High-pressure fan reliability verification test method

Abstract

The invention relates to a reliability verification test method for a high-pressure fan, and the method comprises the steps: carrying out the evaluation of the high-pressure fan through an acceleration test simulated by a test room, so as to confirm whether the reliability requirement of a whole vehicle is met or not; fan reliability verification is performed in advance through a test room, so that the fan which does not meet the requirement can be prevented from being subjected to a whole vehicle road test, and the reliability test period and the road test cost can be effectively shortened; the method has the advantages that whether the high-pressure fan product can meet the reliability requirement of the whole vehicle or not is evaluated through the reliability acceleration test, the evaluation mode is simple, and the test cost is low; for different whole vehicle working conditions, only test parameters such as T1 and T2, M1 and M2, n1 and n2 and the like need to be replaced, and the method is suitable for platform development; the reliability of a high-pressure fan product is effectively evaluated, the situation that the fan does not meet the reliability requirement after being tested after getting on a vehicle can be avoided, the development period of the fan can be effectively shortened, and the later vehicle verification cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to an engine cooling system, in particular to a high-pressure fan reliability verification test method. BACKGROUND

[0002] In a new energy vehicle, the core of the cooling system is a radiator and a group of electronic fans arranged on the radiator.

[0003] With the increasing popularity of new energy vehicles, electronic fans are increasingly widely used, and various brands of electronic fans on the market are booming like mushrooms after rain; with the increasing power consumption of the vehicle, the cooling demand of the cooling system is also increasing, and the number of electronic fans arranged on a single radiator is increasing, and the fan arrangement is also more and more dense; in the aftermarket, due to the uneven quality of domestic electronic fans, the reliability is also different, and the failure rate of electronic fans is increasing year by year, and this is particularly true for new energy commercial vehicles, because the working conditions of commercial vehicles are harsh, and they often drive on water or dusty roads, which puts more stringent challenges on the service life and reliability of electronic fans; with the increasing power consumption of the vehicle, the energy saving demand of the vehicle is gradually increasing, and the configuration of traditional one-to-many low-voltage electronic fans is restricted due to the low efficiency of a single fan and the need for additional wiring harness connection, etc., which restricts the development of high heat dissipation demand vehicles.

[0004] In view of the above situation, high-voltage electronic fans are gradually emerging, and high-voltage fans refer to electronic fans with high-voltage power supply, such as 800V voltage platform, which can effectively reduce the current consumption of the motor and improve the efficiency of high-voltage electronic fans; combined with large-diameter fan blades, the heat dissipation of a single high-voltage electronic fan can often offset 6-8 traditional low-voltage fans.

[0005] With the rise of high-voltage electronic fans, the testing field related to them is still a blue ocean, and there is currently no unified testing method for various high-voltage motors that have emerged like mushrooms after rain, especially in terms of service life and durability; considering the harsh working environment of commercial vehicles, vehicle OEMs are also very concerned about the reliability and service life of high-voltage electronic fans, and through rigorous road tests, they evaluate the reliability, so a large amount of test cost is required, and there is currently no reliable simulation test method to estimate the service life and reliability of high-voltage electronic fans in advance. SUMMARY

[0006] To solve the above problems, the present application provides a high-pressure fan reliability verification test method, which uses laboratory simulation accelerated test to evaluate high-pressure fans to confirm whether they meet the vehicle reliability requirements; early fan reliability verification in the laboratory can avoid vehicle road tests of fans that do not meet the requirements, effectively shortening the reliability test cycle and road test cost.

