Ripple electronic load simulation device, ripple current simulation method and controller test system

Abstract

The present disclosure provides a ripple electronic load simulation device, a ripple current simulation method and a controller test system. The ripple electronic load simulation device comprises a communication module, a current setting module, a main control module and an electronic load module; the communication module comprises an MCU, the current setting module comprises two current setting channels, the main control module comprises an FPGA, and the electronic load module comprises four electronic load channels. The FPGA superimposes the programmable ripple current simulation parameters received by the MCU from the upper computer and the basic load current digital signal output by the current setting module, and generates a digital ripple current control signal, which is then output to the controller by the electronic load module as a target ripple current. The controller analyzes the ripple current and performs corresponding actions according to the analysis results. This design is different from the energy feedback circuit, realizes direct and parameterized control of the ripple characteristics, and provides a more flexible, more accurate and lower-cost simulation means for controller testing.

Description

Technical Field

[0001] This disclosure relates to the field of electronic testing and simulation technology, and in particular to a ripple electronic load simulation device, a ripple current simulation method, and a controller testing system. Background Technology

[0002] In the field of vehicle electronic control, brushed DC motors are widely used in automatic lifting devices such as windows and sunroofs. The development and testing of their controllers requires high-precision simulation of the motor's current characteristics during operation, especially the ripple current related to motor commutation, to verify key functions such as the controller's anti-pinch algorithm, position estimation, and stall protection.

[0003] Currently, there are simulation schemes that combine motor simulation models with current regulators (such as the motor simulation circuit disclosed in publication number CN117193036A). These schemes simulate the target current signal by establishing a mathematical model of the motor, and the current regulator reproduces this current between the control terminals of the controller. To improve energy efficiency, some advanced schemes further employ energy feedback architectures, aiming to feed the electrical energy consumed during the simulation back to the power grid or DC bus.

[0004] However, the inventors discovered through in-depth research that this energy feedback simulation scheme has a series of inherent defects in practical applications, especially in testing scenarios such as automotive electronic controllers that require low to medium power, high reliability, and high cost-effectiveness:

[0005] (1) High cost and high complexity: Its core circuit requires a large number of switching devices and precision control chips, and needs to be equipped with synchronous circuits such as phase-locked loops, resulting in high hardware and manufacturing costs.

[0006] (2) Slow dynamic response: Due to the involvement of multiple levels of power conversion, there is an inherent control delay, which results in a slow dynamic response speed of current tracking, making it difficult to accurately reproduce the rapid transient processes such as motor start-up, shutdown, and commutation.

[0007] (3) Poor waveform quality and electromagnetic interference: The high-frequency switching action of power switching devices will introduce switching noise and additional ripple, which not only degrades the accuracy of the simulated waveform, but also makes it a significant source of electromagnetic interference.

[0008] (4) Safety risks and maintenance difficulties: Since energy is directly fed back to the power grid, there is a high voltage risk, which imposes stringent requirements on insulation and safety design, increasing the complexity of the system and the maintenance threshold.

[0009] (5) Low cost performance in low power scenarios: For low power applications such as car window motors, the value of energy saved by energy feedback is limited, but the resulting cost, complexity and reliability issues are very prominent, resulting in low overall cost performance.

[0010] Therefore, existing energy feedback simulation circuits are not well-suited for widespread testing of automotive controllers due to issues such as cost, response speed, waveform quality, and complexity. There is an urgent need in this field for a ripple current simulation technology that can balance high accuracy, high reliability, fast dynamic response, low cost, and ease of maintenance to overcome these shortcomings. Summary of the Invention

[0011] To address the aforementioned issues, this disclosure provides a ripple electronic load simulation device, a ripple current simulation method, and a controller testing system. These differ from energy feedback simulation circuits in their operating principle, directly generating high-precision ripple current through programmable hardware, thus providing a more flexible and accurate simulation method for controller testing.

[0012] On the one hand, a ripple electronic load simulation device is provided, which includes: a communication module, a current setting module, a main control module and an electronic load module;

[0013] The communication module is connected to the main control module and the host computer, and is used to receive ripple current simulation parameter setting instructions from the host computer and transmit the instructions to the main control module.

