Chassis dynamometer-based multi-system collaborative test system and development and test method

Abstract

The invention discloses a multi-system collaborative test system based on a chassis dynamometer, and a development and test method, the system comprises a controller cabinet, the controller cabinet comprises a real-time controller and a multi-protocol fusion data communication module, the multi-protocol fusion data communication module is used for being connected with a plurality of test devices through a plurality of protocols, and the real-time controller is connected with the multi-protocol fusion data communication module; and the real-time controller is connected with an automatic test module, is used for automatically executing a test case, analyzing the test case and obtaining a test result, and comprises upper computer software, lower computer software and a database. According to the multi-system collaborative test system based on the chassis dynamometer and the development and test method, multi-device collaborative control can be realized, and integrated automatic test is carried out for the whole vehicle test of a new energy vehicle; the problems of equipment discretization, protocol fragmentation and data asynchronization are solved, the test efficiency and the test coverage rate are improved, and an efficient and accurate solution is provided for all-condition verification of a complex electrical system of a new energy automobile.

Description

Technical Field

[0001] This invention relates to the field of vehicle chassis dynamometer technology, and more specifically, to a multi-system collaborative testing system based on a chassis dynamometer, its development, and testing methods. Background Technology

[0002] With the rapid development of new energy vehicles, their electrical architecture and functional logic are extremely complex, making the comprehensive and systematic verification of their functions increasingly massive. For example, a certain high-end new energy vehicle has over 15,000 low-voltage functional test cases and over 1,000 high-voltage functional test cases, which cannot be completed manually and requires automated testing methods. Furthermore, the chassis dynamometer laboratory, as a crucial testing site for vehicle performance testing, possesses testing equipment such as benches and chassis dynamometers, driving robots, programmable charging piles, programmable power supplies, and electronic loads to conduct most vehicle testing tasks. However, the current discrete nature of the testing equipment lacks rapid and efficient automated testing capabilities. Therefore, addressing the core needs of new energy vehicle testing, this paper proposes an automated testing device based on the chassis dynamometer, featuring multi-system collaborative control. This device integrates and interactively controls the chassis dynamometer, driving robot, programmable charging pile, programmable power supply, and electronic loads. Then, an automated testing methodology is constructed, and a standardized test process is designed to achieve full-process control of test cases, test equipment control sequences, test execution, and management. This results in a testing device that shortens the testing cycle, covers all operating conditions, and improves overall vehicle quality.

[0003] Current vehicle testing strategies based on chassis dynamometers mainly involve the following: Traditional vehicle testing methods using chassis dynamometers require manual connection of each dynamometer, charging station, power analyzer, and other equipment before testing, with manual setting of parameters for each device. Test personnel follow the operating documentation step-by-step: starting the dynamometer → configuring other test equipment → setting vehicle speed → driver pressing the accelerator, brake, and shifting gears → recording instrument data → stopping the equipment → manually saving data → test data processing → issuing a test report. Data is recorded in a distributed manner: dynamometer data is stored on a local industrial control computer, data from charging stations, power analyzers, and other test equipment is exported via USB drive, and vehicle CAN data needs to be collected using a separate CAN device. Results are analyzed manually; engineers manually compare and analyze multi-source test data, and then the report is generated using a Word / Excel template.

[0004] Current vehicle testing based on chassis dynamometers suffers from the following problems: Low efficiency: dynamometers and various testing equipment require manual configuration and debugging, resulting in long setup times; test cases are executed manually, leading to slow execution speeds; Lack of collaborative control: Protocol incompatibility—dynamometers use TCP / IP AK protocol while charging piles use non-standard CAN, requiring custom conversion interfaces; Asynchronous signals—data acquisition from CAN bus, analog, digital, and network ports is asynchronous, leading to calculation errors; Uncontrolled execution sequence—various testing equipment cannot be started synchronously, resulting in data loss; Data management deficiencies: inconsistent timestamps across different devices require manual alignment; Fragmented data storage formats—data formats include .txt, .blf, .xlsx, .csv, and mf4, consuming significant test cycle time for integration; Insufficient scalability: Limited hardware interfaces cannot meet the parallel needs of multiple devices; Closed software architecture—re-adaptation is required when replacing with new test vehicles.

