Distributed electric drive assembly offline detection method
By employing a comprehensive offline testing method that includes CAN communication, software version testing, resolver self-learning, motor external characteristics testing, and NVH testing of the distributed powertrain, the problem of incomplete testing in existing technologies has been solved, thereby improving product reliability and safety.
Patent Information
- Application Number
- CN202610053070.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-15
- Publication Date
- 2026-04-14
AI Technical Summary
Existing technologies do not provide comprehensive off-line testing for distributed powertrains, which may lead to control failures after installation in the vehicle.
A distributed powertrain off-line testing method is adopted, which includes testing the controller's CAN communication, software and hardware versions, left and right motor resolver self-learning, motor external characteristics and NVH testing, and comprehensive testing through CAN communication protocol and UDS command.
This enables comprehensive testing of the distributed powertrain, improves product reliability, reduces the risk of vehicle control failures, and enhances product quality and safety.
Smart Images
Figure CN121856685A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of new energy vehicle powertrain technology, specifically to a method for testing the off-line performance of a distributed powertrain. Background Technology
[0002] With the development of new energy vehicles, distributed powertrains have been widely adopted due to their advantages such as high drive efficiency, flexible spatial layout, more precise torque control, and high energy recovery. As a crucial component of the overall powertrain system of new energy vehicles, the distributed powertrain consists of a controller, left and right motors, and a transmission. Currently, the use of distributed powertrain products in new energy vehicles is increasing, and ensuring the comfort and reliability of the powertrain has become a critical issue for the driving experience and safety of new energy vehicles.
[0003] The main problems with distributed powertrains in vehicles include poor NVH (noise, vibration, and harshness) performance during driving, which negatively impacts the customer experience. Off-line testing of distributed powertrains is an effective way to manage these issues. Targeted and effective off-line testing allows for quality monitoring and enhances a company's market competitiveness and overall strength. However, current off-line testing technologies for distributed powertrains are not comprehensive enough, thus failing to guarantee that control failures will not occur after the distributed powertrain is installed in the vehicle. Summary of the Invention
[0004] In view of the above-mentioned shortcomings of the existing technology, the technical problem to be solved by the present invention is: how to provide a method for testing distributed powertrains after they are installed in vehicles, which can comprehensively test distributed powertrains, improve product reliability, and reduce control failure problems after the distributed powertrains are installed in vehicles.
[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:
[0006] A method for detecting the off-line operation of a distributed powertrain includes the following steps:
[0007] Step 1) Check if the CAN communication of the controller in the distributed powertrain is normal;
[0008] Step 2) Detect the software and hardware versions of the controllers in the distributed powertrain;
[0009] Step 3) Check whether the self-learning of the left and right motor resolvers in the distributed powertrain is successful;
[0010] Step 4) Check whether the external characteristics of the left and right motors in the distributed powertrain meet the powertrain requirements;
[0011] Step 5) Perform NVH testing on the distributed powertrain.
[0012] As an optimization, in step 1), the communication between the controller and the external testing station is checked using a specific signal in the CAN communication protocol of the controller in the distributed powertrain.
[0013] As an optimization, in step 2), the signal address location stored in the software version number and hardware version number of the controller in the distributed powertrain is detected. The signal address location stored in the software version number and hardware version number of the controller is obtained in real time through CAN communication or UDS command.
[0014] As an optimization, step 3) includes the following steps:
[0015] Step 3.1) Install the distributed powertrain on the test bench, apply low voltage and high voltage to the controller of the distributed powertrain respectively, and drag the left and right motors of the powertrain to the target speed using the test bench frame. According to the UDS communication protocol of the controller, trigger the left and right motors to perform resolver self-learning using the resolver self-learning trigger command of the left and right motors respectively and obtain the resolver self-learning result signal.
[0016] Step 3.2) Detect whether the resolver self-learning was successful based on the resolver self-learning result signal in Step 3.1);
[0017] Step 3.3) Obtain the initial angle value of the resolver based on the resolver self-learning result signal from Step 3.1);
[0018] Step 3.4) Stop the left and right motors of the bench drive powertrain;
[0019] Step 3.5) Repeat steps 3.1) to 3.4) n times, and then execute step 3.6).