[0007] The technical scheme adopted by the application is: a high-pressure fan motor reliability verification test method, characterized by comprising the following steps: S1, installing the to-be-tested high-pressure fan motor on a test bench; S2, constantly increasing the temperature of the cooling liquid inlet of the motor at a certain temperature gradient until the high-pressure fan motor is de-rated to determine the highest cooling liquid temperature T2 at this time; S3, determining the life acceleration test time t by using the Arrhenius model wherein Af is the acceleration factor, Ea is the activation energy, Kb is the Boltzmann constant, T2 is the temperature value of the reliability acceleration test, T1 is the temperature value under normal use conditions, and Q is the whole vehicle life requirement; The life acceleration test is performed through a cycle test, and the length of a single cycle is 3 hours, and t / 3 cycles are required in total. The specific steps are as follows: S31, from 0 min to 1 min, the speed is 0 rpm and the load is 0 Nm; S32, at 1 min, the speed is adjusted to n1 and the load is M1; S33, from 1 min to 2 min, the speed and load in S32 are maintained; S34, from 0 min to 30 min, the steps S31-S33 are cycled for a total of 15 times; S35, from 30 min to 30.5 min, the speed is 0 rpm and the load is 0 Nm; S36, from 30.5 min to 31 min, the speed is increased to n2 and the load is adjusted to M2; S37, from 31 min to 179.5 min, the speed n2 and the load M2 are maintained; S38, from 179.5 min to 180 min, the speed is reduced to 0 rpm and the load is 0 Nm; wherein n1 is 50% of the maximum speed, n2 is the maximum speed allowed by the fan blade, M2 is the maximum load of the motor when the maximum speed of the fan blade is n2, and M1 is the load of the motor when the maximum speed of the fan blade is n1; S4, after step S3, if the performance of the to-be-tested high-pressure fan motor is good, the life of the to-be-tested high-pressure fan motor meets the whole vehicle reliability requirement; otherwise, the life of the to-be-tested high-pressure fan motor does not meet the whole vehicle reliability requirement.

[0008] Preferably, in step S1, the to-be-tested high-pressure fan motor and the auxiliary drag motor are arranged back-to-back on the test bench.

[0009] As preferred, in step S1, the high-pressure fan motor to be tested and the auxiliary driving motor are connected through a shaft coupling, so as to ensure the alignment of the two motors.

[0010] As preferred, in step S1, the high-pressure fan motor to be tested is in a speed mode, and the auxiliary driving motor is in a torque mode.

[0011] As preferred, a torque sensor is arranged between the high-pressure fan motor to be tested and the auxiliary driving motor.

[0012] As preferred, in step S2, a gradient change of 1℃ / min is adopted to continuously increase the temperature of the water inlet of the cooling liquid of the motor.

[0013] As preferred, T1 is 43.5℃, and T2 is 90℃.

[0014] The application has the following advantages: 1. The reliability acceleration test is used to evaluate whether the high-pressure fan product can meet the reliability requirements of the whole vehicle, and the evaluation method is simple and the test cost is low. 2. For different vehicle conditions, only the test parameters of T1 and T2, M1 and M2, n1 and n2 need to be changed, which is suitable for platform development. 3. The reliability of the high-pressure fan product can be effectively evaluated, which can avoid the situation that the fan does not meet the reliability requirements after being tested on the vehicle, and can effectively shorten the development cycle of the fan and reduce the verification cost of the whole vehicle. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 Fig. 1 is a structural schematic diagram of the high-pressure fan of the application; Figure 2 Fig. 2 is a structural schematic diagram of a test bench of the high-pressure fan of the application; In the figure: 1.1, fan blade; 1.2, motor; 1.3, controller; 1.4, cooling liquid water inlet; 2.1, high-pressure fan motor to be tested; 2.2, auxiliary driving motor; 2.3, test bench platform; 2.4, first support; 2.5, second support; 2.6, torque sensor; 2.7, first shaft coupling; 2.8, second shaft coupling. DETAILED DESCRIPTION

[0016] The application will be further described below with reference to the accompanying drawings.

[0017] As Figure 1As shown, the high-pressure fan includes: fan blade 1.1, motor 1.2 and controller 1.3, and the controller 1.3 is provided with a cooling liquid inlet 1.4. In this example, the motor 1.2 and the controller 1.3 are designed as one body, but the motor 1.2 and the controller 1.3 can also be designed as a split type, which is not limited.

