New Energy Flow Testing Platform and Testing Methods

Abstract

This invention provides a new energy energy flow testing platform and method, belonging to the field of new energy vehicle power system testing technology. The platform includes: a rectifier power supply, a conjugate DC / DC transformer, a drive and load motor assembly, a mechanical coupling mechanism, and a data acquisition and processing platform. The rectifier power supply converts grid AC power into a first-stage DC bus. The conjugate DC / DC transformer forms two independently programmable output voltages for a second-stage DC bus, which are respectively connected to the drive motor and the load motor. The mechanical coupling mechanism connects the motors to the test object and constructs a mechanical power transfer loop. The data acquisition and processing platform communicates with various electrical, mechanical, and sensing units to achieve synchronous data acquisition and processing across the entire system. This invention significantly improves the energy efficiency and integration level of new energy vehicle power component testing.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle power system testing technology, specifically to a new energy energy flow testing platform and testing method. Background Technology

[0002] With the rapid development of the new energy vehicle industry, new energy powertrain systems, centered on motors, electric drive assemblies, and inverters, have become a key component of vehicles. To ensure the safety, reliability, economy, and regulatory compliance of these components in actual operation, comprehensive and accurate testing is essential during the research and development and certification phases. Against this backdrop, new energy powertrain testing platforms designed to simulate real-world operating conditions and evaluate powertrain performance have emerged.

[0003] Currently, most common new energy power testing platforms adopt a scheme based on AC grid power supply, driving motors through frequency converters, and using mechanical loading devices for performance testing. These platforms typically only test motors of a single voltage level or fixed type, making it difficult to adapt to a wide range of testing needs, from low-voltage platforms (e.g., 48V) to high-voltage platforms (e.g., 800V and above). Furthermore, existing testing systems mostly employ a single mode of energy management—resistive consumption or grid feedback—resulting in low energy utilization efficiency and poor system scalability, making it difficult to support complex testing scenarios involving multiple motors and multiple operating conditions. During testing, the power, mechanical, and data subsystems often operate independently, lacking unified scheduling and coordination. This leads to cumbersome testing procedures, low overall energy efficiency, and difficulty in achieving accurate analysis and evaluation of energy flow across all operating conditions.

[0004] Therefore, existing new energy power testing platforms generally suffer from problems such as limited test voltage range, low system energy utilization efficiency, insufficient flexibility in testing multiple motors and operating conditions, and weak overall system collaborative control capabilities. There is an urgent need for a new testing platform architecture that can support a wide voltage range, achieve efficient energy recycling, have high flexibility and scalability, and integrate multi-system collaborative testing capabilities. Summary of the Invention

[0005] In view of this, it is necessary to provide a new energy energy flow testing platform to solve the technical problems of narrow voltage adaptation range, low energy utilization rate and insufficient system coordination capability caused by the existing testing platform being based on AC grid power supply and driving motor through frequency converter for performance testing.

[0006] To address the aforementioned technical problems, in a first aspect, the present invention provides a new energy flow testing platform, comprising: The rectifier power supply has its input end connected to a common three-phase industrial power grid and its output end forming the first-stage DC bus. A conjugate DC / DC transformer, the input of which is connected to the first-stage DC bus, the conjugate DC / DC transformer includes two DC / DC converters with equal power capacity and operating in a conjugate state, the high-voltage output terminal of each DC / DC converter forms an independent second-stage DC bus, and the output voltage of the second-stage DC bus is programmable and adjustable; At least one drive motor and at least one load motor, wherein the drive motor and the load motor are respectively connected to the second-stage DC bus via corresponding inverters; A mechanical coupling mechanism is used to connect the drive motor, the loading motor, and the object under test to form a mechanical power transmission circuit; The data acquisition and processing platform is communicatively connected to the rectifier power supply, the conjugate DC / DC transformer, the drive motor, the loading motor, and the sensors mounted on the mechanical linkage mechanism, and is used to acquire and process power data, mechanical status data, and sensor data.

[0007] In one possible implementation, the output voltage of the second-stage DC bus can be programmably adjusted within the range of 24V to 1200V.

[0008] In one possible implementation, the two DC / DC converters in the conjugate DC / DC transformer are configured to operate in a conjugate state, such that their energy flow directions are always opposite.

[0009] In one possible implementation, at least one of the second-stage DC buses output by the conjugate DC / DC transformer is configured to simultaneously provide test power to multiple inverters and motors of the same voltage level.