[0014] The current setting module is connected to the main control module and is used to receive analog voltage signals from the outside. These analog voltage signals are converted into digital signals of the base load current by the current setting module.

[0015] The main control module is connected to the communication module, the current setting module and the electronic load module respectively. It is used to receive and parse the ripple current simulation parameters from the communication module and the basic load current digital signal from the current setting module. Based on the received ripple current simulation parameters, it generates a high-precision digital ripple signal in real time through an internal algorithm. Then, it digitally superimposes the generated digital ripple signal with the basic load current digital signal to generate a ripple current control signal, which is then transmitted to the electronic load module to output the target ripple current.

[0016] The electronic load module is connected to the main control module and receives instructions from the main control module to output the target ripple current.

[0017] In one possible implementation, the communication module includes an MCU (Microcontroller Unit) for receiving ripple current simulation parameter setting instructions from a host computer. The ripple current simulation parameters include ripple frequency, ripple amplitude, stall current, and number of pulses.

[0018] The current setting module includes at least two current setting channels;

[0019] The main control module includes an FPGA (Field-Programmable Gate Array), which generates high-precision digital ripple signals in real time based on the received ripple current simulation parameter instructions.

[0020] The electronic load module includes multiple electronic load channels;

[0021] Furthermore, the current setting module includes two current setting channels; the electronic load module includes four electronic load channels, namely CH1, CH2, CH3 and CH4; CH1 and CH4 are the first group of electronic load channels, used to simulate the forward rotation of the motor; CH2 and CH3 are the second group of electronic load channels, used to simulate the reverse rotation of the motor.

[0022] In one possible implementation, the current setting channel includes a current signal input terminal and an analog-to-digital converter; current signal input terminal 1 serves as the current input interface for CH1 and CH4, and current signal input terminal 2 serves as the current input interface for CH2 and CH3; an external programmable power supply is connected to the current signal input terminal to input an analog voltage, which is then converted into a digital signal of the base load current by the analog-to-digital converter and transmitted to the FPGA for processing.

[0023] In one possible implementation, the electronic load module further includes a positive load power supply input terminal, a grounded negative load power supply input terminal, a positive load output terminal, and a negative load output terminal, the positive and negative load output terminals being used to connect to the controller under test.

[0024] In one possible implementation, each electronic load channel includes an isolation module, a digital-to-analog converter, and a current regulation module;

[0025] The isolation module is connected to the FPGA, and the digital-to-analog converter (DAC) is connected to both the isolation module and the current regulation module. The FPGA superimposes the base load current digital signal output from the current setting module with the digital ripple signal processed by the FPGA to generate a ripple current control signal. This signal is then transmitted via the isolation module to the DAC to be converted into an analog ripple current signal. Finally, the analog current ripple signal is adjusted by the current regulation module to be converted into the target ripple current and transmitted to the controller. The isolation module is used to isolate the digital control terminal from the high-voltage power load terminal, block interference, and ensure accurate transmission of the DAC output signal. The current regulation module is a negative feedback closed-loop system used to adjust the analog ripple current signal output by the DAC to the target ripple current.

[0026] In one possible implementation, the current regulation module for each electronic load channel includes a first operational amplifier, a second operational amplifier, a first regulating transistor, a sampling resistor, and an isolation power supply. The first operational amplifier is connected to a digital-to-analog converter, the first regulating transistor is connected to a first amplifying operational unit and the sampling resistor, the second operational amplifier is connected in parallel with the sampling resistor and to the first operational amplifier, and the sampling resistor is connected to the isolation power supply. The first operational amplifier, the second operational amplifier, the first regulating transistor, the sampling resistor, and the isolation power supply together constitute a negative feedback closed-loop system to ensure that the output target ripple current is precisely equal to the set value.

[0027] Furthermore, the first regulating transistor in the current regulation module is an N-type metal-oxide-semiconductor transistor.

