Rotary transformer testing device and method

Abstract

The invention discloses a rotary transformer testing device and method. The rotary transformer testing device comprises a motor, a motor controller, a high-voltage direct-current power supply, an upper computer, an oscilloscope and low-voltage electrical performance testing equipment, the motor drives the rotary transformer rotor to rotate; the high-voltage direct-current end of the motor controller is connected with a high-voltage direct-current power supply, and the output end of the low-voltage electricity performance test equipment is connected with the low-voltage power supply end of the motor controller to generate a low-voltage interference signal or provide stable low-voltage electricity to be input to the motor controller; the communication ends of the motor controller, the high-voltage direct-current power supply and the low-voltage electrical performance test equipment are connected with the upper computer; the excitation end and the acquisition end of the motor controller are respectively connected with the input end and the output end of the resolver stator, and the motor controller provides excitation signals for the resolver stator and acquires induction signals fed back by the resolver stator; the acquisition end of the oscilloscope is connected with the input end and the output end of the rotary transformer stator, and the oscilloscope acquires and displays waveforms of excitation signals and induction signals. According to the invention, the accurate resolver condition can be obtained, and misjudgment can be avoided.

Description

Technical Field

[0001] This invention belongs to the field of component testing for electric drive systems of new energy vehicles, and specifically relates to a resolver testing device and method. Background Technology

[0002] Resolvers are the core components of motor position feedback. Signal distortion in resolvers can lead to control errors, directly impacting the performance, safety, and reliability of electric drive systems. Therefore, it is essential to conduct targeted testing on resolvers (such as eddy current resolvers) to assess the presence of distortions in their amplitude, phase, and harmonics, ensuring proper matching with the motor controller. Traditional resolver testing relies solely on fault messages uploaded by the motor controller, making it difficult to pinpoint the root cause (resolver itself, wiring, or software issues) when resolver-related faults are reported. Therefore, it is necessary to simulate changing environmental conditions and interference scenarios to test resolvers for anomalies. This allows for rapid identification of whether signal distortion originates from resolver-related abnormalities caused by external environmental changes or interference, effectively supporting resolver selection decisions. Summary of the Invention

[0003] The purpose of this invention is to provide a resolver testing device and method to obtain accurate resolver information and avoid misjudgment.

[0004] In a first aspect, the present invention provides a resolver testing device, which includes: a motor, a motor controller, a high-voltage DC power supply, a host computer, an oscilloscope, and a low-voltage electrical performance testing device. The motor's output shaft is fixedly connected to the resolver rotor, and the motor drives the resolver rotor to rotate. The high-voltage DC terminal of the motor controller is connected to a high-voltage DC power supply, which provides the power source for the motor controller's operation and output. The output terminal of the low-voltage electrical performance testing equipment is connected to the low-voltage power supply terminal of the motor controller. The low-voltage electrical performance testing equipment generates low-voltage interference signals or provides stable low-voltage electrical input to the motor controller, which can simulate various unstable low-voltage output conditions on the vehicle or provide low-voltage operating power to the motor controller. The communication terminals of the motor controller, high-voltage DC power supply, and low-voltage electrical performance testing equipment are connected to a host computer. The host computer controls the motor controller, high-voltage DC power supply, and low-voltage electrical performance testing equipment to operate according to the set operating conditions, and the motor controller uploads message data to the host computer. The excitation terminal and acquisition terminal of the motor controller are respectively connected to the input terminal and output terminal of the resolver stator. The motor controller provides an excitation signal to the resolver stator and acquires the induced signal (reflecting the position of the resolver rotor) fed back by the resolver stator. The acquisition terminal of the oscilloscope is connected to the input terminal and output terminal of the resolver stator, and acquires and displays the waveforms of the excitation signal and the induced signal.