[0005] Therefore, there is an urgent need for a multi-system collaborative testing system based on a chassis dynamometer, as well as its development and testing methods. Summary of the Invention

[0006] The purpose of this invention is to provide a multi-system collaborative testing system, development and testing method based on a chassis dynamometer, in order to solve the problems in the prior art, realize multi-device collaborative control, and carry out integrated and automated testing for new energy vehicle whole vehicle testing.

[0007] This invention provides a multi-system collaborative testing system based on a chassis dynamometer, comprising:

[0008] The controller chassis includes a real-time controller and a multi-protocol fusion data communication module. The multi-protocol fusion data communication module is used to connect to multiple test devices through multiple protocols. The real-time controller is connected to an automated testing module, which is used to automatically execute test cases, parse test cases, and obtain test results. The automated testing module includes host computer software, slave computer software, and a database.

[0009] The multi-system collaborative testing system based on a chassis dynamometer, as described above, preferably includes a multi-protocol fusion data communication module comprising an Ethernet module, a CAN module, a high-speed digital I / O module, an RTD acquisition module, an analog input / output module, and an RS485 / 232 serial port module, wherein:

[0010] The Ethernet module is used for in-vehicle Ethernet communication with the chassis dynamometer or driving robot.

[0011] The CAN module is used for CAN or LIN communication with the vehicle or charging station.

[0012] The high-speed digital I / O module is used to acquire high-speed digital I / O signals from the fuel consumption meter or power analyzer;

[0013] The RTD acquisition module is used to acquire the resistance value of the thermocouple and convert the resistance value of the thermocouple into a temperature signal.

[0014] The analog input / output module is used to acquire analog signals from the chassis dynamometer or current clamp.

[0015] The RS485 / 232 serial port module is used for serial communication with low-voltage load boxes or power meters.

[0016] In the multi-system collaborative testing system based on a chassis dynamometer as described above, preferably, a power button and an external module status indicator are provided on the bottom front of the controller chassis.

[0017] As described above, in the multi-system collaborative testing system based on a chassis dynamometer, preferably, the host computer software runs on a PC for interaction with the user; the slave computer software runs on an NI controller for system operation, hardware control, and test case execution; and the database, developed based on the MySQL platform, runs on a local PC for storing user information, managing test cases, storing and managing test data, and storing equipment information.

[0018] As described above, in the multi-system collaborative testing system based on a chassis dynamometer, preferably, the host computer software includes a user login interface, an automated testing interface, a manual testing interface, a system self-test interface, a task query interface, and a historical data query interface.

[0019] The user login interface is used for test personnel to log in using an account and password;

[0020] The automated testing interface is used to select test cases, start automated execution, monitor the progress of the test, display key data during the test through curves, and display the test results after the test is completed.

[0021] The manual testing interface is used to debug test cases step by step and complete the test step by step. It is also used as a manual testing tool to manually control the test equipment and independently execute test operations. The manual testing interface as a manual testing tool includes at least one of the following: driving robot throttle and brake control interface, gear control interface, vehicle central control screen control interface, chassis dynamometer control interface, and wheel hub control interface.

[0022] The system self-test interface is used to locate abnormal parts of the system and to perform polling self-tests on the equipment before the test;

[0023] The task query interface is connected to the cloud and is used to query test tasks, display the status of test tasks, and view test results.

[0024] The historical data query interface is used to query historical data, compare data, and display the data through curves.

[0025] In the multi-system collaborative testing system based on a chassis dynamometer as described above, preferably, the lower-level software includes a hardware control module, a data acquisition module, and a data processing module, wherein:

[0026] The hardware control module is used to integrate the hardware control communication protocol. After receiving the test cases sent by the host computer, it parses the test cases sent by the host computer, determines the test execution actions, edits the test equipment control steps, sends hardware control commands, and completes the test operation.