[0010] In one possible implementation, the two second-stage DC buses are configured to support testing of dual-wheel motor drive systems, plug-in hybrid motor drive systems, or back-to-back motor-driven systems.

[0011] In one possible implementation, the rectifier power supply integrates a power analyzer for measuring the total electrical power output from the first-stage DC bus.

[0012] In one possible implementation, the data acquisition and processing platform receives digital instructions and switching signals via a bus, and receives digital or analog sensing data via sensor communication lines.

[0013] In one possible implementation, the new energy flow testing platform includes an environmental chamber connected to the data acquisition and processing platform, which is used to provide controllable environmental testing conditions for the tested object.

[0014] In one possible implementation, the object under test is an electric drive assembly or an electric drive bridge that includes an inverter and a reducer.

[0015] On the other hand, the present invention also provides a testing method based on a new energy energy flow testing platform. The testing platform includes a rectifier power supply, a conjugate DC / DC transformer, an electric drive assembly, an auxiliary drive motor, a loading motor, a mechanical coupling mechanism, and a data acquisition and processing platform. The testing method based on the new energy energy flow testing platform includes: The rectifier power supply converts three-phase AC power into DC power to provide the first-stage DC bus voltage. Based on the testing requirements of the object under test, target output voltage values ​​are set for the two second-stage DC buses in the conjugate DC / DC transformer. Control the operation of the conjugate DC / DC transformer so that two of its DC / DC converters are in a conjugate state, converting the electrical energy of the first-stage DC bus into DC power of the target output voltage value, and supplying power to the corresponding drive motor and / or load motor; During the test, the electrical energy flowing between the drive motor and the load motor is recycled in a loop formed by two second-stage DC buses through two DC / DC converters in a conjugate state. The data acquisition and processing platform synchronously collects and processes data from the rectifier power supply, the conjugate DC / DC transformer, the electric drive assembly, the load motor, and related sensors to analyze the energy flow status during the test process.

[0016] The beneficial effects of this invention are as follows: The new energy flow testing platform provided by this invention establishes a first-stage DC bus by using a rectified power supply connected to a three-phase power grid, and combines it with a transformer composed of two conjugate DC / DC converters to form two second-stage DC buses with independently programmable output voltages. These buses are then connected to the drive motor and the load motor via corresponding inverters. At the same time, a mechanical coupling mechanism is configured to connect the tested object to construct a mechanical power transmission loop. A unified data acquisition and processing platform is set up to communicate with various power, mechanical units and sensors, realizing the schedulable cycle of energy flow within the testing platform and the synchronous acquisition and analysis of data from multiple systems. This improves the voltage adaptability, energy utilization rate and system collaborative management efficiency of new energy power component testing. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic diagram of an embodiment of the new energy flow testing platform provided by the present invention; Figure 2 This is a schematic flowchart of an embodiment of the testing method based on the new energy energy flow testing platform provided by the present invention. Detailed Implementation

[0019] 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 a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] In the description of the embodiments of the present invention, unless otherwise stated, "multiple" means two or more. "And / or" describes the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can represent three situations: A exists alone, A and B exist simultaneously, and B exists alone.

[0021] The terms "first," "second," etc., used in the embodiments of this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a technical feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature.

[0022] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0023] Before demonstrating the embodiments, the following terms will be explained.

[0024] A rectifier power supply is a power conversion device that converts alternating current (AC) to direct current (DC). In this platform, it serves as the system's main input, responsible for converting the AC power from the three-phase industrial power grid into stable DC power and providing the first-stage DC bus voltage for subsequent circuits. The rectifier power supply also has the function of automatically adjusting the first-stage DC bus voltage value according to the requirements of the high-voltage channel in the second-stage DC bus.

[0025] The first-stage DC bus refers to the common connection point of the DC voltage formed by the output of the rectifier power supply. It serves as the main DC power distribution channel for the entire test system, providing a unified input power supply for the subsequent DC / DC converters.

[0026] A conjugate DC / DC transformer is a power conversion unit consisting of two DC / DC converters with equal power capacity and coupled operating states. The two converters operate in "conjugate" mode, meaning that the energy flow directions are always opposite, achieving efficient circulation and recovery of electrical energy within the system.

[0027] A DC / DC converter is a power electronic device that converts DC voltage from one level to another. Voltage level can be increased or decreased by adjusting the switching frequency and duty cycle of the switching devices or by using a transformer.