[0005] Preferably, the resolver testing device further includes: a three-phase AC load, a cooling system, and a variable frequency speed controller; the three-phase AC load is connected to the three-phase output terminals of the motor controller, simulating the stator windings of the drive motor and providing load to the three-phase AC output of the motor controller; the cooling system is connected to the cooling channels of the motor controller, and the communication terminal of the cooling system is connected to a host computer, which controls the cooling system to cool the motor controller and ensure its normal operation; the variable frequency speed controller is connected to the motor, which is a variable frequency motor, and controls the motor to rotate at the required speed to drive the resolver rotor. By using a variable frequency motor to drive the resolver rotor, the operating speed of the drive motor driving the resolver rotor during vehicle operation is simulated. The three-phase AC load simulates the stator windings of the drive motor, providing load to the three-phase AC output of the motor controller. The variable frequency motor only needs to drive the resolver rotor, making it small in size and easy to assemble. Therefore, this resolver testing device does not require a drive motor or electric drive assembly to ensure the acquisition of complete resolver signals, thereby effectively reducing testing costs.

[0006] Preferably, the resolver testing device further includes: a motor mounting base, a base, and a resolver stator mounting base. The motor mounting base and the resolver stator mounting base are fixed on the base. The motor is mounted on the motor mounting base, and the resolver stator is mounted on the resolver stator mounting base, thereby ensuring the secure installation of the resolver and the motor.

[0007] Preferably, the resolver testing device further includes an environmental test chamber for simulating the temperature and humidity conditions required for vehicle use, wherein the motor controller, resolver rotor, and resolver stator are all located within the environmental test chamber. By changing the temperature and humidity within the environmental test chamber, the impact of environmental changes on the resolver can be simulated, and whether the resolver will malfunction due to environmental changes can be tested, thereby effectively supporting resolver selection decisions.

[0008] Preferably, the resolver testing device further includes: a combined on / off switch device, which is connected to the wiring harness between the excitation end and acquisition end of the motor controller and the input end and output end of the resolver stator. The communication end of the combined on / off switch device is connected to a host computer. The host computer controls the combined on / off switch device to short-circuit, loosely connect, or disconnect the wiring harness to simulate a short circuit, loose connection, or open circuit in the resolver signal line. This verifies whether the motor controller can output current while ensuring the safe operation of the vehicle when a short circuit, loose connection, or open circuit occurs in the resolver signal line, which is beneficial for optimizing the software control logic of the motor controller.

[0009] Secondly, the first resolver testing method provided by the present invention employs the above-mentioned resolver testing apparatus, and the method includes:

[0010] The test conditions are set, and the motor operates according to the test conditions, driving the resolver rotor to rotate.

[0011] The host computer controls the low-voltage electrical performance testing equipment to generate a low-voltage interference signal, which is input to the motor controller. This controls the operation of the motor controller and the high-voltage DC power supply. The motor controller provides an excitation signal to the resolver stator and collects the induced signal fed back by the resolver stator. The host computer records the message data uploaded by the motor controller, and the oscilloscope collects and displays the waveforms of the excitation signal and the induced signal.

[0012] The message data recorded by the host computer and the waveforms of the excitation signal and the induced signal acquired and displayed by the oscilloscope are analyzed to determine whether the resolver is abnormal; wherein, the induced signal includes sine signal and cosine signal.

[0013] The second method for refractive index testing provided by this invention employs the aforementioned refractive index testing apparatus, and the method includes:

[0014] Based on the testing requirements, the temperature and humidity inside the environmental test chamber were set to simulate the real environment of vehicle usage scenarios.

[0015] The test conditions are set, and the motor operates according to the test conditions, driving the resolver rotor to rotate.

[0016] The host computer controls the low-voltage electrical performance testing equipment to generate a stable low-voltage electrical input to the motor controller, controls the motor controller and the high-voltage DC power supply to work, the motor controller provides an excitation signal to the resolver stator and collects the induced signal fed back by the resolver stator, the host computer records the message data uploaded by the motor controller, and the oscilloscope collects and displays the waveforms of the excitation signal and the induced signal.

[0017] The message data recorded by the host computer and the waveforms of the excitation signal and the induced signal acquired and displayed by the oscilloscope are analyzed to determine whether the resolver is abnormal; wherein, the induced signal includes sine signal and cosine signal.

