A test method for a high-power motor of a new energy vehicle

Abstract

This invention discloses a testing method for high-power motors in new energy vehicles. The technical solution of this invention includes the following steps: S1: Test system construction and initialization: Constructing a test bench containing the motor under test, a coupled load motor, a motor controller, a high-dynamic DC power supply, a data acquisition system, and a main control computer; S2: Graded loading limit performance testing: Under the control of the main control computer, performing low-speed high-torque zone testing, constant power zone testing, and high-speed overspeed testing sequentially; S3: Dynamic cyclic operating condition and fault simulation testing: Performing high-dynamic power cyclic testing, thermal cycling shock testing, and electrical fault simulation testing; S4: Data fusion analysis and health status assessment: Based on the test data from steps S2 and S3, generating a comprehensive performance boundary map of the motor, analyzing the degradation of key parameters, and calculating a comprehensive health status score. The solution provided by this invention can simulate real complex operating conditions and efficiently and comprehensively evaluate the performance of high-power motors.

Description

Technical Field

[0001] This invention relates to the field of motor testing technology, and in particular to a testing method for high-power motors in new energy vehicles. Background Technology

[0002] As new energy vehicles develop towards high performance and long range, drive motors are evolving towards high power density, high speed, and high efficiency. Traditional motor testing methods mainly focus on steady-state performance (such as rated point and peak point efficiency) and testing under normal operating conditions (such as NEDC cycle), which has the following shortcomings: Insufficient coverage of extreme operating conditions: There is a lack of systematic testing and evaluation methods for harsh operating conditions that motors may encounter in actual driving, such as extreme stalling, continuous operation in high-speed weak magnetic fields, and frequent high-power step changes. Lack of system coupling testing: Existing tests are usually conducted on individual motor benches, without fully considering the thermal coupling, electromagnetic interference, and control response characteristics of the motor, controller, and reducer in the actual vehicle system. Insufficient reliability verification: There is a lack of accelerated testing methods for the long-term reliability of insulation systems, bearings, and rotor structures under high dv / dt, high centrifugal force, and thermal cycling stress. Low testing efficiency: Traditional testing procedures are performed sequentially, which is time-consuming and cannot quickly and comprehensively evaluate the overall performance boundaries of the motor. Therefore, there is an urgent need for a testing method that can simulate real complex operating conditions and efficiently and comprehensively evaluate the performance and reliability of high-power motors. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the main objective of this invention is to provide a testing method for high-power motors of new energy vehicles that solves the problems of insufficient coverage of extreme working conditions, lack of system coupling testing, insufficient reliability verification and low testing efficiency in the existing technology.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a testing method for a high-power motor of a new energy vehicle, the method comprising the following steps: S1: Test System Construction and Initialization: Construct a test bench for the motor under test, the motor under load, the motor controller, the high dynamic DC power supply, the data acquisition system and the main control computer. S2: Graded loading limit performance test: Under the control of the main control computer, the low speed and high torque zone test, constant power zone test and high speed overspeed test are carried out in sequence. S3: Dynamic Cyclic Operating Condition and Fault Simulation Test: Conduct high dynamic power cycle test, thermal cycle shock test and electrical fault simulation test; S4: Data Fusion Analysis and Health Status Assessment: Based on the test data from steps S2 and S3, generate a comprehensive performance boundary map of the motor, analyze the degradation of key parameters, and calculate the comprehensive health status score.

[0005] Preferably, in step S2, the low-speed, high-torque zone test specifically involves: stabilizing the speed of the motor under test at a preset low-speed point, increasing its output from rated torque to peak torque and maintaining it until the winding temperature stabilizes or reaches a preset time, and recording the temperature rise curve and torque response time; the constant power zone test specifically involves: controlling the motor under test to accelerate from the peak power point to the highest speed, maintaining peak power output, and recording changes in efficiency and iron loss; the high-speed overspeed test specifically involves: driving the motor under test to 1.1-1.3 times the maximum design speed and running it stably, and testing the mechanical structure and vibration.