[0028] The second-stage DC bus is an independent adjustable DC voltage channel output from a conjugate DC / DC transformer. The voltage of each bus can be programmed and is used to provide test power for motors and inverters of different voltage levels.

[0029] Programmable adjustment refers to the ability to set the output voltage or operating mode through digital control signals (such as those from a host computer or PLC), thereby enabling flexible configuration and dynamic adjustment of test parameters.

[0030] An electric drive assembly is the object under test in a test system. It consists of a drive motor, a drive motor controller, and other auxiliary devices. It receives electrical energy and outputs mechanical energy, and also has the ability to convert mechanical energy into electrical energy.

[0031] An auxiliary drive motor is used to simulate the non-electric power source drive motor of the test object. It receives electrical energy and outputs mechanical energy, and also has the ability to convert mechanical energy into electrical energy.

[0032] A load motor is a motor that simulates a load during testing. It typically operates in a generator state, absorbing mechanical energy and converting it into electrical energy to feed back to the system. It is used to simulate various resistances encountered while driving a vehicle and also has the ability to convert electrical energy into mechanical energy.

[0033] An inverter is essentially a bidirectional power electronic device that converts direct current (DC) to alternating current (AC) and vice versa. In this platform, it is used both to provide AC power to the auxiliary drive motor and as a rectifier for the load motor, feeding the power back to the secondary DC bus.

[0034] Mechanical linkage mechanisms are transmission and support structures used to connect mechanical components such as motors, objects under test, and sensors. They include couplings, bearing housings, dynamometer hubs, etc., forming a mechanical power transmission path.

[0035] The Data Acquisition and Processing Platform is a central control unit that integrates hardware acquisition modules and software analysis systems. It is responsible for synchronously collecting, processing, and storing data from various sensors such as those for power, machinery, and environment, and supports real-time monitoring and post-analysis.

[0036] A sensor is a device used to detect physical quantities (such as voltage, current, rotational speed, torque, temperature, vibration, etc.) and convert them into electrical signals. It is the basic unit for data acquisition.

[0037] An environmental chamber is a testing device that can simulate environmental conditions such as temperature, humidity, and vibration, and is used to provide controllable composite environmental stress testing conditions for the test object.

[0038] An electric drive axle (E-Axle) is a highly integrated electric drive unit that typically includes a motor, a reducer, and a differential, used for axle drive in electric vehicles.

[0039] Conjugated Operating State refers to a working mode in which two DC / DC converters coordinate with each other in control, so that one of them acts as an energy output source while the other acts as an energy recovery sink, and the energy flow directions remain dynamically opposite.

[0040] A power analyzer is a high-precision electrical energy measuring instrument that can simultaneously measure multiple electrical parameters such as voltage, current, power, and power factor. It is commonly used for energy efficiency assessment and power quality analysis.

[0041] The back-to-back motor dynamometer test is a test configuration in which two motors are directly coupled through mechanical shafts, with one serving as the drive motor and the other as the load motor, forming a closed mechanical and energy cycle test loop.

[0042] Bus refers to industrial communication networks, such as CAN, EtherCAT, and Modbus, which are used to transmit control commands, status signals, and synchronization data.

[0043] Digital I / O signals are digital signals with only two states (such as on / off, high / low level), and are often used to control the status of relays, contactors or transmission equipment.

[0044] Analog sensor data refers to continuously changing signals from sensors, such as analog quantities like voltage, current, and temperature, which need to be converted from analog to digital before being processed by the system.

[0045] This invention provides a new energy flow testing platform and method. The technical solutions of the embodiments of this 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 this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0046] Figure 1 An example diagram of an embodiment of the new energy flow testing platform provided by the present invention is shown below. Figure 1 As shown, the new energy energy flow testing platform includes: The rectifier power supply 102 has its input end connected to the distribution cabinet 101 and the common three-phase industrial power grid, and its output end forms the first-stage DC bus 103. The conjugate DC / DC transformer 104 has its input terminal connected to the first-stage DC bus 103. The conjugate DC / DC transformer 104 includes two DC / DC converters with equal power capacity and operating in a conjugate state. The high-voltage output terminal of each DC / DC converter forms an independent second-stage DC bus 105 and 106. The output voltage of the second-stage DC bus 105 and 106 can be independently programmed and adjusted. At least one test object electric drive assembly 107 and at least one load motor 109 are connected to the second-stage DC bus 105 and 106 respectively through the corresponding controller or inverter 112; The mechanical connection mechanism 110 is used to connect the auxiliary drive motor 108, the loading motor 109 and the electric drive assembly 107 of the test object to form a mechanical power transmission circuit. The data acquisition and processing platform 113 is communicatively connected to the rectifier power supply 102, the conjugate DC / DC transformer 104, the electric drive assembly 107, the auxiliary drive motor 108, the loading motor 109, and the sensor 111 mounted on the mechanical linkage mechanism 110, and is used to acquire and process power data, mechanical status data, and sensor data.