[0027] The data acquisition module is used to parse test cases, determine data acquisition channels, and unify data timing using the NI PXI internal clock.

[0028] The data processing module is used to design data processing scripts based on the characteristics of test cases, and after data collection, call the preset scripts to complete data processing and upload the test results.

[0029] This invention also provides a development method for the above-mentioned multi-system collaborative testing system based on a chassis dynamometer, comprising the following steps:

[0030] Construct typical experimental models and determine experimental equipment and procedures;

[0031] Modular control matrix: Set control content and complete equipment control timing;

[0032] Test input management involves designing and developing automated test cases, digitizing experimental operations, and transforming them into storable and identifiable test cases.

[0033] Develop automated testing software and determine the system control logic and human-computer interaction logic;

[0034] Develop data management functions, develop data processing scripts, programmatic data processing workflows and evaluation of experimental results, and store and manage experimental data.

[0035] The development method of the multi-system collaborative testing system based on a chassis dynamometer, as described above, preferably includes the following: Constructing a typical test model and determining the test equipment and test procedures.

[0036] Determine the testing equipment;

[0037] Analyze the test scenario;

[0038] Analysis of the test standards;

[0039] Feasibility analysis of automated testing

[0040] The modular control matrix sets the control content and completes the equipment control timing, including:

[0041] Determine the scope of equipment testing;

[0042] Parse the communication protocol;

[0043] Develop a test equipment control module.

[0044] The test input management involves designing and developing automated test cases, digitizing experimental operations, and converting them into storable and identifiable test cases, including:

[0045] Develop and design test cases;

[0046] Based on the test cases developed and designed, construct a library of typical experimental test cases;

[0047] Customize the test case editing functionality.

[0048] The development of the automated testing software determines the system control logic and human-computer interaction logic, including:

[0049] Develop automated testing logic;

[0050] Design the user interface;

[0051] Develop equipment status monitoring functions.

[0052] The data management function development includes developing data processing scripts, programmatic data processing workflows and experimental result evaluation, and storing and managing experimental data, including:

[0053] Store and manage the experimental data;

[0054] Evaluate the test results and issue a report;

[0055] A vehicle information database and a verification index database were established based on the test data.

[0056] The present invention also provides a multi-system collaborative testing method based on a chassis dynamometer for the above-mentioned system, comprising the following steps:

[0057] Preparations before the test: Prepare automated test cases, set up test execution actions, configure data acquisition channels, develop data processing scripts, and connect hardware harnesses;

[0058] Open the host computer software: Log in as a user, select the test cases to be executed, click Start Test, send the test cases to the slave computer, monitor the execution progress of the test cases, view the key real-time data during the test run, and display the results when the test is completed;

[0059] Start the lower-level software: parse the test cases, map the test execution actions to the device control commands to determine the best control sequence, operate the test equipment, configure the data acquisition channel according to the test cases, select key data and upload it to the upper-level software in real time, and call the data processing script after the test operation is completed to process the test data, generate test results and upload them.

[0060] Upload the saved raw data and test results to the database.

[0061] This invention provides a multi-system collaborative testing system, development, and testing method based on a chassis dynamometer, using the chassis dynamometer as the core and through NI... The PXI control hardware (equipped with a PXIe-8842 real-time controller and multi-protocol communication module) and customized software system enable collaborative control of multiple devices, including chassis dynamometers, driving robots, AC / DC charging piles, power analyzers, low-voltage loads, and vehicle control interfaces. This allows for integrated and automated testing of new energy vehicles. By uniformly parsing TCP / IP (AK commands), CAN (custom / non-standard protocols), RS485, digital I / O, and analog signals, a high-precision timing synchronization mechanism (error ≤ 0.8ms) is constructed. Automated test management software is developed to support test case editing, device control sequence generation, dynamic anomaly response (three-level fault handling), and data fusion analysis. This overcomes the challenges of device discretization, protocol fragmentation, and data asynchronization in traditional testing, improving testing efficiency by 12 times (single test case time reduced from 25 minutes to 2.1 minutes), increasing test coverage from 83% to 100%, and supporting 24-hour unattended testing. It provides an efficient and accurate solution for full-condition verification of complex electrical systems in new energy vehicles. Attached Figure Description