[0028] On the other hand, this disclosure provides a ripple current simulation method, applied to the above-mentioned ripple electronic load simulation device, including the following steps:

[0029] Step 1: According to the simulation test requirements, select the corresponding electronic load channel group to work, connect the external programmable power supply to the current signal input terminal, input the analog voltage, and then convert it into a basic load current digital signal through the analog-to-digital converter;

[0030] Step 2: The MCU receives the ripple current simulation parameter setting instruction from the host computer through the communication interface. The ripple current simulation parameters include ripple amplitude, ripple frequency, stall current, and number of pulses. The MCU receives these parameters and transmits them to the FPGA.

[0031] Step 3: The FPGA generates a digital ripple signal based on the ripple current simulation parameters, and superimposes the digital ripple signal with the basic load current digital signal to generate a ripple current control signal;

[0032] Step 4: The ripple current control signal is converted into an analog ripple current signal through a digital-to-analog converter;

[0033] Step 5: The simulated ripple current signal is adjusted to the target ripple current through the current adjustment module.

[0034] Furthermore, this disclosure also provides a controller testing system. The controller testing system includes: a host computer, a controller for a DC brushed motor, and a ripple electronic load simulation device as described in any of the designs in the first aspect above; the host computer is connected to the communication module of the ripple electronic load simulation device, and the electronic load module of the ripple electronic load simulation device is connected to the controller. The ripple electronic load simulation device superimposes the ripple current parameters transmitted by the host computer with the base load current to form a target ripple current, which is then transmitted to the controller. The controller analyzes the ripple current and controls the motor to perform corresponding actions based on the analysis results. By setting different ripple current parameters to simulate different operating conditions, the response accuracy of the controller can be tested.

[0035] The beneficial effects of the technical solutions provided in this disclosure include at least the following: the implementation of the ripple electronic load simulation device, ripple current simulation method, and controller testing system in the embodiments of this disclosure simulates a real DC brushed motor, enabling the controller under test to process the received current signal as the ripple current signal output by the motor, thereby completing the semi-physical simulation test of the controller under test. The electronic load simulation device provided in this disclosure can directly and flexibly generate high-fidelity programmable ripple current. By adopting a simple hardware circuit architecture, it significantly reduces system complexity and manufacturing costs while achieving microsecond-level fast dynamic response and high-fidelity smooth current output, completely avoiding switching noise and electromagnetic interference. It provides a more accurate, faster-responding, more reliable, and more cost-effective simulation method for controller testing, and is especially suitable for the testing and verification of anti-pinch DC brushed motor controllers for automotive windows, sunroofs, electric seats, etc.

[0036] It should be understood that the descriptions in this section are not intended to identify key or essential features of the embodiments of this disclosure, nor are they intended to limit the scope of this disclosure. Other features of this disclosure will become readily apparent from the detailed description section of this specification. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0038] Figure 1 An exemplary schematic diagram of the controller testing system provided in Embodiment 1 of this disclosure is shown;

[0039] Figure 2 A schematic diagram of the structure of the ripple electronic load simulation device provided in Embodiment 1 of this disclosure is shown as an example.

[0040] Figure 3 A schematic diagram of the structure of the ripple electronic load simulation device provided in Embodiment 2 of this disclosure is shown as an example.

[0041] Figure 4 A schematic diagram of the structure of the ripple electronic load simulation device provided in Embodiment 3 of this disclosure is shown as an example.

[0042] Figure 5 An exemplary schematic diagram of the structure of a single channel of the electronic load module provided in this disclosure is shown. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of this disclosure clearer, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this disclosure, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without creative effort are within the scope of protection of this disclosure.

[0044] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this disclosure should have the ordinary meaning understood by one of ordinary skill in the art to which this disclosure pertains. The terms "first," "second," and similar terms used in the embodiments of this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0045] Example 1

[0046] Figure 1 An exemplary schematic diagram of the controller testing system provided in Embodiment 1 of this disclosure is shown, such as... Figure 1 As shown, in this example, the controller test system includes: a host computer 200, a ripple electronic load simulation device 100, and a controller 300 connected in sequence.