[0020] Step 3.6) Determine whether the n initial angle values of the resolver obtained by repeating the learning n times are all within the range of 0-360°, and whether the difference between the maximum and minimum values of the n initial angle values is less than 1°. If both are true, the resolver self-learning is determined to be successful; otherwise, the resolver self-learning is determined to be unsuccessful.
[0021] As an optimization, step 4) includes the following steps:
[0022] Step 4.1) According to the controller's CAN communication protocol, request the torque of the left and right motors in the distributed powertrain to be the external characteristic test torque, and then increase the motor speed and motor torque in a gradient manner according to the test requirements.
[0023] Step 4.2) Determine whether the external characteristics of the motor in the distributed powertrain meet the powertrain requirements based on the output torque and speed feedback from the testing station.
[0024] As an optimization, step 4.1) includes the following steps:
[0025] Step 4.1.1) Switch the motor mode to torque mode and request that the motor torque in the distributed powertrain be 0 N•m;
[0026] Step 4.1.2) Gradually request the motor speed to the target speed in an increasing gradient of 0.2 seconds, with the request time calculated based on an acceleration of 1000 rpm / s;
[0027] Step 4.1.3) After the speed is reached, the motor torque is gradually requested to reach the target torque in an increasing gradient of 0.2 seconds, with the request time calculated as 100 N•m / s.
[0028] As an optimization, in step 4.2), it is determined whether the output torque fed back by the left and right loading motor ends of the test platform is within ±3% of the target torque, and at the same time, it is determined whether the output speed fed back by the left and right loading motor ends of the test platform is within ±5 rpm of the target speed. If both are true, it is determined that the motor external characteristics of the distributed powertrain meet the requirements of the distributed powertrain; otherwise, it is determined that the motor external characteristics of the distributed powertrain do not meet the requirements of the distributed powertrain.
[0029] As an optimization, in step 5), the torque and speed of the motors in the distributed powertrain are controlled according to the CAN communication protocol of the distributed powertrain controller in order to perform NVH detection. The NVH detection includes high torque acceleration condition detection, medium torque acceleration condition detection, medium torque deceleration condition detection, forward low torque low speed condition detection, and reverse low torque low speed condition detection.
[0030] As an optimization, the high torque acceleration condition detection includes: setting a fixed high torque and speed for the motor of the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain when the motor outputs high torque and accelerates.
[0031] The mid-torque acceleration condition detection includes: setting a fixed mid-torque and increasing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain under the condition of mid-torque acceleration from the motor output.
[0032] The mid-torque deceleration condition detection includes: setting a fixed mid-torque and reducing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain under the condition of mid-torque deceleration of the motor output.
[0033] The positive low torque and low speed operating condition detection includes: setting a fixed positive low torque and running a fixed low speed on the motor of the distributed powertrain, and using an NVH detection system to detect gear collision damage on the gears of the transmission part of the powertrain.
[0034] The reverse low torque and low speed condition detection includes: setting a fixed reverse low torque and running a fixed low speed on the motor of the distributed powertrain, and using an NVH detection system to detect gear impact damage on the gears of the transmission part of the powertrain.
[0035] Compared with existing technologies, the distributed powertrain off-line testing method provided by this invention enables objective evaluation of the performance of the distributed powertrain during the off-line testing stage, and effectively intercepts substandard products in combination with the actual situation of the whole vehicle, thereby improving the product reliability.
