded. In addition, the device continuously monitors the motor drive signal output by the motor controller 1 under test. If the motor drive signal is detected, step S2 is performed. If the motor drive signal is not detected, the device returns to continue monitoring the motor drive signal.

[0025] At this point, the modified configuration parameters are the modified default configuration parameters. That is, during testing, if no modified configuration parameters are loaded into the motor simulation test device 2, the motor simulation test device 2 will load the default configuration parameters to ensure that the motor simulation test device 2 can operate normally. If the tester modifies the default configuration parameters through the host computer 4 to form modified configuration parameters, the motor simulation test device 2 will load the modified configuration parameters, thereby completing the simulation test of different drive motors and different scenarios, providing the conditions for obtaining Hall feedback signals in the future.

[0026] In addition, both the default and modified configuration parameters include the device information of the drive motor, the motor running direction, the motor running speed, the Hall pulse width, the number of motor magnetic poles, the device movement stroke, and the Hall disturbance data during start / stop, meeting the testing needs of different motors under different operating conditions.

[0027] Step S2, simulate motor feedback signal; If an event is injected, the motor simulation test device 2 simulates the motor's motion state under the current conditions based on the loaded motor's configuration parameters and motor drive signals. Its internal signal control circuit calculates and simulates the Hall feedback signal under the current conditions and feeds it back to the feedback structure of the motor controller 1 under test. If an event is injected, the motor simulation test device 2 simulates the motor's motion state under the current conditions based on the loaded motor's configuration parameters, motor drive signals, and the injected event. Its internal signal control circuit calculates and simulates the Hall feedback signal under the current conditions and feeds it back to the feedback structure of the motor controller 1 under test.

[0028] This embodiment provides the changes in Hall velocity and Hall direction during stall event injection. Figure 6 This invention relates to an in-loop testing method for a Hall-signal-based motor controller, specifically the relationship between the Hall speed and Hall direction in the Hall feedback signal and the motor drive signal during a stall event injection. For example... Figure 5 and Figure 6As shown, with the injection of a stall event, the Hall speed in the Hall feedback signal disappears, leaving only the Hall direction signal. This indicates that the Hall feedback signal contains a stall event, which is helpful for verifying the control performance of motor controller 1.

[0029] In addition, this embodiment also provides a comparison between the Hall speed during overtravel event injection and the Hall speed under normal conditions. Figure 7 This invention relates to an in-loop testing method for a Hall-signal-based motor controller, detailing the relationship between the Hall speed in the Hall feedback signal during overtravel event injection and the Hall speed in the Hall feedback signal under normal conditions, and the motor drive signal. For example... Figure 7 As shown, when an overtravel event is injected into the motor simulation test device 2, it can be seen that under normal circumstances, when the motor runs to the set motion formation point, the Hall speed that should have disappeared will not disappear, but will maintain the original Hall speed. This indicates that the Hall feedback signal contains an overtravel event, which also facilitates the verification of the control performance of the motor controller 1.

[0030] Furthermore, the simulated Hall feedback signal includes Hall speed and Hall direction signals, and the combination of these signals represents different injected events. These injected events include stall, hand clamping, loss of Hall speed, incorrect Hall direction, overtravel, and repositioning. The Hall speed signal is a pulse signal, related to the pulse period and the number of pole pairs, specifically: motor speed n = 60 / (T×P) rpm, where T is the pulse period and P is the number of pole pairs. The Hall direction signal is a digital level signal determined by the motor's rotation direction; a high level indicates forward rotation, and a low level indicates reverse rotation. Arbitrary combinations of the Hall speed and direction signals simulate various operating conditions of the motor. For example, in cases of stall or hand clamping, the pulse period gradually increases until the Hall speed signal disappears, leaving only the Hall direction signal, indicating that the motor is completely stalled.

[0031] Step S3: Update and upload your exercise status; After receiving the Hall feedback signal, the motor controller 1 under test controls the motor simulation test device 2 to update and upload the motor motion status under the current condition in real time. It is worth noting that the real-time updated motor motion status under the current condition is displayed on the screen 22 of the motor simulation test device 2. The motion status information is refreshed through the screen 22, and the real-time updated motor motion status under the current condition is uploaded to the host computer 4 for synchronous updating.