[0018] Preferably, if the motor controller reports a resolver fault in the message data recorded by the host computer, and the waveform of the excitation signal displayed on the oscilloscope shows clipping or distortion, or the waveform of the induction signal shows clipping or distortion, then the resolver is determined to be abnormal. If the motor controller does not report a resolver fault in the message data recorded by the host computer, then first use the cursor of the oscilloscope to measure the peak-to-peak voltage Vpp of the excitation signal, the period T of the excitation signal, the peak voltage Vsin of the sine signal, the peak voltage Vcos of the cosine signal, and the time difference Δt when the sine and cosine signals are adjacent and cross zero; then calculate the amplitude Vrms of the excitation signal, the frequency f of the excitation signal, the amplitude consistency error δ of the sine and cosine signals, and the phase difference Φ respectively; if Vrms is not within the preset amplitude range, or f is not within the preset frequency range, or δ is not within the preset error range, or Φ is not within the preset phase difference range (these ranges are described in the resolver specification), then the resolver is determined to be abnormal. If the host computer records no resolver fault in the motor controller's message data, and the waveforms of the excitation signal and the induced signal displayed on the oscilloscope are normal, then the resolver is determined to be normal. If the host computer records a resolver fault in the motor controller's message data, and the waveforms of the excitation signal and the induced signal displayed on the oscilloscope are normal, then the resolver is determined to be normal, but the connection harness at the motor controller's acquisition end is faulty, or the motor controller itself is faulty.

[0019] The third method for refractive index testing provided by this invention uses the above-mentioned refractive index testing device, and the method includes:

[0020] The test conditions are set, and the motor runs according to the test conditions, driving the resolver rotor to rotate; the resolver is normal (i.e., the resolver itself has no abnormalities).

[0021] The host computer controls the low-voltage electrical performance testing equipment to generate a stable low-voltage electrical input to the motor controller, controls the operation of the motor controller and the high-voltage DC power supply, controls the combined on-off switch to short-circuit, loosely connect, or disconnect the wiring harness, the motor controller provides an excitation signal to the resolver stator and collects the induced signal fed back by the resolver stator, the host computer records the message data uploaded by the motor controller, and the oscilloscope collects and displays the waveforms of the excitation signal and the induced signal, thereby simulating the short circuit, loose connection, or open circuit of the resolver signal line.

[0022] The message data recorded by the host computer and the waveforms of the excitation signal and induction signal acquired and displayed by the oscilloscope are analyzed.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] (1) Add an oscilloscope to determine whether the resolver is abnormal based on the message data uploaded by the motor controller recorded by the host computer and the waveform combination of the excitation signal and the induction signal displayed by the oscilloscope. Compared with the existing method of judging only by the message data uploaded by the motor controller, it can obtain a more accurate resolver situation and avoid the misjudgment that the resolver is abnormal but the motor controller does not report a fault or the resolver is normal but the motor controller reports a fault.

[0025] (2) Use low-voltage electrical performance testing equipment to generate low-voltage interference signals to simulate the interference that may exist in the operation of the whole vehicle, thereby testing the anti-interference capability of the resolver and verifying whether the resolver will be abnormal under interference, thus effectively supporting the resolver selection decision.

[0026] (3) The motor controller, resolver rotor and resolver stator are placed in the environmental test chamber. The environmental test chamber simulates the temperature and humidity environment conditions used by the whole vehicle. By changing the temperature and humidity in the environmental test chamber, the influence of environmental conditions on the resolver can be simulated, and the resolver can be tested to see if it will become abnormal due to environmental changes, thereby effectively supporting the resolver selection decision.

[0027] (4) A variable frequency motor is used to drive the resolver rotor to rotate, simulating the speed condition of the drive motor driving the resolver rotor to rotate when the whole vehicle is running. A three-phase AC load is used to simulate the stator winding of the drive motor and provide load to the three-phase AC output of the motor controller. The variable frequency motor only needs to drive the resolver rotor to rotate. It is small in size and easy to assemble. Therefore, the resolver test device does not need to use a drive motor or electric drive assembly, and can also ensure the acquisition of complete resolver signals, thereby effectively reducing the test cost. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of a refractive index testing device in an embodiment of the present invention.

[0029] Figure 2 This is a flowchart of the first refractive index testing method in an embodiment of the present invention.

[0030] Figure 3 This is a flowchart of the second resolver testing method in an embodiment of the present invention.

[0031] Figure 4 This is a schematic diagram of another structure of the resolver testing device in an embodiment of the present invention.