[0047] This embodiment constructs a highly integrated energy flow testing platform for testing the powertrain systems of new energy vehicles. The core architecture of this platform is based on a two-stage DC bus system, aiming to achieve efficient and accurate testing of the tested objects such as motors and electric drive assemblies over a wide voltage range.

[0048] The rectifier power supply 102 serves as the system's energy input, converting standard AC power from the distribution cabinet 101 and the common three-phase industrial power grid into DC power, thereby establishing a stable first-stage DC bus 103. This first-stage DC bus 103 provides a unified DC power supply foundation for the entire test system.

[0049] Downstream of the first-stage DC bus 103 is the energy management unit of this embodiment—the conjugate DC / DC transformer 104. This unit consists of two parametrically symmetrical DC / DC converters operating in a special conjugate state. A control algorithm enables the two converters to work collaboratively, ensuring that when one converter supplies energy to the load, the other receives feedback energy as a load, and the energy flow directions between them remain dynamically opposite. Each converter outputs an independent second-stage DC bus 105 or 106 from its high-voltage side. Programmable adjustment here refers to setting a target voltage value via a digital controller such as a PLC or industrial computer, and then using the closed-loop control circuit of the DC / DC converter to precisely and continuously adjust the output voltage of this bus, covering a range from low voltage to up to 1200V DC voltage.

[0050] The second-stage DC buses 105 and 106 provide flexible power interfaces for the test execution unit. The electric drive assembly 107, the auxiliary drive motor 108, and the load motor 109 are all connected to the second-stage DC buses 105 and 106 respectively through their matching inverters.

[0051] In one application, a reducer motor assembly or an auxiliary drive motor is configured in drive mode to simulate a power source, while another load motor is configured in loading mode to simulate a mechanical load. The two are physically connected to the object under test, such as a reducer motor assembly, via a mechanical connection mechanism 110, such as a drive shaft, coupling, or dynamometer hub, thereby forming a complete mechanical power transmission and loading circuit.

[0052] The data acquisition and processing platform 113 exchanges data in real time with rectifier power supplies, DC / DC converters, motor controllers, and various sensors via multiple industrial communication buses such as CAN, EtherCAT, and digital I / O. The acquired data streams include electrical parameters such as voltage, current, and power; mechanical parameters such as speed, torque, and vibration; and environmental parameters such as temperature obtained through additional sensors.

[0053] By synchronously acquiring, time-stamping, and comprehensively analyzing these multi-source heterogeneous data, the platform can reconstruct and visualize the complete energy flow path and loss distribution during the testing process.

[0054] This embodiment achieves efficient recycling of test power and flexible voltage level matching by introducing a conjugate DC / DC transformer and an independently programmable second-stage DC bus. Simultaneously, a highly integrated data acquisition and processing platform enables unified control and in-depth analysis of power flow, mechanical flow, and data flow, which improves the energy utilization efficiency, operating condition coverage, and the comprehensiveness and accuracy of test results for testing new energy power components.

[0055] In some embodiments of the present invention, the second-stage DC buses 105 and 106 have a wide range of programmable output voltage capabilities, specifically, they can be precisely set and adjusted within the DC voltage range of 24V to 1200V. This function is mainly realized based on the programmable DC / DC converter in the conjugate DC / DC transformer 104.

[0056] Programmable regulation refers to setting the reference voltage of the DC / DC converter by sending digital commands through host computer software or an embedded controller. This, in turn, drives the power devices via a high-precision closed-loop control circuit within the converter, ultimately generating the target voltage value stably at the output terminals of the second-stage DC buses 105 and 106. The 24V lower limit is compatible with the testing requirements of traditional low-voltage control systems and some micro-hybrid systems, while the 1200V upper limit proactively covers the testing requirements of current and next-generation high-voltage and ultra-high-voltage new energy vehicle platforms, such as 800V systems and their derived voltage levels.