[0047] Figure 2 An exemplary schematic diagram of the structure of a ripple electronic load simulation device 100 according to an embodiment of this disclosure is shown, such as... Figure 1 As shown, in this example, the ripple electronic load simulation device 100 includes: a communication module 110, a current setting module 120, a main control module 130, and an electronic load module 140.

[0048] The communication module 110 is connected to the main control module 130 and is used to receive ripple current simulation parameter setting instructions from the host computer 200 and transmit the ripple current simulation parameters to the main control module 130.

[0049] The current setting module 120 is connected to the main control module 130 and is used to receive the analog voltage signal from the external programmable power supply. The voltage signal is converted into a digital signal of the basic load current by the current setting module 120. The current setting module 120 is configured to input a 1V voltage and output a 3A current. The maximum setting voltage can reach 10V, that is, the basic load current can reach 30A.

[0050] The main control module 130 is connected to the communication module 110, the current setting module 120 and the electronic load module 140 respectively. It is used to receive and parse the ripple current simulation parameters from the communication module 110 and the basic load current digital signal from the current setting module 120. Based on the received ripple current simulation parameters, it generates a high-precision digital ripple signal in real time through internal programming. Then, it digitally superimposes the generated digital ripple signal with the basic load current signal to generate a ripple current control signal, which is then transmitted to the electronic load module 140 to output the target ripple current.

[0051] The electronic load module 140 is connected to the main control module 130 and receives instructions from the main control module 130 to output the target ripple current.

[0052] Example 2

[0053] Figure 3 A schematic diagram of the structure of the ripple electronic load simulation device 100 according to Embodiment 2 of this disclosure is shown as an example.

[0054] like Figure 3 As shown, in this example, the communication module 110 includes an MCU (Microcontroller Unit) for receiving ripple current simulation parameter instructions set by the host computer 100. These ripple current simulation parameters include ripple frequency f, ripple amplitude A, stall current I, and pulse count N. Furthermore, these ripple current simulation parameters can be adjusted in real time according to different test conditions to meet the testing requirements of the controller 300. Additionally, the interface for communication with the host computer can be CAN (Controller Area Network), RS485 (Recommended Standard 485), or Ethernet, which can be selected according to the actual application; this embodiment does not impose specific limitations.

[0055] The current setting module 120 includes two current setting channels, namely current setting channel 1 and current setting channel 2, which can be connected to an external programmable power supply to set the base load current.

[0056] The main control module 130 includes an FPGA (Field-Programmable Gate Array). The FPGA generates a high-precision digital ripple signal in real time based on the ripple current simulation parameters received by the MCU. The generated digital ripple signal is then digitally superimposed with the basic load current digital signal to generate a ripple current control signal, which is then transmitted to the electronic load module 140.

[0057] The electronic load module 140 includes four identical electronic load channels, namely CH1, CH2, CH3 and CH4; CH1 and CH4 form the first group of electronic load channels, used to simulate the forward rotation of the motor; CH2 and CH3 form the second group of electronic load channels, used to simulate the reverse rotation of the motor.

[0058] Example 3

[0059] Figure 4 A schematic diagram of the structure of the ripple electronic load simulation device 100 according to Embodiment 3 of this disclosure is shown as an example.

[0060] like Figure 4 As shown in this example, the current setting channel 1 in the current setting module 120 includes a current signal input terminal 1 and an analog-to-digital converter 121. The current setting channel 2 is configured the same as channel 1. The current setting channel 1 is configured to set the basic load current signals of CH1 and CH4, and the current setting channel 2 is configured to set the basic load current signals of CH2 and CH3. The two channels cannot set the current signals at the same time. An external programmable power supply is connected to the current signal input terminal to input an analog voltage. The analog voltage is then converted into a basic load current digital signal by the analog-to-digital converter 121 and then transmitted to the FPGA for processing.