[0032] Figure 5 This is a flowchart of the third resolver testing method in this embodiment of the invention. Detailed Implementation

[0033] To gain a more detailed understanding of the features and technical content of the embodiments of the present invention, the implementation of the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for reference and illustration only and are not intended to limit the embodiments of the present invention.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing embodiments of the invention only and is not intended to limit the invention.

[0035] In the following description, references are made to “some embodiments,” which describe a subset of all possible embodiments. However, it is understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict.

[0036] like Figure 1 As shown, the resolver testing device in this embodiment of the invention includes: a motor 1, a motor controller 2, a high-voltage DC power supply 3, a host computer 4, an oscilloscope 5, a low-voltage electrical performance testing device 6, a three-phase AC load 9, a cooling system 10, and a frequency converter speed controller 11.

[0037] The variable frequency speed controller 11 is connected to the motor 1, which is a variable frequency motor. The variable frequency speed controller 11 controls (adjusts) the motor 1 to rotate at the required speed according to the test requirements. The output shaft of the motor 1 is fixedly connected to the resolver rotor 71, and the motor 1 drives the resolver rotor 71 to rotate. The high-voltage DC terminal of the motor controller 2 is connected to the high-voltage DC power supply 3 via a high-voltage wiring harness. The high-voltage DC power supply 3 provides the power source for the motor controller 2's operation and output. The output terminal of the low-voltage electrical performance testing equipment 6 is connected to the low-voltage power supply terminal of the motor controller 2 via a low-voltage wiring harness. The low-voltage electrical performance testing equipment 6 generates low-voltage interference signals or provides stable low-voltage electrical input to the motor controller 2, providing low-voltage operating power and simulating various unstable low-voltage output conditions on the vehicle. The three-phase AC load 9 is connected to the three-phase output terminal of the motor controller 2. The three-phase AC load 9 simulates the drive motor stator winding, providing load to the three-phase AC output of the motor controller 2. The cooling system 10 is connected to the cooling channel of the motor controller 2 via a hose. The cooling system 10 cools the motor controller 2, ensuring its normal operation. The communication terminals of motor controller 2, high-voltage DC power supply 3, low-voltage electrical performance testing equipment 6, and cooling system 10 are connected to host computer 4 via communication harnesses. Host computer 4 controls motor controller 2, high-voltage DC power supply 3, low-voltage electrical performance testing equipment 6, and cooling system 10 to operate according to set working conditions. Motor controller 2 uploads message data (such as CAN message data) to host computer 4. The excitation terminal and two acquisition terminals of motor controller 2 are connected to the input terminal (i.e., excitation signal terminal) and output terminal (i.e., sine signal terminal and cosine signal terminal) of resolver stator 72 via low-voltage harnesses. Motor controller 2 provides excitation signals to resolver stator 72 and acquires the induced signals (i.e., sine and cosine signals) fed back by resolver stator 72 (reflecting the position of resolver rotor). The acquisition terminals of oscilloscope 5 are connected to the excitation signal terminal, sine signal terminal, and cosine signal terminal of resolver stator 72 via low-voltage harnesses, acquiring and displaying the waveforms of the excitation signal, sine signal, and cosine signal.

[0038] In some embodiments, the resolver testing apparatus further includes an environmental test chamber 15 for simulating the temperature and humidity conditions required for use in a vehicle. The motor controller 2, resolver rotor 71, and resolver stator 72 are all located within the environmental test chamber 15. The environmental test chamber 15 contains a thermometer and a hygrometer, which can display the temperature and humidity within the chamber. The environmental test chamber 15 also includes equipment for adjusting the temperature and humidity within the chamber, as well as insulation equipment. The temperature and humidity within the chamber can be changed according to testing requirements to ensure that the motor controller 2 and the resolver operate under the required environmental conditions and maintain this condition.

[0039] In some embodiments, the resolver testing device further includes: a motor mounting base 12, a base 13, and a resolver stator mounting base 14. The motor mounting base 12 and the resolver stator mounting base 14 are fixed to the base 13 by screws. The motor 1 is mounted on the motor mounting base 12 by screws, and the resolver stator 72 is mounted on the resolver stator mounting base 14 by screws.