[0057] The wide-range voltage programmability achieved in this embodiment brings a significant improvement in testing flexibility. Specifically, the same test platform can be adapted to vastly different test objects, ranging from low-voltage auxiliary motors to ultra-high-voltage main drive motors, through software configuration without changing the main hardware.

[0058] For example, in R&D verification, the bus voltage can be quickly set to 400V to test the electric drive assembly of current mainstream electric vehicle platforms, and then the voltage can be adjusted to 800V to verify the performance of high-voltage platform components for future applications. This effectively solves the problems of narrow applicability and large redundant investment in traditional testing equipment due to fixed voltage levels.

[0059] Therefore, this embodiment expands the versatility and applicability of the testing platform, and improves the convenience and economy of testing new energy power components with different voltage specifications.

[0060] In some embodiments of the present invention, the two DC / DC converters in the conjugate DC / DC transformer 104 are configured to operate in a conjugate state, such that the energy flow directions of the two are always opposite.

[0061] Specifically, in this embodiment, the conjugate operating state refers to using a specific cooperative control strategy to coordinate the turn-on and turn-off timings of the internal power semiconductor devices of the two converters during operation, thereby ensuring that the current flowing through them is always electrically opposite. For example, a centralized or master-slave digital controller can be used to collect the input and output current signals of the two converters in real time, and dynamically adjust the phase or duty cycle of one of them through an algorithm, so that it operates in inverter mode (energy flows from the DC side to the AC side / load side) while forcing the other to operate in rectification mode (energy is fed back from the AC side / load side to the DC side).

[0062] In a specific example, when one motor acts as a drive unit consuming electrical energy and another acts as a load unit generating power as feedback, the converter connected to the drive motor operates in "source" mode, outputting electrical energy; while the converter connected to the load motor automatically enters "sink" mode, receiving the feedback electrical energy. Both work collaboratively under conjugate control, ensuring that most of the energy circulates directly within the closed loop formed by the #1 secondary DC bus 105 and the #2 secondary DC bus 106, rather than being dissipated or inefficiently returned to the grid.

[0063] The method described in this embodiment significantly reduces the net power drawn from the external power grid, thereby reducing energy consumption and heat accumulation during the testing process. It also helps maintain the stability of the DC bus voltage of the test platform, creating a better electrical environment for high-precision, long-duration testing conditions.

[0064] In some embodiments of the present invention, at least one second-stage DC bus 105 or 106 output from the conjugate DC / DC transformer 104 is configured to simultaneously provide power paths for multiple inverters and motors of the same voltage level.

[0065] In some embodiments of the present invention, the rectifier power supply 102, the first-stage DC bus 103, and the conjugate DC / DC transformer 104 can be integrated into a dual-channel programmable high-precision conjugate DC power supply. In this case, the rectifier power supply 102 and the first-stage DC bus 103 are both hidden inside, which results in higher device integration and smaller space occupation.

[0066] In some embodiments of the present invention, the two second-stage DC buses 105, 106 are configured to support a dual-wheel motor drive system or a back-to-back motor drag test.

[0067] In some embodiments of the present invention, at least one second-stage DC bus 105 or 106 output from the conjugate DC / DC transformer 104 is configured to simultaneously power multiple inverters and motors operating at the same voltage level. For example, a second-stage DC bus configured to 400V can connect two or more 400V motor drive systems, thereby enabling parallel synchronous testing of multiple identical components or subsystems, which significantly improves the platform's test throughput and equipment utilization efficiency.

[0068] In some embodiments of the present invention, this extended capability is specifically applied to composite testing scenarios. A second-level DC bus 105 or 106 is specifically configured as a drive source to support dual-wheel motor drive system testing or back-to-back motor towing testing. In dual-wheel drive system testing, this bus provides a unified power supply to the drive motor controllers on both sides to simulate the dual-motor cooperative drive condition in a real vehicle. In back-to-back towing testing, the electronic control units of the two mechanically coupled motors (one drive motor 108 and one load motor 109) are both powered by this bus, forming a closed energy loop for accurately evaluating the efficiency and dynamic performance of the electric drive system. This embodiment employs this configuration, enabling the platform to directly and efficiently verify key complex systems in new energy vehicles, enhancing the realism and scenario coverage of the tests.