[0018] As shown in the figure, Figure 2 As shown, the to-be-tested high-pressure fan motor 2.1 is installed on the test bench platform 2.3 through the first support 2.4, and the auxiliary drag motor 2.2 is installed on the test bench platform 2.3 through the second support 2.54; the to-be-tested high-pressure fan motor 2.1 and the auxiliary drag motor 2.2 are connected through the first coupling 2.7 and the second coupling 2.8 to ensure that the two motors are centered; the to-be-tested high-pressure fan motor 2.1 and the auxiliary drag motor 2.2 are provided with a torque sensor 2.6; the to-be-tested high-pressure fan motor 2.1 and the auxiliary drag motor 2.2 are connected through the torque sensor 2.6, and back-to-back testing is performed, and the to-be-tested high-pressure fan motor 2.1 adopts the 3.2 working mode specified in ISO16750-1.

[0019] The high-pressure fan motor reliability verification test method of the application comprises the following steps: S1, the to-be-tested high-pressure fan motor 2.1 and the auxiliary drag motor 2.2 are installed back-to-back on the test bench, and the to-be-tested high-pressure fan motor 2.1 and the auxiliary drag motor 2.2 are connected through the first coupling 2.7 and the second coupling 2.8 to ensure that the two motors are centered; the to-be-tested high-pressure fan motor 2.1 is in speed mode, and the auxiliary drag motor 2.2 is in torque mode; S2, the performance of the high-pressure fan motor is tested on the dynamometer, and the temperature gradient changes (in this example, the gradient change is 1℃ / min), the temperature of the cooling liquid inlet 1.4 of the to-be-tested high-pressure fan motor 2.1 is constantly increased, and the running is maintained until the to-be-tested high-pressure fan motor 2.1 starts to reduce the capacity, and the cooling liquid inlet temperature at this time is determined as the highest cooling liquid temperature T2 (90℃); S3, according to the highest cooling liquid temperature T2 (90℃), the average normal operating temperature T1 (43.5℃), and the whole vehicle life requirement Q (40000 hours), the life acceleration test time t (hours) is determined by using the Arrhenius model.

[0020] Wherein: Af is the acceleration factor; Ea is the activation energy (0.7eV); Kb is the Boltzmann constant (its value is 8.61733x10-5 eV / K); T2 is the temperature value of the reliability acceleration test (90℃), the temperature value here needs to be converted into absolute temperature value, calculated in K (Kelvin) unit; T1 is the temperature value under normal use conditions (non-accelerated state) (43.5℃), the temperature value here needs to be converted into absolute temperature value, calculated in K (Kelvin) unit; Q is the whole vehicle life requirement (40000 hours); Thus the acceleration factor Af=26.8 is obtained; Thus t=1492h is obtained; The life acceleration test it adopts is carried out through a cycle test, and the single cycle time is 3h (180min), a total of t / 3=498 cycles are needed, and the specific steps are as follows: First stage: S31, 0min to 1min, the speed is 0rpm and the load is 0Nm; S32, 1min, the speed is adjusted to n1 and the load is M1; S33, 1min to 2min, the speed and load in S32 are maintained; S34, from 0min to 30min, a total of 15 times of step S31-S33 cycle test is carried out; Second stage: S35, 30min to 30.5min, the speed is 0rpm and the load is 0Nm; S36, 30.5min to 31min, the speed is increased to n2 and the load is adjusted to M2; S37, 31min to 179.5min, the speed n2 and the load M2 are maintained; S38, 179.5min to 180min, the speed is reduced to 0rpm and the load is 0Nm; Wherein: n1 is 50% of the maximum speed (925rpm); n2 is the maximum speed allowed by the fan blade (1850rpm); M2 is the maximum load of the motor when the fan blade speed is n2 (40Nm); M1 is the load of the motor when the fan blade speed is n1 (10Nm); S4, after step S3, if the performance of the high-pressure fan motor to be tested is good, the life of the high-pressure fan motor to be tested meets the whole vehicle reliability requirement; otherwise, the life of the high-pressure fan motor to be tested does not meet the whole vehicle reliability requirement. After 498 cycles, the performance of a certain product is good, it is confirmed that the reliability acceleration test is passed, and the whole vehicle reliability requirement can be met.