[0040] like Figure 2 As shown, the first resolver testing method in this embodiment of the invention is used to test whether an anomaly will occur when the resolver is disturbed under specific environmental conditions (i.e., maintaining a certain temperature and humidity). It employs the aforementioned resolver testing device, and the method includes the following steps:

[0041] S11. Set the test conditions. The variable frequency speed controller 11 controls the motor 1 to run according to the test conditions, driving the resolver rotor 71 to rotate.

[0042] Specifically, according to the required test conditions, set the flow rate and temperature of the cooling system 10, set the speed condition to be verified (constant speed or dynamic speed) in the panel of the variable frequency speed controller 11, set the corresponding operation mode and torque value in the host computer 4, set the ambient temperature and humidity parameters in the environmental test chamber 15, and confirm whether the temperature and humidity in the chamber meet the requirements through a thermometer and a hygrometer. After meeting the requirements, perform heat preservation.

[0043] S12, the host computer 4 controls the low-voltage electrical performance testing equipment 6 to generate a low-voltage interference signal, which is input to the motor controller 2. This controls the operation of the motor controller 2, the high-voltage DC power supply 3, and the cooling system 10. The motor controller 2 provides an excitation signal (generally a sinusoidal excitation signal) to the resolver stator 72 and collects the sinusoidal and cosine signals fed back by the resolver stator 72. The host computer 4 records the message data uploaded by the motor controller 2, and the oscilloscope 5 collects and displays the waveforms of the excitation signal, the sinusoidal signal, and the cosine signal. In some embodiments, the low-voltage interference signal is a low-voltage electrical signal superimposed with an AC ripple signal, a voltage drop reset signal, a voltage instantaneous drop signal, or a load dump signal, which is different from a stable low-voltage electrical signal (i.e., a low-voltage electrical signal without superimposed interference signals, such as 5V).

[0044] S13. Analyze the message data recorded by the host computer 4 and the waveforms of the excitation signal, sine signal and cosine signal collected and displayed by the oscilloscope 5 to determine whether the resolver is abnormal.

[0045] like Figure 3 As shown, the second resolver testing method in this embodiment of the invention is used to test whether the resolver will malfunction due to environmental changes (i.e., whether the resolver can be used in a variable environment). It employs the aforementioned resolver testing device, and the method includes the following steps:

[0046] S21. Set the temperature and humidity inside the environmental test chamber 15 to the first environmental condition that meets the test requirements. The test requirements are to test the rotation under n environmental conditions, and each environmental condition corresponds to a temperature and a humidity.

[0047] S22. Set the test conditions. The variable frequency speed controller 11 controls the motor 1 to run according to the test conditions, driving the resolver rotor 71 to rotate.

[0048] Specifically, according to the required test conditions, set the flow rate and temperature of the cooling system 10, set the speed condition (constant speed or dynamic speed) to be verified in the panel of the variable frequency speed controller 11, and set the corresponding operation mode and torque value in the host computer 4.

[0049] S23. The host computer 4 controls the low-voltage electrical performance testing equipment 6 to generate a stable low-voltage electrical input to the motor controller 2, controlling the operation of the motor controller 2, the high-voltage DC power supply 3, and the cooling system 10. The motor controller 2 provides an excitation signal (generally a sinusoidal excitation signal) to the resolver stator 72 and collects the sine and cosine signals fed back by the resolver stator 72. The host computer 4 records the message data uploaded by the motor controller 2, and the oscilloscope 5 collects and displays the waveforms of the excitation signal, sine signal, and cosine signal.

[0050] S24. Analyze the message data recorded by the host computer 4 and the waveforms of the excitation signal, sine signal and cosine signal collected and displayed by the oscilloscope 5 to determine whether the resolver is abnormal.

[0051] S25. Set the temperature and humidity in the environmental test chamber 15 to the next environmental condition that meets the test requirements, and then repeat S22 to S24 until the rotation test under n environmental conditions is completed.

[0052] In some embodiments, if the host computer 4 records a resolver fault in the message data, and the waveform of the excitation signal displayed on the oscilloscope 5 shows clipping or distortion, or the waveform of the sine signal shows clipping or distortion, or the waveform of the cosine signal shows clipping or distortion, then the resolver is determined to be abnormal. The method for determining clipping or distortion of the excitation signal, sine signal, and cosine signal waveforms is prior art; testers can determine this by visually observing the waveforms on the oscilloscope.