[0032] This embodiment provides an in-loop testing device and method for a motor controller based on Hall signals. It includes a motor simulation testing device 2 electrically connected to a power supply 3, and the motor simulation testing device 2 is electrically connected to a motor controller 1 under test. The configuration parameters of the motor under test are loaded, and the motor drive signal emitted by the motor controller 1 is detected. Upon detection of the motor drive signal, the device simulates the motion state information of the driven motor under the current condition and simulates the generation of Hall feedback signals, feeding them back to the motor controller 1 to form a hardware loop, thus realizing in-loop testing. This verifies the correctness of the logic of the motor controller 1's functionality. The entire testing process does not require any actual upstream or downstream components to cooperate with the testing, resulting in lower test passivity, fewer test limitations, higher test efficiency, and the ability to directly simulate motor state changes under extreme operating conditions. This provides broader test coverage, better adaptability, and shortens the development cycle of the motor controller 1.

[0033] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. An in-loop testing device for a motor controller based on Hall signals, used to test a motor controller that acquires Hall feedback signals, characterized in that, include: The motor simulation test device is electrically connected to the motor controller that acquires Hall feedback signals. It is used to load the configuration parameters of the motor, and after the loading is completed, continuously detect the motor drive signal output by the motor controller. Based on the configuration parameters, the motor drive signal, and the Hall feedback signal of the motor under the current condition when there is an injection event, it simulates the Hall feedback signal of the motor and feeds it back to the motor controller. The power supply is electrically connected to the motor simulation test device to provide power for the operation of the motor simulation test device.

2. The in-loop testing device for a motor controller based on Hall signals according to claim 1, characterized in that, It also includes a host computer, which is communicatively connected to the motor simulation test device. The host computer is used to load the configuration parameters of the motor into the motor simulation test device, modify the configuration parameters of the motor, inject events into the calculation process of simulating the Hall feedback signal, and receive and display the updated motor motion status under the current conditions from the motor simulation test device.

3. The in-loop testing device for a motor controller based on Hall signals according to claim 1, characterized in that, The motor simulation test device also includes external buttons for injecting events into the calculation process of the simulated Hall feedback signal.

4. The in-loop testing device for a motor controller based on Hall signals according to claim 1, characterized in that, The motor simulation testing device includes a screen that displays the configuration parameters of the loaded motor and updates the current motion status information in real time.

5. A loop-in-the-loop testing method for a Hall-signal-based motor controller, using the loop-in-the-loop testing apparatus for a Hall-signal-based motor controller as described in any one of claims 1-4, characterized in that, It includes the following steps: Step S1: Start the testing device; When the device is powered on, the motor simulation test device loads the configuration parameters of the motor and continuously detects the motor drive signal output by the motor controller under test. If the motor drive signal is detected, step S2 is performed; if the motor drive signal is not detected, the device returns to continue detecting the motor drive signal. Step S2, simulate motor feedback signal; If there is no event injection, the motor simulation test device simulates the motor motion state under the current condition according to the configuration parameters of the loaded motor and the motor drive signal, and simulates the Hall feedback signal under the current condition, and feeds the Hall feedback signal back to the feedback structure of the motor controller under test. If an event is injected, the motor simulation test device simulates the motor motion state under the current condition according to the configuration parameters of the loaded motor, the motor drive signal and the injected event, and simulates the Hall feedback signal under the current condition, and feeds the Hall feedback signal back to the feedback structure of the motor controller under test; Step S3: Update and upload your exercise status; After receiving the Hall feedback signal, the motor controller under test controls the motor simulation test device to update the motor motion status under the current condition in real time and upload it.

6. The in-loop testing method for a motor controller based on Hall signals according to claim 5, characterized in that, In step S1, the configuration parameters of the loaded motor include default configuration parameters and modified configuration parameters, and the modified configuration parameters are the configuration parameters after modifying the default configuration parameters.

7. The in-loop testing method for a motor controller based on Hall signals according to claim 6, characterized in that, The default configuration parameters or the modified configuration parameters include the device information of the drive motor, the motor running direction, the motor running speed, the Hall pulse width, the number of motor magnetic poles, the device movement stroke, and the Hall disturbance data during start / stop.

8. The in-loop testing method for a motor controller based on Hall signals according to claim 5, characterized in that, The Hall feedback signal includes a Hall speed signal and a Hall direction signal. The Hall speed signal is a pulse signal and is related to the pulse period and the number of magnetic pole pairs. The Hall direction signal is a digital level signal and is determined by the rotation direction of the drive motor.

9. The in-loop testing method for a motor controller based on Hall signals according to claim 5, characterized in that, The injected events include stall, hand clamping, Hall speed loss, Hall direction error, overtravel, and position modification.

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