[0062] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described below with reference to the accompanying drawings, wherein:

[0063] Figure 1 A flowchart illustrating an embodiment of the multi-system collaborative testing system based on a chassis dynamometer provided by the present invention;

[0064] Figure 2 This is a schematic diagram of the hardware integration of the controller chassis;

[0065] Figure 3 This is a functional architecture diagram of the automated testing module;

[0066] Figure 4This is a technical roadmap for an embodiment of the development method of a multi-system collaborative testing system based on a chassis dynamometer provided by the present invention.

[0067] Figure 5 This is a schematic diagram illustrating the operational steps of an embodiment of the multi-system collaborative testing method based on a chassis dynamometer provided by the present invention.

[0068] Explanation of reference numerals in the attached diagram: 1-Controller chassis, 2-Power button, 3-External module status indicator, 4-Real-time controller, 5-Ethernet module, 6-CAN module, 7-High-speed digital I / O module, 8-RTD ​​acquisition module, 9-Analog input / output module, 10-RS485 / 232 serial port module, 11-Automatic test module. Detailed Implementation

[0069] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The descriptions of the exemplary embodiments are merely illustrative and are in no way intended to limit the present disclosure or its application or use. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangement of components and steps, the composition of materials, numerical expressions, and values ​​set forth in these embodiments should be interpreted as merely exemplary and not as limiting.

[0070] The terms “first,” “second,” and similar words used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Words such as “including” or “contains” mean that the element preceding the word encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as “above” and “below” are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.

[0071] In this disclosure, when a specific component is described as being located between a first component and a second component, an intermediary component may or may not be present between the specific component and the first or second component. When a specific component is described as connecting to other components, the specific component may be directly connected to the other components without having an intermediary component, or it may not be directly connected to the other components but may have an intermediary component.

[0072] All terms used in this disclosure (including technical or scientific terms) have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, such as a dictionary, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as having an idealized or highly formalized meaning, unless expressly defined herein.

[0073] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0074] like Figure 1 and Figure 2 As shown, the multi-system collaborative testing system based on a chassis dynamometer provided in this embodiment includes: a controller chassis 1, which includes a real-time controller 4 and a multi-protocol fusion data communication module. The multi-protocol fusion data communication module is used to connect to multiple test devices through multiple protocols. The real-time controller 4 is connected to an automated testing module 11, which is used to automatically execute test cases, parse test cases, and obtain test results, such as... Figure 3 As shown, the automated testing module 11 includes host computer software, slave computer software, and a database.

[0075] Among them, the real-time controller 4 is an NI PXIe-8842, which integrates communication protocols and control logic with its high performance and real-time operating system; the controller chassis 1 is an NI PXIe-1092 (8 slots), which enables modular system design and has scalability.

[0076] In one embodiment of the present invention, the configuration of the multi-protocol fusion data communication module integrated on the controller chassis 1 is shown in Table 1.

[0077] Table 1 Configuration of Multi-protocol Fusion Data Communication Module

[0078]

[0079] Specifically, the multi-protocol fusion data communication module includes an Ethernet module 5, a CAN module 6, a high-speed digital I / O module 7, an RTD acquisition module 8, an analog input / output module 9, and an RS485 / 232 serial port module 10, wherein:

[0080] The Ethernet module 5 is used for in-vehicle Ethernet communication with the chassis dynamometer or driving robot.

[0081] The CAN module 6 is used for CAN or LIN communication with the vehicle or charging station.

[0082] The high-speed digital I / O module 7 is used to acquire high-speed digital I / O signals from the fuel consumption meter or power analyzer;

[0083] The RTD acquisition module 8 is used to acquire the resistance value of the thermocouple and convert the resistance value of the thermocouple into a temperature signal.