[0053] In some embodiments, if the motor controller 2 does not report a resolver fault in the message data recorded by the host computer 4, the peak-to-peak voltage Vpp of the excitation signal, the period T of the excitation signal, the peak voltage Vsin of the sine signal, the peak voltage Vcos of the cosine signal, and the time difference Δt between the adjacent zero points of the sine and cosine signals are first measured using the cursor of the oscilloscope 5; then the amplitude of the excitation signal is calculated respectively. frequency of excitation signal Amplitude consistency error between sine and cosine signals and phase difference If Vrms is not within the preset amplitude range, or f is not within the preset frequency range, or δ is not within the preset error range, or Φ is not within the preset phase difference range (the preset amplitude range, preset frequency range, preset error range, and preset phase difference range are all recorded in the resolver specification sheet), then the resolver is determined to be abnormal; otherwise, the resolver is determined to be normal (i.e., the resolver is not abnormal).

[0054] In some embodiments, if the motor controller 2 does not report a resolver fault in the message data recorded by the host computer 4, and the waveforms of the excitation signal, sine signal, and cosine signal displayed by the oscilloscope 5 are all normal, then the resolver is determined to be normal.

[0055] In some embodiments, if the motor controller 2 reports a resolver fault in the message data recorded by the host computer 4, but the waveforms of the excitation signal, sine signal, and cosine signal displayed by the oscilloscope 5 are all normal, then it is determined that the resolver is normal, and the connection harness (i.e., low-voltage harness) at the acquisition end of the motor controller 2 is abnormal or the motor controller is abnormal.

[0056] like Figure 4 As shown, in some embodiments, the resolver testing device further includes a combined on / off switch device 8, which is connected to the low-voltage wiring harness between the excitation terminal of the motor controller 2, the two acquisition terminals and the excitation signal terminal, sine signal terminal and cosine signal terminal of the resolver stator 72. The communication terminal of the combined on / off switch device 8 is connected to the host computer 4 through the communication wiring harness. The host computer 4 controls the combined on / off switch device 8 to short-circuit, loosely connect or disconnect the low-voltage wiring harness it is connected to, so as to simulate the resolver signal line short-circuiting, loosely connecting or open-circuiting.

[0057] like Figure 5 As shown, the third resolver test method in this embodiment of the invention is used to simulate short circuit, loose connection, or open circuit tests of the resolver signal line, and it employs the following... Figure 4 The shown resolver testing apparatus includes the following steps:

[0058] S31. Set the test conditions. The variable frequency speed controller 11 controls the motor 1 to run according to the test conditions, driving the resolver rotor 71 to rotate. In this test condition, the resolver must be normal and there should be no abnormalities.

[0059] S32, the host computer 4 controls the low-voltage electrical performance testing equipment 6 to generate a stable low-voltage electrical input to the motor controller 2, controls the operation of the motor controller 2, the high-voltage DC power supply 3, and the cooling system 10, controls the combined on / off switch equipment 8 to short-circuit, loosely connect, or disconnect its connected low-voltage wiring harness, the motor controller 2 provides an excitation signal (generally a sinusoidal excitation signal) to the resolver stator 72, and collects the sine and cosine signals fed back by the resolver stator 72, the host computer 4 records the message data uploaded by the motor controller 2, and the oscilloscope 5 collects and displays the waveforms of the excitation signal, sine signal, and cosine signal, thereby performing short-circuit, loosely connected, or open-circuit tests on the module resolver signal line.

[0060] S33. Analyze the message data recorded by the host computer 4 and the waveforms of the excitation signal, sine signal, and cosine signal acquired and displayed by the oscilloscope 5 to verify the impact of short circuit, loose connection, or open circuit conditions (such as short circuit, open circuit, or loose connection of the resolver signal line due to vibration, aging, or damage during vehicle operation) on the motor controller 2. For example, whether the control board of the motor controller 2 will be damaged under such short circuit or open circuit conditions, and whether the output function can be restored.