[0036] This invention effectively solves the problem of insufficient off-line testing of distributed powertrains in existing technologies, greatly improving product reliability and comfort, reducing control failures after the distributed powertrain is installed in the vehicle, and reducing the occurrence of safety accidents. Attached Figure Description
[0037] Figure 1 These are the off-line testing indicators for the distributed powertrain off-line testing bench of this invention;
[0038] Figure 2 This is a flowchart of the distributed powertrain off-line testing method of the present invention;
[0039] Figure 3 Example diagram of the self-learning features of the left and right motor resolvers in the distributed powertrain offline detection method of the present invention. Detailed Implementation
[0040] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0041] Example: Common problems revealed during the production run of distributed powertrains include: failure of self-learning of the left and right motor resolvers, failure of external characteristics of the left and right motors (output speed or torque exceeding limits), and NVH non-compliance (failure of peak or order determination). Based on different models of distributed powertrains and their performance in the vehicle, the indicators to be tested and the corresponding functions of each indicator are as follows: Figure 1 As shown.
[0042] To meet the above requirements for the offline testing of distributed powertrains, this embodiment provides a method for offline testing of distributed powertrains, such as... Figure 2 As shown, it includes the following steps:
[0043] Step 1) Check if the CAN communication of the controller in the distributed powertrain is normal;
[0044] Step 2) Detect the software and hardware versions of the controllers in the distributed powertrain;
[0045] Step 3) Check whether the self-learning of the left and right motor resolvers in the distributed powertrain is successful;
[0046] Step 4) Check whether the external characteristics of the left and right motors in the distributed powertrain meet the powertrain requirements;
[0047] Step 5) Perform NVH testing on the distributed powertrain.
[0048] In this specific embodiment, in step 1), the communication between the controller and the external testing station is checked using specific signals in the CAN communication protocol of the controller in the distributed powertrain. Specifically, the Counter signal and Check_Sum signal in frame 17A of the CAN communication protocol are used to verify and check whether the communication between the controller and the testing station is normal.
[0049] In this specific embodiment, in step 2), the detection is performed based on the DID signal address location stored in the software version number and hardware version number of the controller in the distributed powertrain, and the signal address location stored in the software version number and hardware version number of the controller is obtained in real time through CAN communication or UDS command.
[0050] In this specific embodiment, step 3) includes the following steps:
[0051] Step 3.1) Install the distributed powertrain on the test bench, apply low voltage and high voltage to the controller of the distributed powertrain respectively, and drag the left and right motors of the powertrain to the target speed. According to the UDS communication protocol of the controller, use the left and right motor resolver self-learning trigger command to trigger the left and right motors to perform resolver self-learning and obtain the resolver self-learning result signal.
[0052] Step 3.2) Detect whether the resolver self-learning was successful based on the resolver self-learning result signal in Step 3.1);
[0053] Step 3.3) Obtain the initial angle value of the resolver based on the resolver self-learning result signal from Step 3.1);
[0054] Step 3.4) Stop the left and right motors of the bench drive powertrain;
[0055] Step 3.5) Repeat steps 3.1) to 3.4) n times, and then execute step 3.6).
[0056] Step 3.6) Determine whether the n initial angle values of the resolver obtained by repeating the learning n times are all within the range of 0-360°, and whether the difference between the maximum and minimum values of the n initial angle values is less than 1°. If both are true, the resolver self-learning is determined to be successful; otherwise, the resolver self-learning is determined to be unsuccessful.
[0057] In this specific embodiment, step 4) includes the following steps:
[0058] Step 4.1) According to the controller's CAN communication protocol, request the motor torque in the distributed powertrain to be the external characteristic test torque, and then perform gradient speed increase on the motor speed and motor torque according to the test requirements.
[0059] Specifically, step 4.1 includes the following steps:
[0060] Step 4.1.1) Switch the motor mode to torque mode and request that the motor torque in the distributed powertrain be 0 N•m;
[0061] Step 4.1.2) Gradually request the motor speed to the target speed in an increasing gradient of 0.2 seconds, with the request time calculated based on an acceleration of 1000 rpm / s;
[0062] Step 4.1.3) After the speed is reached, the motor torque is gradually requested to reach the target torque in an increasing gradient of 0.2 seconds, with the request time calculated at 100 N•m / s.
[0063] Step 4.2) Determine whether the external characteristics of the motor in the distributed powertrain meet the powertrain requirements based on the output torque and speed feedback from the testing station.