[0084] The analog input / output module 9 is used to acquire analog signals from the chassis dynamometer or current clamp.

[0085] The RS485 / 232 serial port module 10 is used for serial communication with a low-voltage load box or power meter.

[0086] This invention utilizes a multi-protocol fusion data communication module to uniformly parse heterogeneous protocols. It supports a hybrid parsing engine for TCP / IP (AK commands), custom CAN protocols, RS485, digital IO (PWM), and RTD temperature signal and analog signals, achieving seamless integration of six types of protocols. It also includes dynamic compilation of AK commands (dynamometer communication commands), CAN signal parsing protocols, and fuel consumption algorithms for fuel consumption meter pulse signals, enabling integrated equipment to cover various test scenarios. This solves the problems of discrete chassis dynamometer laboratory testing equipment and difficulties in equipment coordination, thereby improving the efficiency of test implementation.

[0087] Meanwhile, based on the high-precision hardware clock built into the NI PXI device, synchronization is achieved with high-precision data timing. Specifically, a multi-system collaborative control system is used to collect data in a unified manner, and a linear difference data alignment algorithm is integrated to realize cross-device data synchronization, solve the problem of excessive timing deviation in data collection from multiple devices, improve data synchronization accuracy, and enhance the accuracy of data result processing.

[0088] Furthermore, the multi-system collaborative testing system based on a chassis dynamometer of the present invention adopts a distributed hardware architecture to realize a multi-module collaborative control mechanism on the NI PXI platform. Specifically, it is developed based on the NI PXI real-time control platform, integrating modules such as Ethernet (PXIe-8523), CAN (PXIe-8510), digital I / O (PXIe-6537), analog (PXIe-4303), and RTD temperature (PXIe-4375), supporting 8-slot expansion. The hardware system is divided into a control layer → communication layer → execution layer, with each layer operating independently and modularly designed, achieving a comprehensive improvement in scalability, real-time performance, and reliability, providing a cost-effective hardware foundation for multi-device collaborative testing. Based on multi-protocol fusion acquisition technology, the present invention integrates communication protocols through a unified testing system, enabling instruction distribution and data acquisition for six protocols (TCP / IP, CAN, RS485, digital I / O, analog, and RTD temperature) within a 1ms cycle, achieving unified access to data from heterogeneous devices.

[0089] Furthermore, such as Figure 2 As shown, the controller chassis 1 has a power button 2 and an external module status indicator 3 on the bottom front.

[0090] Specifically, the host computer software runs on a PC and is used to interact with the user; the slave computer software runs in the NI controller and is used to implement system operation, hardware control and test case execution; the database is developed based on the MySQL platform, runs on the local PC, and is used to store user information, manage test cases, store and manage test data, and store device information database.

[0091] Furthermore, such as Figure 3 As shown, the host computer software includes a user login interface, an automated testing interface, a manual testing interface, a system self-test interface, a task query interface, and a historical data query interface.

[0092] The user login interface is used for test personnel to log in using an account and password;

[0093] The automated testing interface is used to select test cases, start automated execution, monitor the progress of the test, display key data during the test through curves, and display the test results after the test is completed.

[0094] The manual testing interface is used to debug test cases step by step and complete the test step by step. It is also used as a manual testing tool to manually control the test equipment and independently execute test operations. The manual testing interface as a manual testing tool includes at least one of the following: driving robot throttle and brake control interface, gear control interface, vehicle central control screen control interface, chassis dynamometer control interface, and wheel hub control interface.

[0095] The system self-test interface is used to locate abnormal parts of the system and to perform polling self-tests on the equipment before the test;

[0096] The task query interface is connected to the cloud and is used to query test tasks, display the status of test tasks, and view test results.

[0097] The historical data query interface is used to query historical data, compare data, and display data through curves to achieve data analysis and comparison, thereby improving data utilization.

[0098] Furthermore, such as Figure 3 As shown, the lower-level machine software includes a hardware control module, a data acquisition module, and a data processing module, wherein:

[0099] The hardware control module is used to integrate the hardware control communication protocol. After receiving the test cases sent by the host computer, it parses the test cases sent by the host computer, determines the test execution actions, edits the test equipment control steps, sends hardware control commands, and completes the test operation.