[0021] The above shows and describes the basic principles and main structural features of the present application. The present application is not limited by the above examples, and various changes and improvements can be made to the present application without departing from the spirit and scope of the present application, and all such changes and improvements fall within the scope of the present application claimed. The scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A reliability verification test method for a high-voltage fan, characterized in that: Includes the following steps: S1. Install the high-voltage fan motor to be tested on the test bench; S2. With a certain temperature gradient, continuously increase the coolant inlet temperature of the motor until the high-pressure fan motor is drated, and determine the highest coolant temperature T2 at this time. S3. Determine the accelerated life test time t using the Arrhenius model. Where: Af is the acceleration factor, Ea is the activation energy, Kb is the Boltzmann constant, T2 is the temperature value of the reliability acceleration test, T1 is the temperature value under normal use conditions, and Q is the vehicle life requirement; S4. After step S3, if the high-voltage fan motor under test performs well, then the lifespan of the high-voltage fan motor under test meets the reliability requirements of the whole vehicle; otherwise, the lifespan of the high-voltage fan motor under test does not meet the reliability requirements of the whole vehicle.

2. The high-voltage fan reliability verification test method according to claim 1, characterized in that: In step S3, the accelerated life test is conducted through a cyclic test, with each cycle lasting 3 hours, and a total of t / 3 cycles need to be completed. The specific steps are as follows: S31. From 0 min to 1 min, the rotation speed is 0 rpm and the load is 0 Nm; S32, in the first minute, the rotation speed is adjusted to n1 and the load is M1; S33, from the 1st minute to the 2nd minute, maintain the speed and load from S32; S34. From 0 min to 30 min, repeat steps S31 to S33 15 times in total; S35, from 30 min to 30.5 min, the rotational speed is 0 rpm and the load is 0 Nm; S36, from 30.5 min to 31 min, the speed is increased to n2 and the load is adjusted to M2; S37, from 31 min to 179.5 min, maintain rotational speed n2 and load M2; S38, from 179.5 min to 180 min, the speed drops to 0 rpm and the load is 0 Nm; Where: n1 is 50% of the maximum speed; n2 is the maximum allowable speed of the fan blade; M2 is the maximum load of the motor when the fan blade reaches its maximum speed n2; M1 is the load of the motor when the fan blade reaches 50% of its maximum speed n1.

3. The high-voltage fan reliability verification test method according to claim 1, characterized in that: In step S1, the high-voltage fan motor to be tested and the auxiliary drive motor are set back to back on the test bench.

4. The high-voltage fan reliability verification test method according to claim 3, characterized in that: In step S1, the high-voltage fan motor under test and the auxiliary drive motor are connected by a coupling to ensure that the two motors are aligned.

5. The high-voltage fan reliability verification test method according to claim 3, characterized in that: In step S1, the high-voltage fan motor under test is in speed mode, and the auxiliary drive motor is in torque mode.

6. The high-voltage fan reliability verification test method according to claim 3, characterized in that: A torque sensor is installed between the high-voltage fan motor under test and the auxiliary drive motor.

7. The high-voltage fan reliability verification test method according to claim 1, characterized in that: In step S2, a gradient change of 1℃ / min is used to continuously increase the temperature of the motor's coolant inlet.

8. The high-voltage fan reliability verification test method according to claim 1, characterized in that: T1 is 43.5℃, and T2 is 90℃.

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