[0061] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A resolver testing device, characterized in that, include: The motor (1), motor controller (2), high voltage DC power supply (3), host computer (4), oscilloscope (5) and low voltage electrical performance testing equipment (6) are connected. The output shaft of the motor (1) is fixed to the resolver rotor (71). The high voltage DC terminal of the motor controller (2) is connected to the high voltage DC power supply (3). The output terminal of the low voltage electrical performance testing equipment (6) is connected to the low voltage power supply terminal of the motor controller (2). The communication terminals of the motor controller (2), high voltage DC power supply (3) and low voltage electrical performance testing equipment (6) are connected to the host computer (4). The excitation terminal and acquisition terminal of the motor controller (2) are respectively connected to the input terminal and output terminal of the resolver stator (72). The acquisition terminal of the oscilloscope (5) is connected to the input terminal and output terminal of the resolver stator (72).

2. The resolvent testing apparatus according to claim 1, characterized in that, Also includes: The three-phase AC load (9), cooling system (10) and variable frequency speed controller (11) are connected. The three-phase AC load (9) is connected to the three-phase output terminal of the motor controller (2). The cooling system (10) is connected to the cooling channel of the motor controller (2). The communication terminal of the cooling system (10) is connected to the host computer (4). The variable frequency speed controller (11) is connected to the motor (1). The motor (1) is a variable frequency motor.

3. The resolvent testing apparatus according to claim 1, characterized in that, Also includes: Motor mounting base (12), base (13) and resolver stator mounting base (14), the motor mounting base (12) and resolver stator mounting base (14) are fixed on the base (13), the motor (1) is mounted on the motor mounting base (12) and the resolver stator (72) is mounted on the resolver stator mounting base (14).

4. The resolvent testing apparatus according to any one of claims 1 to 3, characterized in that, Also includes: The environmental test chamber (15) is used to simulate the temperature and humidity conditions of a vehicle. The motor controller (2), resolver rotor (71), and resolver stator (72) are all located inside the environmental test chamber (15).

5. The resolvent testing apparatus according to claim 4, characterized in that, It also includes: a combination on / off switch device (8), which is connected to the wire harness between the excitation end and the acquisition end of the motor controller (2) and the input end and the output end of the resolver stator (72), and the communication end of the combination on / off switch device (8) is connected to the host computer (4).

6. A method for testing resolvers, characterized in that: The method, using the resolvent testing apparatus as described in any one of claims 1 to 4, comprises: Set the test conditions, and the motor (1) runs according to the test conditions, driving the resolver rotor (71) to rotate; The host computer (4) controls the low-voltage electrical performance testing equipment (6) to generate a low-voltage interference signal input to the motor controller (2), and controls the motor controller (2) and the high-voltage DC power supply (3) to work. The motor controller (2) provides an excitation signal to the resolver stator (72) and collects the induction signal fed back by the resolver stator (72). The host computer (4) records the message data uploaded by the motor controller (2). The oscilloscope (5) collects and displays the waveforms of the excitation signal and the induction signal. The message data recorded by the host computer (4) and the waveforms of the excitation signal and the induction signal collected and displayed by the oscilloscope (5) are analyzed to determine whether the resolver is abnormal; wherein, the induction signal includes sine signal and cosine signal.

7. The resolvent testing method according to claim 6, characterized in that: If the motor controller (2) reports a resolver fault in the message data recorded by the host computer (4), and the waveform of the excitation signal displayed by the oscilloscope (5) shows clipping or distortion, or the waveform of the induction signal shows clipping or distortion, then the resolver is determined to be abnormal. If the motor controller (2) does not report a resolver fault in the message data recorded by the host computer (4), the cursor of the oscilloscope (5) is used to measure the peak-to-peak voltage Vpp of the excitation signal, the period T of the excitation signal, the peak voltage Vsin of the sine signal, the peak voltage Vcos of the cosine signal, and the time difference Δt when the sine signal and the cosine signal are adjacent and cross zero. Then the amplitude Vrms of the excitation signal, the frequency f of the excitation signal, the amplitude consistency error δ of the sine signal and the cosine signal, and the phase difference Φ are calculated respectively. If Vrms is not within the preset amplitude range, or f is not within the preset frequency range, or δ is not within the preset error range, or Φ is not within the preset phase difference range, then the resolver is determined to be abnormal. If the motor controller (2) does not report a resolver fault in the message data recorded by the host computer (4), and the waveforms of the excitation signal and the induction signal displayed by the oscilloscope (5) are normal, then the resolver is determined to be normal. If the motor controller (2) reports a resolver fault in the message data recorded by the host computer (4), and the waveforms of the excitation signal and the induction signal displayed by the oscilloscope (5) are normal, then it is determined that the resolver is normal, or the connection harness of the acquisition end of the motor controller (2) is abnormal or the motor controller is abnormal.