[0006] Preferably, in step S3, the high dynamic power cycle test specifically involves: the main control computer importing a power-time sequence simulating intense driving to drive the motor under test; the thermal cycle shock test specifically involves: actively and rapidly changing the temperature and flow rate of the coolant during the loading test to form a thermal shock; and the electrical fault simulation test specifically involves: simulating non-destructive controller fault signals to test the motor's fault operation and diagnostic capabilities.

[0007] Preferably, in step S4, the comprehensive performance boundary map includes at least a three-dimensional cloud map of torque-speed-efficiency, a safe operating boundary line based on temperature rise limitation, and a peak power envelope.

[0008] Preferably, the test system in step S1 further includes a thermal management simulation subsystem (7) for precisely controlling the temperature and flow rate of the cooling medium in step S3 to simulate the thermal management environment of the vehicle and perform thermal cycling shock tests.

[0009] Compared with the prior art, the present invention has the following advantages: comprehensiveness: through graded loading limit performance test, dynamic cyclic working condition and fault simulation test, it covers the complete working conditions from steady state to transient state and from normal to fault, especially strengthening the assessment of extreme and harsh working conditions.

[0010] Systematic approach: The motor under test is tested as a whole with the controller and thermal management system, taking into account the coupling effect of multiple physical fields of electricity, heat and machinery, which is closer to the actual vehicle operating environment.

[0011] High efficiency: By integrating multiple test items into an orderly process and executing them continuously through automated control, the total test time is shortened and the test efficiency is improved.

[0012] Forward-looking: Through data fusion analysis and health status assessment, we can not only determine whether a product is qualified, but also predict its performance degradation trend, providing data support for product optimization and lifespan prediction.

[0013] High reliability verification: Through tests such as thermal cycling shock and high-speed overspeed, potential defects in materials, processes and designs under extreme conditions are effectively exposed, thereby improving product reliability. Attached Figure Description

[0014] Figure 1 This is a flowchart of a testing method for a high-power motor in a new energy vehicle according to the present invention. Detailed Implementation

[0015] The invention will now be further described with reference to the accompanying drawings.

[0016] like Figure 1 As shown, a testing method for a high-power motor in a new energy vehicle includes the following steps: S1: Test System Construction and Initialization: Construct a test bench for the motor under test, the motor under load, the motor controller, the high dynamic DC power supply, the data acquisition system and the main control computer. S2: Graded loading limit performance test: Under the control of the main control computer, the low speed and high torque zone test, constant power zone test and high speed overspeed test are carried out in sequence. S3: Dynamic Cyclic Operating Condition and Fault Simulation Test: Conduct high dynamic power cycle test, thermal cycle shock test and electrical fault simulation test; S4: Data Fusion Analysis and Health Status Assessment: Based on the test data from steps S2 and S3, generate a comprehensive performance boundary map of the motor, analyze the degradation of key parameters, and calculate the comprehensive health status score.

[0017] Preferably, in step S2, the low-speed, high-torque zone test specifically involves: stabilizing the speed of the motor under test at a preset low-speed point, increasing its output from rated torque to peak torque and maintaining it until the winding temperature stabilizes or reaches a preset time, and recording the temperature rise curve and torque response time; the constant power zone test specifically involves: controlling the motor under test to accelerate from the peak power point to the highest speed, maintaining peak power output, and recording changes in efficiency and iron loss; the high-speed overspeed test specifically involves: driving the motor under test to 1.1-1.3 times the maximum design speed and running it stably, and testing the mechanical structure and vibration.

[0018] Preferably, in step S3, the high dynamic power cycle test specifically involves: the main control computer importing a power-time sequence simulating intense driving to drive the motor under test; the thermal cycle shock test specifically involves: actively and rapidly changing the temperature and flow rate of the coolant during the loading test to form a thermal shock; and the electrical fault simulation test specifically involves: simulating non-destructive controller fault signals to test the motor's fault operation and diagnostic capabilities.

[0019] Preferably, in step S4, the comprehensive performance boundary map includes at least a three-dimensional cloud map of torque-speed-efficiency, a safe operating boundary line based on temperature rise limitation, and a peak power envelope.