[0069] In some embodiments of the present invention, the rectifier power supply 101 integrates a multi-channel power analyzer for measuring the total three-phase AC power at the input terminal of the rectifier power supply 102, the input power of all drive motors on the two second-stage DC buses 105 and 106, and all mechanical power output by the electric drive assembly 107 of the test object.

[0070] Specifically, the power analyzer, as a multi-channel, high-precision power measurement device, can collect and calculate in real time the voltage, current, and power parameters of the three-phase input of the test system and the necessary branches on the second-level DC bus, as well as the torque, speed, and other parameters of the mechanical output of the electric drive assembly 107 of the tested object.

[0071] This embodiment employs this configuration, providing an accurate raw data benchmark for the energy efficiency assessment of the entire testing system. By continuously monitoring this total input power and combining it with the output measurements at the load end, the comprehensive efficiency of the testing platform itself and the tested object under different operating conditions can be accurately calculated. This provides direct and reliable data support for evaluating energy recovery effects and system optimization, effectively improving the measurability and analytical depth of the testing process.

[0072] In some embodiments of the present invention, the data acquisition and processing platform 113 receives digital instructions and switch signals via a bus, and receives digital or analog sensing data via sensor communication lines.

[0073] Specifically, the data acquisition and processing platform 113 adopts a multi-path integrated communication method. It receives digital commands and device status switch signals from the host computer or control unit via an industrial bus, and simultaneously acquires digital or analog measurement data from various sensors via independent sensor communication lines. The bus may include, but is not limited to, industrial fieldbuses such as CAN bus, EtherCAT, or Modbus, for transmitting control commands and system status; the sensor communication lines encompass analog acquisition channels, digital I / O, or dedicated sensor protocol interfaces for high-precision acquisition of physical quantity signals such as temperature, vibration, and strain.

[0074] This communication architecture separates control signals and measurement data along the transmission path, which helps reduce interference between signals and improves the real-time performance and accuracy of data acquisition. This provides a reliable communication foundation for the test platform to achieve synchronous monitoring of multiple systems and high-precision energy flow analysis.

[0075] In some embodiments of the present invention, the new energy flow testing platform includes an environmental chamber 114, which is connected to a data acquisition and processing platform 113 to provide controllable environmental testing conditions for the tested object.

[0076] Specifically, the new energy energy flow testing platform further integrates an environmental chamber 114. The environmental chamber 114 establishes a communication connection with the data acquisition and processing platform 113, and its core function is to provide the tested object with precisely programmable and controllable environmental testing conditions.

[0077] The environmental chamber 114 is an experimental device that can simulate specific climatic and mechanical environments, and typically includes a temperature and humidity control system, an air circulation system, and possibly an integrated vibration table.

[0078] Its connection to the control system and its operation can be described as follows: Set parameters (such as a temperature range of -40°C to +150°C, a specific humidity curve, or a vibration spectrum) sent by the data acquisition and processing platform 113 are used by an independent controller or integrated PLC inside the environmental chamber 114 to drive actuators for cooling, heating, humidification, and vibration, thereby creating the required steady-state or transient environmental conditions within the chamber. During the test, monitoring data from sensors inside the environmental chamber 114 (such as actual temperature and humidity) are also fed back to the data acquisition and processing platform 113 in real time, achieving closed-loop control and recording of environmental parameters.

[0079] A typical application example of this embodiment is that the motor controller under test is placed in an environmental chamber 114. While the platform performs electrical power testing and mechanical loading, the controller is subjected to dual stress conditions of high temperature (e.g., 85°C) and high temperature (e.g., 85% relative humidity) to assess its performance and reliability under this harsh environment. In this way, this embodiment deeply integrates traditional performance testing and environmental adaptability verification on the same platform, achieving comprehensive testing and energy flow analysis under the coupled conditions of multiple physical fields such as electricity, mechanics, heat, and humidity. Therefore, adding an environmental chamber allows the test platform to more realistically simulate the various complex operating conditions faced by the test object in actual applications, significantly improving the comprehensiveness of the test and the accuracy of the evaluation results.

[0080] In some embodiments of the present invention, the test object is a motor and drive transmission assembly, an inverter, or an electric drive axle containing a reducer.

[0081] Specifically, the testing platform can be adapted to a variety of typical new energy vehicle power core components as test objects, including but not limited to motors and drive transmission assemblies, inverters, and electric drive axles containing reducers.