[0061] The electronic load module 140 also includes a positive load power supply input terminal VBAT, a grounded negative load power supply input terminal GND, a positive load output terminal LOAD1, and a negative load output terminal LOAD2; LOAD1 and LOAD2 are used to connect to the controller 300; VBAT is connected to an external power supply with a voltage not higher than 30V, and a freewheeling power supply is also connected, with the freewheeling power supply being a 5V DC power supply with a power of not less than 200W.

[0062] Furthermore, each electronic load channel includes an isolation module 141, a digital-to-analog converter 142, and a current regulation module 143. The isolation module 141 is connected to the FPGA, and the digital-to-analog converter 142 is connected to both the isolation module 141 and the current regulation module 143. The FPGA superimposes the base load current digital signal output from the current setting module 120 with the digital ripple signal processed by the FPGA to generate a ripple current control signal. This signal is then transmitted via the isolation module 141 to the digital-to-analog converter 142 to be converted into an analog ripple current signal. Finally, the current regulation module 143 adjusts and converts this signal into the target ripple current, which is then transmitted to the controller 300. Changing the ripple current simulation parameters changes the target ripple current, which is used to test whether the controller 300 performs different actions based on different ripple currents.

[0063] Example 4

[0064] Figure 5 An exemplary schematic diagram of the structure of a single channel, such as CH1, of the electronic load module 140 provided in this disclosure is shown.

[0065] like Figure 5 As shown, the current regulation module 143 in the first channel CH1 of the electronic load module 140 includes a first operational amplifier OP1, a second operational amplifier OP2, a first regulating transistor Q1, a sampling resistor R1, and an isolation power supply.

[0066] For example, the first regulating transistor Q1 is an NMOS transistor. The gate of Q1 is connected to OP1, and its gate voltage is controlled by the output of OP1. The source of Q1 is connected in series with R1, and the drain of Q1 is connected to an external power supply. Additionally, the non-inverting input of OP1 is connected to the digital-to-analog converter 142 to receive the target voltage signal from the converter, and the inverting input is connected to the output of OP2. Simultaneously, OP2 is connected in parallel across R1, acting as a differential amplifier to sample the voltage drop across R1, converting the weak current sampling signal into a stable feedback voltage that is fed into the inverting input of OP1. An isolation power supply is connected to R1, providing an independent, safe, and potential-matched drive power supply for Q1 and its feedback control circuit (OP1 / OP2) operating in a high-potential floating state. Thus, R1, Q1, OP1, OP2, and the isolation power supply together constitute a high-precision negative feedback closed-loop system.

[0067] See Figure 5 In this example, the working process of the above current regulation will be described.

[0068] R1 is connected in series in the current path, with a resistance of 20mΩ. According to Ohm's law, the load current flowing through R1 will produce a voltage drop. This weak signal is amplified by OP2 and converted into a feedback voltage representing the actual load current. OP1 compares the target voltage (non-inverting input) and the feedback voltage (inverting input) in real time.

[0069] If the actual current is too small, the feedback voltage will be lower than the target voltage. The output voltage of OP1 will increase, raising the gate voltage of Q1 and increasing its conduction degree, thereby increasing the load current.

[0070] Conversely, if the actual current is too large, the feedback voltage will be higher than the target voltage, the output voltage of OP1 will decrease, weakening the conduction of Q1 and reducing the load current.

[0071] Through this dynamic and continuous adjustment process, the system will eventually stabilize at a state where the feedback voltage equals the target voltage. At this point, according to Ohm's law, the target current will also be exactly equal to the set value.

[0072] In this application, Q1 acts as a voltage-controlled variable resistor. Driven by OP1, Q1 operates in the linear region, rather than in a saturated switching state. By continuously adjusting its gate-source voltage, the equivalent resistance between the drain and source is changed, thereby achieving precise linear control of the load current.

[0073] In summary, the electronic load simulation device 200 of this embodiment can simulate the ripple current of a real DC brushed motor, so that the controller 300 can treat the received ripple current signal as the ripple current signal returned by the DC brushed motor and process it, thereby completing the semi-physical simulation test of the controller 300.