[0100] The data acquisition module is used to parse test cases, determine the data acquisition channel, and use the internal clock of NI PXI to unify the data timing in order to solve the problem of asynchronous data timing.

[0101] The data processing module is used to design data processing scripts based on the characteristics of test cases, and after data collection, call the preset scripts to complete data processing and upload the test results.

[0102] In summary, the automated testing module 11 of the present invention can provide user-interactive software for test case editing, automatic test case execution, data acquisition, data processing, and result presentation, and can realize intelligent automated testing.

[0103] Furthermore, such as Figure 4 As shown, the present invention also provides a development method for the above-mentioned multi-system collaborative testing system based on a chassis dynamometer, comprising the following steps:

[0104] Step SA: Construct a typical experimental model and determine the experimental equipment and experimental procedures.

[0105] In one embodiment of the development method of the multi-system collaborative testing system based on a chassis dynamometer of the present invention, step SA may specifically include:

[0106] Step SA1: Determine the test equipment.

[0107] Step SA2: Analyze the test scenario.

[0108] Step SA3: Analyze the test standards.

[0109] Step SA4: Feasibility analysis of automated testing.

[0110] Step SB: Modular control matrix, set control content, and complete equipment control timing.

[0111] In one embodiment of the development method of the multi-system collaborative testing system based on a chassis dynamometer of the present invention, step SB may specifically include:

[0112] Step SB1: Determine the equipment test content.

[0113] Step SB2: Parse the communication protocol.

[0114] Step SB3: Develop the test equipment control module.

[0115] Step SC, Test Input Management, Design and Development of Automated Test Cases, Digitize Experimental Operations, and Transform Them into Storeable and Recognizable Test Cases.

[0116] In one embodiment of the development method of the multi-system collaborative testing system based on a chassis dynamometer of the present invention, step SC may specifically include:

[0117] Step SC1: Develop and design test cases.

[0118] Step SC2: Based on the test cases designed in the development, build a library of typical test cases.

[0119] Step SC3: Customize the test case editing function.

[0120] Step SD, automated test software development, and determination of system control logic and human-computer interaction logic.

[0121] In one embodiment of the development method of the multi-system collaborative testing system based on a chassis dynamometer of the present invention, step SD may specifically include:

[0122] Step SD1: Develop automated testing logic.

[0123] Step SD2: Design the user interface.

[0124] Step SD3: Develop equipment status monitoring functions.

[0125] Step SE, data management function development, development of data processing scripts, programmatic data processing flow and experimental result evaluation, and storage management of experimental data.

[0126] In one embodiment of the development method of the multi-system collaborative testing system based on a chassis dynamometer of the present invention, step SE may specifically include:

[0127] Step SE1: Store and manage the experimental data.

[0128] Step SE2: Evaluate the test results and issue a report.

[0129] Step SE3: Establish a vehicle information database and a verification index database based on the test data.

[0130] In summary, this invention develops control and automated testing methods for testing equipment in modules.

[0131] Furthermore, such as Figure 5 As shown, the present invention also provides a multi-system collaborative testing method based on a chassis dynamometer, which specifically includes the following steps in actual execution:

[0132] Step S1: Preparatory work before the test: Prepare automated test cases, set the test execution actions, configure the data acquisition channel, develop data processing scripts, and connect the hardware harness.

[0133] Step S2: Open the host computer software: Log in, select the test cases to be executed, click Start Test, send the test cases to the slave computer, monitor the execution progress of the test cases, view the key real-time data during the test run, and display the results when the test is completed.

[0134] Step S3: Start the lower-level software: parse the test cases, map the test execution actions to the device control commands to determine the correct control timing, operate the test equipment, configure the data acquisition channel according to the test cases, select key data and upload it to the upper-level software in real time, and call the data processing script after the test operation is completed to process the test data, generate test results and upload them.