[0082] For example, when the test object is an electric drive assembly, which typically includes a motor body and an integrated reducer, it can be connected to the electric drive assembly 107 and the loading motor 109 of the platform through the mechanical coupling mechanism 110 to perform efficiency, NVH or durability tests.

[0083] The test platform in this embodiment, through unified electrical, mechanical, and data interfaces, enables extensive testing support for key components of new energy power systems, from individual components to integrated systems, and from electrical to mechanical components, significantly improving the versatility and comprehensive verification capabilities of the test platform.

[0084] Figure 2 This is a schematic flowchart of an embodiment of the testing method based on a new energy energy flow testing platform provided by the present invention. The new energy energy flow testing platform includes a rectifier power supply, a conjugate DC / DC transformer, a drive motor, a loading motor, a mechanical connection mechanism, and a data acquisition and processing platform, such as... Figure 2As shown, the method includes: S201. Converts three-phase AC power to DC power through a rectifier power supply to provide the first-stage DC bus voltage; S202. Based on the test requirements of the object under test, set the target output voltage value for the two second-stage DC buses in the conjugate DC / DC transformer. S203. Control the operation of the conjugate DC / DC transformer so that two of the DC / DC converters are in a conjugate state, converting the electrical energy of the first-stage DC bus into DC power of the target output voltage value, and supplying power to the corresponding drive motor and / or load motor. S204. During the test, the electrical energy flowing between the drive motor and the load motor is recycled in a loop formed by two second-stage DC buses through two DC / DC converters in a conjugate state. S205. Through the data acquisition and processing platform, data from the rectifier power supply, conjugate DC / DC transformer, drive motor, load motor and related sensors are collected and processed simultaneously to analyze the energy flow status during the test.

[0085] This embodiment provides a specific testing method based on the aforementioned new energy energy flow super testing platform. Through steps S201 to S205, this method achieves efficient and accurate testing and energy flow analysis of new energy power components under multiple voltage and operating conditions.

[0086] First, the AC power from the public three-phase industrial power grid is converted to DC power by the rectifier power supply in the platform, thereby establishing a stable first-stage DC bus voltage. This first-stage DC bus serves as the common DC power supply hub for the entire test system.

[0087] Subsequently, based on the specific testing requirements of the object under test, such as its rated operating voltage or specific test procedure requirements, a target output voltage value is set for one or both secondary DC buses of the conjugate DC / DC transformer. This step demonstrates the platform's wide voltage adaptability.

[0088] For example, when it is necessary to conduct comparative tests on a 400V electric drive assembly and an 800V inverter at the same time, the target output voltages of the two secondary DC buses can be set to 400V and 800V respectively, thereby enabling parallel testing of components with different voltage platforms.

[0089] Next, the conjugate DC / DC transformer is controlled to enter the working state. The conjugate state here is one of the core control logics of this method, which means that the two DC / DC converters work together, and their energy flow directions always remain opposite.

[0090] Specifically, in a typical motor-to-motor test scenario, one DC / DC converter can be configured to power the connected drive motor, enabling it to output mechanical energy as a power source; simultaneously, another DC / DC converter operates in energy recovery mode, processing the electrical energy generated by its connected load motor when operating as a generator. In this way, the electrical energy of the first-stage DC bus is efficiently converted into DC power at the required voltage level and used to power the corresponding motor.

[0091] During the test, based on the conjugate operation of the two DC / DC converters, most of the electrical energy exchanged between the drive motor and the load motor is internally circulated and recovered within the electrical loop formed by the first-stage DC bus and the second-stage DC bus, rather than being dissipated. This energy flow management method significantly reduces the net power drawn from the grid, achieving a high degree of energy saving during the test process.

[0092] Finally, the data acquisition and processing platform synchronously collects and processes various data from the rectified power supply (e.g., total input power), conjugate DC / DC transformer (e.g., bus voltage and current), drive and load motors (e.g., speed, torque, temperature), and sensors on the mechanical linkage mechanism (e.g., vibration signals). Through comprehensive analysis of this spatiotemporal synchronized data, the energy flow status throughout the entire test process can be accurately plotted and evaluated, including total system energy consumption, internal circulation power between motors, and efficiency losses at each stage.