[0074] The following will provide an exemplary description of the ripple current simulation method based on the above-described ripple electronic load simulation device 100 through embodiments.

[0075] It should be noted that the description of the ripple current simulation method in this embodiment is similar to the description of the above device embodiment, and has similar beneficial effects as the device embodiment. For technical details not disclosed in this method embodiment, please refer to the description of the device embodiment of this disclosure for understanding.

[0076] This disclosure illustrates a ripple current simulation method, implemented by the ripple electronic load simulation device 100 described in any of the above embodiments. The ripple current simulation method includes the following steps:

[0077] Step 1: According to the simulation test requirements, select the corresponding electronic load channel group to work. Connect the external programmable power supply to one of the current control signal input terminals, input the analog voltage (0-10V), and then convert it into a basic load current digital signal through the analog-to-digital converter 121.

[0078] Step 2: The MCU receives ripple current simulation parameter instructions from the host computer 200 through the communication interface. The ripple current simulation parameters include ripple amplitude A, ripple frequency f, stall current I, and pulse number N. The MCU parses these parameters and transmits the ripple current simulation parameters to the FPGA.

[0079] Step 3: The FPGA generates a digital ripple signal based on the ripple current simulation parameters, and superimposes the digital ripple signal with the basic load current digital signal to generate a ripple current control signal;

[0080] Step 4: The ripple current control signal is converted into an analog ripple current signal by the digital-to-analog converter 142;

[0081] Step 5: The simulated ripple current signal is adjusted to the target ripple current by the current adjustment module 143.

[0082] As a specific example, to simulate a 1.5-second forward rotation, with a ripple frequency f of 500Hz, a stall current I of 20A, a ripple amplitude A of 2A, and a pulse count N of 750, the setup steps are as follows: First, send the following commands via the CAN bus: f=500Hz, I=20A, A=2A, N=750. Simultaneously, connect an external programmable power supply to current signal input terminal 1, select CH1 and CH4 to operate, and output a 5V analog voltage, setting the base load current to 15A. The FPGA will generate one cycle containing 750 digital ripples with an amplitude of 2A, which are then superimposed on the base load current. The output is then precisely adjusted by the digital-to-analog converter 142 and the current regulation module 143 to obtain the ripple load current, with a maximum value of 17A and a minimum value of 13A.

[0083] Various embodiments of this disclosure have been described above. However, it should be understood that the above description is exemplary and not exhaustive, and is not limited to the disclosed embodiments. Any modifications, equivalent substitutions, improvements, etc., made by those skilled in the art without departing from the scope and spirit of the described embodiments should be included within the scope of protection of this disclosure. The terminology used herein is chosen to best explain the principles, practical applications, or technical improvements to the embodiments in the market, or to enable other those skilled in the art to understand the various embodiments disclosed herein.

Claims

1. A ripple electronic load simulation device, connected to a host computer and a controller of a DC brushed motor, characterized in that, The ripple electronic load simulation device includes: a communication module, a current setting module, a main control module, and an electronic load module; The communication module is connected to the host computer and the main control module, and is used to receive ripple current simulation parameter setting instructions from the host computer and transmit the ripple current simulation parameters to the main control module. The current setting module is connected to the main control module and is used to receive external analog voltage signals and convert the analog voltage signals into basic load current digital signals. The main control module is connected to the communication module, the current setting module, and the electronic load module respectively. The main control module is used to receive and parse the ripple current simulation parameters and the basic load current digital signals. The main control module generates digital ripple signals in real time according to the ripple current simulation parameters, superimposes the digital ripple signals with the basic load current digital signals to generate ripple current control signals, and transmits the ripple current control signals to the electronic load module. The electronic load module is connected to the main control module and is used to adjust the ripple current control signals to the target ripple current and transmit them to the controller.

2. The ripple electronic load simulation device according to claim 1, characterized in that, The communication module includes an MCU; the main control module includes an FPGA, the FPGA is configured with a waveform generation algorithm, which is used to generate the digital ripple signal according to the ripple current simulation parameters, the ripple current simulation parameters including ripple amplitude, ripple frequency, stall current and pulse number; The current setting module includes at least two current setting channels; the electronic load module includes multiple electronic load channels.