[0064] Specifically, in step 4.2), it is determined whether the output torque fed back by the motor end of the test bench is within ±3% of the target torque, and at the same time, it is determined whether the output speed fed back by the motor end of the test bench is within ±5 rpm of the target speed. If both are true, it is determined that the motor external characteristics of the distributed powertrain meet the requirements of the distributed powertrain; otherwise, it is determined that the motor external characteristics of the distributed powertrain do not meet the requirements of the distributed powertrain.
[0065] In this specific embodiment, in step 5), the torque and speed of the motor of the distributed powertrain are controlled according to the CAN communication protocol of the distributed powertrain controller in order to perform NVH detection. The NVH detection includes high torque acceleration condition detection, medium torque acceleration condition detection, medium torque deceleration condition detection, forward low torque low speed condition detection, and reverse low torque low speed condition detection.
[0066] Specifically, the high torque acceleration condition detection includes: setting a fixed high torque and increasing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain when the motor outputs high torque and accelerates.
[0067] The mid-torque acceleration condition detection includes: setting a fixed mid-torque and increasing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain under the condition of mid-torque acceleration from the motor output.
[0068] The mid-torque deceleration condition detection includes: setting a fixed mid-torque and reducing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain under the condition of mid-torque deceleration of the motor output.
[0069] The positive low torque and low speed operating condition detection includes: setting a fixed positive low torque and running a fixed low speed on the motor of the distributed powertrain, and using an NVH detection system to detect gear collision damage on the gears of the transmission part of the powertrain.
[0070] The reverse low torque and low speed condition detection includes: setting a fixed reverse low torque and running a fixed low speed on the motor of the distributed powertrain, and using an NVH detection system to detect gear impact damage on the gears of the transmission part of the powertrain.
[0071] Compared with existing technologies, the distributed powertrain off-line testing method provided by this invention enables objective evaluation of the performance of the distributed powertrain during the off-line testing stage. Combined with the actual conditions of the entire vehicle, it effectively intercepts substandard products, improving product reliability. Simultaneously, this invention effectively solves the problem of insufficient comprehensiveness in the off-line testing of distributed powertrains in existing technologies, significantly improving product reliability and comfort, reducing control failures after the distributed powertrain is installed in the vehicle, and decreasing the occurrence of safety accidents.
[0072] Although embodiments of the present invention have been shown and described, those skilled in the art will be able to make various changes, modifications, substitutions and alterations to these embodiments without departing from the principles and basis of the present invention. The scope of the present invention is defined by the appended claims and their equivalents. Therefore, the embodiments of the present invention are merely illustrative examples and should not be construed as limiting the present invention in any way.
Claims
1. A method for detecting the off-line operation of a distributed powertrain, characterized in that, Includes the following steps: Step 1) Check if the CAN communication of the controller in the distributed powertrain is normal; Step 2) Detect the software and hardware versions of the controllers in the distributed powertrain; Step 3) Check whether the self-learning of the left and right motor resolvers in the distributed powertrain is successful; Step 4) Check whether the external characteristics of the left and right motors in the distributed powertrain meet the powertrain requirements; Step 5) Perform NVH testing on the distributed powertrain.
2. The method for detecting the off-line operation of a distributed powertrain according to claim 1, characterized in that, In step 1), based on the CAN communication protocol of the controller in the distributed powertrain, a specific signal in the CAN communication protocol is used to detect whether the communication between the controller and the external testing station is normal.
3. The method for detecting the off-line operation of a distributed powertrain according to claim 1, characterized in that, In step 2), the signal address location stored in the software version number and hardware version number of the controller in the distributed powertrain is detected. The signal address location stored in the software version number and hardware version number of the controller is obtained in real time through CAN communication or UDS command.