[0135] Step S4: Upload the saved raw data and test results to the database.

[0136] In summary, this invention develops intelligent testing software to address the complex testing needs of new energy vehicle chassis dynamometer laboratories. It covers the entire process from test input management, test case editing, equipment control timing design, test operation execution, test data acquisition, real-time data display, test data processing, and test result display. By using software, the testing process is digitized and standardized, thereby improving the efficiency and accuracy of testing.

[0137] The multi-system collaborative testing system, development, and testing method based on a chassis dynamometer provided in this invention embodiment uses a chassis dynamometer as the core and is implemented through NI. The PXI control hardware (equipped with a PXIe-8842 real-time controller and multi-protocol communication module) and customized software system enable collaborative control of multiple devices, including chassis dynamometers, driving robots, AC / DC charging piles, power analyzers, low-voltage loads, and vehicle control interfaces. This allows for integrated and automated testing of new energy vehicles. By uniformly parsing TCP / IP (AK commands), CAN (custom / non-standard protocols), RS485, digital I / O, and analog signals, a high-precision timing synchronization mechanism (error ≤ 0.8ms) is constructed. Automated test management software is developed to support test case editing, device control sequence generation, dynamic anomaly response (three-level fault handling), and data fusion analysis. This overcomes the challenges of device discretization, protocol fragmentation, and data asynchronization in traditional testing, improving testing efficiency by 12 times (single test case time reduced from 25 minutes to 2.1 minutes), increasing test coverage from 83% to 100%, and supporting 24-hour unattended testing. It provides an efficient and accurate solution for full-condition verification of complex electrical systems in new energy vehicles.

[0138] The embodiments of this disclosure have now been described in detail. To avoid obscuring the concept of this disclosure, some details known in the art have not been described. Those skilled in the art can fully understand how to implement the technical solutions disclosed herein based on the above description.

[0139] While specific embodiments of this disclosure have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of this disclosure. Those skilled in the art should understand that modifications can be made to the above embodiments or equivalent substitutions can be made to some technical features without departing from the scope and spirit of this disclosure. The scope of this disclosure is defined by the appended claims.

Claims

1. A multi-system collaborative testing system based on a chassis dynamometer, characterized in that, include: The controller chassis includes a real-time controller and a multi-protocol fusion data communication module. The multi-protocol fusion data communication module is used to connect to multiple test devices through multiple protocols. The real-time controller is connected to an automated testing module, which is used to automatically execute test cases, parse test cases, and obtain test results. The automated testing module includes host computer software, slave computer software, and a database.

2. The multi-system collaborative testing system based on a chassis dynamometer according to claim 1, characterized in that, The multi-protocol fusion data communication module includes an Ethernet module, a CAN module, a high-speed digital I / O module, an RTD acquisition module, an analog input / output module, and an RS485 / 232 serial port module, wherein: The Ethernet module is used for in-vehicle Ethernet communication with the chassis dynamometer or driving robot. The CAN module is used for CAN or LIN communication with the vehicle or charging station. The high-speed digital I / O module is used to acquire high-speed digital I / O signals from the fuel consumption meter or power analyzer; The RTD acquisition module is used to acquire the resistance value of the thermocouple and convert the resistance value of the thermocouple into a temperature signal. The analog input / output module is used to acquire analog signals from the chassis dynamometer or current clamp. The RS485 / 232 serial port module is used for serial communication with low-voltage load boxes or power meters.

3. The multi-system collaborative testing system based on a chassis dynamometer according to claim 1, characterized in that, The controller chassis has a power button and an external module status indicator light on the bottom front.

4. The multi-system collaborative testing system based on a chassis dynamometer according to claim 1, characterized in that, The host computer software runs on a PC and is used to interact with the user; the slave computer software runs in the NI controller and is used to implement system operation, hardware control and test case execution; the database is developed based on the MySQL platform and runs on the local PC, used to store user information, manage test cases, store and manage test data, and store device information database.