[0093] This embodiment integrates key technologies such as wide-range programmable voltage output, conjugate bidirectional energy flow control, and synchronous data acquisition and analysis. This not only enables the test platform to flexibly adapt to multiple voltage levels and multiple test scenarios, but also significantly improves the energy utilization efficiency of the test process.

[0094] Those skilled in the art will understand that all or part of the processes of the methods described in the above embodiments can be implemented by a computer program instructing related hardware (such as a processor, controller, etc.), and the computer program can be stored in a computer-readable storage medium. The computer-readable storage medium may be a disk, optical disk, read-only memory, or random access memory, etc.

[0095] The above provides a detailed description of the new energy flow testing platform and testing method provided by this invention. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. At the same time, those skilled in the art will recognize that there will be changes in the specific implementation methods and application scope based on the ideas of this invention. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A new energy energy flow testing platform, characterized in that, include: The rectifier power supply has its input end connected to a common three-phase industrial power grid and its output end forming the first-stage DC bus. A conjugate DC / DC transformer, the input of which is connected to the first-stage DC bus, the conjugate DC / DC transformer includes two DC / DC converters with equal power capacity and operating in a conjugate state, the high-voltage output terminal of each DC / DC converter forms an independent second-stage DC bus, and the output voltage of the second-stage DC bus is programmable and adjustable; At least one drive motor and at least one load motor, wherein the drive motor and the load motor are respectively connected to the second-stage DC bus via corresponding inverters; A mechanical coupling mechanism is used to connect the drive motor, the loading motor, and the object under test to form a mechanical power transmission circuit; The data acquisition and processing platform is communicatively connected to the rectifier power supply, the conjugate DC / DC transformer, the drive motor, the loading motor, and the sensors mounted on the mechanical linkage mechanism, and is used to acquire and process power data, mechanical status data, and sensor data.

2. The new energy flow testing platform according to claim 1, characterized in that, The output voltage of the second-stage DC bus can be programmably adjusted within the range of 24V to 1200V.

3. The new energy energy flow testing platform according to claim 1 or 2, characterized in that, The two DC / DC converters in the conjugate DC / DC transformer are configured to operate in a conjugate state, so that the energy flow directions of the two are always opposite.

4. The new energy flow testing platform according to claim 1, characterized in that, At least one of the second-stage DC buses output by the conjugate DC / DC transformer is configured to simultaneously provide test power or a power supply path for multiple inverters and motors of the same voltage level.

5. The new energy flow testing platform according to claim 4, characterized in that, One of the second-level DC buses is configured to support dual-wheel motor drive systems or back-to-back motor drag tests.

6. The new energy flow testing platform according to claim 1, characterized in that, The rectifier power supply integrates a power analyzer, which is used to test the voltage, current and power parameters of the three-phase input and necessary branches on the second-stage DC bus, as well as the torque, speed and other parameters of the mechanical output of the electric drive assembly under test.

7. The new energy flow testing platform according to claim 1, characterized in that, The data acquisition and processing platform receives digital commands and switching signals via a bus, and receives digital or analog sensor data via sensor communication lines.

8. The new energy flow testing platform according to claim 1, characterized in that, The new energy energy flow testing platform includes an environmental chamber, which is connected to the data acquisition and processing platform to provide controllable environmental testing conditions for the tested object.

9. The new energy flow testing platform according to claim 1, characterized in that, The test object is a motor and drive transmission assembly, or an electric drive axle containing a reducer.

10. A testing method based on a new energy energy flow testing platform, characterized in that, The new energy flow testing platform includes a rectifier power supply, a conjugate DC / DC transformer, a drive motor, a loading motor, a mechanical connection mechanism, and a data acquisition and processing platform. The method includes: The rectifier power supply converts three-phase AC power into DC power to provide the first-stage DC bus voltage. According to the testing requirements of the object under test, a target output voltage value is set for at least one second-stage DC bus in the conjugate DC / DC transformer; Control the operation of the conjugate DC / DC transformer so that two of its DC / DC converters are in a conjugate state, converting the electrical energy of the first-stage DC bus into DC power of the target output voltage value, and supplying power to the corresponding drive motor and / or load motor; During the test, the electrical energy flowing between the drive motor and the load motor is recycled in a loop formed by two second-stage DC buses through two DC / DC converters in a conjugate state. The data acquisition and processing platform synchronously collects and processes data from the rectifier power supply, the conjugate DC / DC transformer, the drive motor, the load motor, and related sensors to analyze the energy flow status during the test process.

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