3. The ripple electronic load simulation device according to claim 2, characterized in that, The current setting module includes two current setting channels, namely current setting channel 1 and current setting channel 2; the electronic load module includes four electronic load channels, namely CH1, CH2, CH3 and CH4; CH1 and CH4 form the first group of electronic load channels, used to simulate the forward rotation state of the motor; CH2 and CH3 form the second group of electronic load channels, used to simulate the reverse rotation state of the motor.

4. The ripple electronic load simulation device according to claim 3, characterized in that, The current setting channel includes a current signal input terminal and an analog-to-digital converter; Current signal input terminal 1 serves as the current input channel for CH1 and CH4, and current signal input terminal 2 serves as the current input channel for CH2 and CH3. An external programmable power supply is connected to the current signal input terminal to input an analog voltage, which is then converted into a digital signal of the base load current by the analog-to-digital converter.

5. The ripple electronic load simulation device according to claim 1, characterized in that, The electronic load module also includes a positive load power input terminal, a grounded negative load power input terminal, a positive load output terminal, and a negative load output terminal; the positive and negative load output terminals are used to connect to the controller under test.

6. The ripple electronic load simulation device according to any one of claims 1 to 5, characterized in that, Each electronic load channel includes an isolation module, a digital-to-analog converter, and a current regulation module; The isolation module is connected to the FPGA, and the digital-to-analog converter is connected to both the isolation module and the current regulation module. The isolation module is used to isolate the digital control terminal from the high-voltage power load terminal, block interference, and ensure accurate transmission of the digital-to-analog converter output signal. The current regulation module is a negative feedback closed-loop system used to adjust the analog ripple current signal output by the digital-to-analog converter to the target ripple current.

7. The ripple electronic load simulation device according to claim 6, characterized in that, The current regulation module includes a first operational amplifier, a second operational amplifier, a first regulating transistor, a sampling resistor, and an isolation power supply; The first operational amplifier is connected to the digital-to-analog converter, the first regulating transistor is connected to the first amplifying operational unit and the sampling resistor, the second operational amplifier is connected in parallel with the sampling resistor and connected to the first operational amplifier, and the sampling resistor is connected to the isolation power supply; the first operational amplifier, the second operational amplifier, the first regulating transistor, the sampling resistor and the isolation power supply together constitute the negative feedback closed-loop system, ensuring that the target ripple current is accurately output equal to the set value.

8. The ripple electronic load simulation device according to claim 7, characterized in that, The first regulating transistor is an N-type metal-oxide-semiconductor transistor.

9. A ripple current simulation method, characterized in that, The ripple current simulation method is applied to the ripple electronic load simulation device as described in any one of claims 1 to 8, and the ripple current simulation method includes the following steps: Step 1: According to the simulation test requirements, select the corresponding electronic load channel group to work, connect the external programmable power supply to the current signal input terminal, input the analog voltage, and then convert it into a basic load current digital signal through the analog-to-digital converter; Step 2: The MCU receives the ripple current simulation parameter setting instruction from the host computer through the communication interface. The ripple current simulation parameters include ripple amplitude, ripple frequency, stall current, and number of pulses. After receiving the ripple current parameters, the MCU transmits them to the FPGA. Step 3: The FPGA generates a digital ripple signal based on the ripple current simulation parameters, and superimposes the digital ripple signal with the basic load current digital signal to generate a ripple current control signal; Step 4: The ripple current control signal is converted into an analog ripple current signal through a digital-to-analog converter; Step 5: The simulated ripple current signal is adjusted to the target ripple current through the current adjustment module.

10. A controller testing system, characterized in that, The controller testing system includes: a host computer, a controller for a DC brushed motor, and a ripple electronic load simulation device as described in any one of claims 1 to 8. The host computer is connected to the communication module of the ripple electronic load simulation device, and the electronic load module of the ripple electronic load simulation device is connected to the controller.

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