4. The method for detecting the off-line operation of a distributed powertrain according to claim 1, characterized in that, Step 3) includes the following steps: Step 3.1) Install the distributed powertrain on the test bench, apply low voltage and high voltage to the controller of the distributed powertrain respectively, and drag the left and right motors of the powertrain to the target speed using the test bench frame. According to the UDS communication protocol of the controller, trigger the left and right motors to perform resolver self-learning using the resolver self-learning trigger command of the left and right motors respectively and obtain the resolver self-learning result signal. Step 3.2) Detect whether the resolver self-learning was successful based on the resolver self-learning result signal in Step 3.1); Step 3.3) Obtain the initial angle value of the resolver based on the resolver self-learning result signal from Step 3.1); Step 3.4) Stop the left and right motors of the bench drive powertrain; Step 3.5) Repeat steps 3.1) to 3.4) n times, and then execute step 3.6). Step 3.6) Determine whether the n initial angle values of the resolver obtained by repeating the learning n times are all within the range of 0-360°, and whether the difference between the maximum and minimum values of the n initial angle values is less than 1°. If both are true, the resolver self-learning is determined to be successful; otherwise, the resolver self-learning is determined to be unsuccessful.
5. The method for detecting the off-line operation of a distributed powertrain according to claim 1, characterized in that, Step 4) includes the following steps: Step 4.1) According to the controller's CAN communication protocol, request the torque of the left and right motors in the distributed powertrain to be the external characteristic test torque, and then increase the motor speed and motor torque in a gradient manner according to the test requirements. Step 4.2) Determine whether the external characteristics of the motor in the distributed powertrain meet the powertrain requirements based on the output torque and speed feedback from the testing station.
6. The method for detecting the off-line operation of a distributed powertrain according to claim 5, characterized in that, Step 4.1) includes the following steps: Step 4.1.1) Switch the motor mode to torque mode and request that the motor torque in the distributed powertrain be 0 N•m; Step 4.1.2) Gradually request the motor speed to the target speed in an increasing gradient of 0.2 seconds, with the request time calculated based on an acceleration of 1000 rpm / s; Step 4.1.3) After the speed is reached, the motor torque is gradually requested to reach the target torque in an increasing gradient of 0.2 seconds, with the request time calculated as 100 N•m / s.
7. The method for detecting the off-line operation of a distributed powertrain according to claim 5, characterized in that, In step 4.2), it is determined whether the output torque fed back from the left and right loading motor ends of the test platform is within ±3% of the target torque, and at the same time, it is determined whether the output speed fed back from the left and right loading motor ends of the test platform is within ±5 rpm of the target speed. If both are true, it is determined that the motor external characteristics of the distributed powertrain meet the requirements of the distributed powertrain; otherwise, it is determined that the motor external characteristics of the distributed powertrain do not meet the requirements of the distributed powertrain.
8. The method for detecting the off-line operation of a distributed powertrain according to claim 1, characterized in that, In step 5), the torque and speed of the motors in the distributed powertrain are controlled according to the CAN communication protocol of the distributed powertrain controller in order to perform NVH detection. The NVH detection includes high torque acceleration condition detection, medium torque acceleration condition detection, medium torque deceleration condition detection, forward low torque low speed condition detection, and reverse low torque low speed condition detection.
9. The method for detecting the off-line operation of a distributed powertrain according to claim 8, characterized in that, The high-torque acceleration condition detection includes: setting a fixed high torque and increasing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain when the motor outputs high torque and accelerates. The mid-torque acceleration condition detection includes: setting a fixed mid-torque and increasing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain under the condition of mid-torque acceleration from the motor output. The mid-torque deceleration condition detection includes: setting a fixed mid-torque and reducing the speed of the motor in the distributed powertrain, and using an NVH detection system to detect abnormal noises in the distributed powertrain under the condition of mid-torque deceleration of the motor output. The positive low torque and low speed operating condition detection includes: setting a fixed positive low torque and running a fixed low speed on the motor of the distributed powertrain, and using an NVH detection system to detect gear collision damage on the gears of the transmission part of the powertrain. The reverse low torque and low speed condition detection includes: setting a fixed reverse low torque and running a fixed low speed on the motor of the distributed powertrain, and using an NVH detection system to detect gear impact damage on the gears of the transmission part of the powertrain.