5. The multi-system collaborative testing system based on a chassis dynamometer according to claim 4, characterized in that, The host computer software includes a user login interface, an automated testing interface, a manual testing interface, a system self-test interface, a task query interface, and a historical data query interface. The user login interface is used for test personnel to log in using an account and password; The automated testing interface is used to select test cases, start automated execution, monitor the progress of the test, display key data during the test through curves, and display the test results after the test is completed. The manual testing interface is used to debug test cases step by step and complete the test step by step. It is also used as a manual testing tool to manually control the test equipment and independently execute test operations. The manual testing interface as a manual testing tool includes at least one of the following: driving robot throttle and brake control interface, gear control interface, vehicle central control screen control interface, chassis dynamometer control interface, and wheel hub control interface. The system self-test interface is used to locate abnormal parts of the system and to perform polling self-tests on the equipment before the test; The task query interface is connected to the cloud and is used to query test tasks, display the status of test tasks, and view test results. The historical data query interface is used to query historical data, compare data, and display the data through curves.

6. The multi-system collaborative testing system based on a chassis dynamometer according to claim 5, characterized in that, The lower-level machine software includes a hardware control module, a data acquisition module, and a data processing module, wherein: The hardware control module is used to integrate the hardware control communication protocol. After receiving the test cases sent by the host computer, it parses the test cases sent by the host computer, determines the test execution actions, edits the test equipment control steps, sends hardware control commands, and completes the test operation. The data acquisition module is used to parse test cases, determine data acquisition channels, and unify data timing using the NI PXI internal clock. The data processing module is used to design data processing scripts based on the characteristics of test cases, and after data collection, call the preset scripts to complete data processing and upload the test results.

7. A development method for a multi-system collaborative testing system based on a chassis dynamometer as described in any one of claims 1-6, characterized in that, include: Construct typical experimental models and determine experimental equipment and procedures; Modular control matrix: Set control content and complete equipment control timing; Test input management involves designing and developing automated test cases, digitizing experimental operations, and transforming them into storable and identifiable test cases. Develop automated testing software and determine the system control logic and human-computer interaction logic; Develop data management functions, develop data processing scripts, programmatic data processing workflows and evaluation of experimental results, and store and manage experimental data.

8. The development method of the multi-system collaborative testing system based on a chassis dynamometer according to claim 7, characterized in that, The construction of a typical experimental model and the determination of experimental equipment and procedures include: Determine the testing equipment; Analyze the test scenario; Analysis of the test standards; Feasibility analysis of automated testing The modular control matrix sets the control content and completes the equipment control timing, including: Determine the scope of equipment testing; Parse the communication protocol; Develop a test equipment control module. The test input management involves designing and developing automated test cases, digitizing experimental operations, and converting them into storable and identifiable test cases, including: Develop and design test cases; Based on the test cases developed and designed, construct a library of typical experimental test cases; Customize the test case editing functionality. The development of the automated testing software determines the system control logic and human-computer interaction logic, including: Develop automated testing logic; Design the user interface; Develop equipment status monitoring functions. The data management function development includes developing data processing scripts, programmatic data processing workflows and experimental result evaluation, and storing and managing experimental data, including: Store and manage the experimental data; Evaluate the test results and issue a report; A vehicle information database and a verification index database were established based on the test data.

9. A multi-system collaborative testing method based on a chassis dynamometer using the system described in any one of claims 1-6, characterized in that, include: Preparations before the test: Prepare automated test cases, set up test execution actions, configure data acquisition channels, develop data processing scripts, and connect hardware harnesses; Open the host computer software: Log in as a user, select the test cases to be executed, click Start Test, send the test cases to the slave computer, monitor the execution progress of the test cases, view the key real-time data during the test run, and display the results when the test is completed; Start the lower-level software: parse the test cases, map the test execution actions to the device control commands to determine the best control sequence, operate the test equipment, configure the data acquisition channel according to the test cases, select key data and upload it to the upper-level software in real time, and call the data processing script after the test operation is completed to process the test data, generate test results and upload them. Upload the saved raw data and test results to the database.

Images