8. A method for testing a resolver, characterized in that: The method using the resolver testing apparatus as described in claim 4 includes: According to the testing requirements, the temperature and humidity inside the environmental test chamber (15) are set to simulate the real environment of vehicle use scenarios; Set the test conditions, and the motor (1) runs according to the test conditions, driving the resolver rotor (71) to rotate; The host computer (4) controls the low-voltage electrical performance testing equipment (6) to generate a stable low-voltage electrical input to the motor controller (2), and controls the motor controller (2) and the high-voltage DC power supply (3) to work. The motor controller (2) provides an excitation signal to the resolver stator (72) and collects the induction signal fed back by the resolver stator (72). The host computer (4) records the message data uploaded by the motor controller (2). The oscilloscope (5) collects and displays the waveforms of the excitation signal and the induction signal. The message data recorded by the host computer (4) and the waveforms of the excitation signal and the induction signal collected and displayed by the oscilloscope (5) are analyzed to determine whether the resolver is abnormal; wherein, the induction signal includes sine signal and cosine signal.

9. The resolvent testing method according to claim 8, characterized in that: If the motor controller (2) reports a resolver fault in the message data recorded by the host computer (4), and the waveform of the excitation signal displayed by the oscilloscope (5) shows clipping or distortion, or the waveform of the induction signal shows clipping or distortion, then the resolver is determined to be abnormal. If the motor controller (2) does not report a resolver fault in the message data recorded by the host computer (4), the cursor of the oscilloscope (5) is used to measure the peak-to-peak voltage Vpp of the excitation signal, the period T of the excitation signal, the peak voltage Vsin of the sine signal, the peak voltage Vcos of the cosine signal, and the time difference Δt when the sine signal and the cosine signal are adjacent and cross zero. Then the amplitude Vrms of the excitation signal, the frequency f of the excitation signal, the amplitude consistency error δ of the sine signal and the cosine signal, and the phase difference Φ are calculated respectively. If Vrms is not within the preset amplitude range, or f is not within the preset frequency range, or δ is not within the preset error range, or Φ is not within the preset phase difference range, then the resolver is determined to be abnormal. If the motor controller (2) does not report a resolver fault in the message data recorded by the host computer (4), and the waveforms of the excitation signal and the induction signal displayed by the oscilloscope (5) are normal, then the resolver is determined to be normal. If the motor controller (2) reports a resolver fault in the message data recorded by the host computer (4), and the waveforms of the excitation signal and the induction signal displayed by the oscilloscope (5) are normal, then it is determined that the resolver is normal, or the connection harness of the acquisition end of the motor controller (2) is abnormal or the motor controller is abnormal.

10. A method for testing resolvents, characterized in that: The method using the resolver testing apparatus as described in claim 5 includes: The test conditions are set, and the motor (1) runs according to the test conditions, driving the resolver rotor (71) to rotate; the resolver is normal; The host computer (4) controls the low-voltage electrical performance testing equipment (6) to generate a stable low-voltage electrical input to the motor controller (2), controls the motor controller (2) and the high-voltage DC power supply (3) to work, controls the combined on-off switch equipment (8) to short-circuit, loosely connect or disconnect the wire harness, the motor controller (2) provides an excitation signal to the resolver stator (72) and collects the induction signal fed back by the resolver stator (72), the host computer (4) records the message data uploaded by the motor controller (2), and the oscilloscope (5) collects and displays the waveforms of the excitation signal and the induction signal; The message data recorded by the host computer (4) and the waveforms of the excitation signal and the induction signal collected and displayed by the oscilloscope (5) are analyzed.

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