[0020] Preferably, the test system in step S1 further includes a thermal management simulation subsystem (7) for precisely controlling the temperature and flow rate of the cooling medium in step S3 to simulate the thermal management environment of the vehicle and perform thermal cycling shock tests.

[0021] Step S1: Test System Construction and Initialization The motor under test is mechanically connected to the drag load motor via a torque sensor to form a drag test bench. The motor under test controller is electrically connected to the motor under test and the high dynamic DC power supply. A data acquisition system is connected to collect voltage, current, temperature, vibration, torque, and speed signals. The load motor, DC power supply, and motor controller are synchronously controlled by the main control computer.

[0022] Step S2: Tiered Loading Limit Performance Test Under the control of the main control computer, the hierarchical loading test process is executed: S2.1: Low-speed, high-torque zone test: Control the load motor to stabilize the speed of the motor under test at a preset low speed point (e.g., 0-1000rpm). Through the motor controller, gradually increase the output of the motor under test from the rated torque to the peak torque, and maintain the peak torque until the winding stabilizes at a stable temperature or reaches a preset time (e.g., 60s). Record the temperature rise curve, torque response time, and controller bus voltage fluctuation.

[0023] S2.2: Constant Power Zone Test: Starting from the torque and speed corresponding to the peak power point, control the load motor to make the speed of the motor under test rise linearly to the maximum speed, maintain the output power of the motor under test near the peak power, test the effectiveness of the field weakening control algorithm, and record the efficiency map, iron loss changes and rotor temperature rise.

[0024] S2.3: High-speed overspeed test: Control the load motor to drive the motor under test to 1.2 times the maximum design speed and run stably for a preset time to test the rotor mechanical integrity, bearing condition and vibration noise characteristics.

[0025] Step S3: Dynamic Cyclic Operating Condition and Fault Simulation Test S3.1: High Dynamic Power Cyclic Test: The main control computer imports power / torque-time series simulating rapid acceleration, rapid deceleration, and energy recovery to drive the motor under test to respond quickly, and tests the joint efficiency, current harmonics, bus capacitor stress, and cooling system following ability of the motor and controller under drastic operating conditions.

[0026] S3.2: Thermal Cycling Shock Test: Combining the loading conditions of steps S2 and S3.1, and linking with the thermal management simulation subsystem, the coolant temperature and flow rate are actively changed (e.g., from 105℃ / low flow rate to 25℃ / high flow rate) to conduct rapid thermal cycling, and the reliability of stator winding insulation, permanent magnets and power devices under thermal stress is evaluated.

[0027] S3.3: Electrical Fault Simulation Test: Through instructions from the main control computer, simulate non-hardware destructive faults such as single-phase open circuit and signal interference in the controller to test the fault-tolerant operation capability of the motor and the effectiveness of the fault diagnosis system.

[0028] Step S4: Data Fusion Analysis and Health Status Assessment The data acquisition system uploads the multidimensional data collected in steps S2 and S3 to the main control computer. The main control computer then executes: S4.1: Performance boundary map generation: Based on test data, a comprehensive performance boundary map is generated, including torque-speed-efficiency, torque-speed-temperature rise limits, and safe operating range.

[0029] S4.2: Degradation Analysis of Key Parameters: By comparing the parameters such as motor winding resistance, inductance, and peak power attenuation rate before and after multiple thermal cycles and dynamic cycles, a degradation model of key performance indicators is established.

[0030] S4.3: Comprehensive Health Status Score: Based on the performance boundary retention rate, parameter degradation degree, and performance in fault testing, calculate the comprehensive health status score of the motor and output a test report.

[0031] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A test method for high-power motors in new energy vehicles, characterized in that: The method includes the following steps: S1: Test System Construction and Initialization: Construct a test bench for the motor under test, the motor under load, the motor controller, the high dynamic DC power supply, the data acquisition system and the main control computer. S2: Graded loading limit performance test: Under the control of the main control computer, the low speed and high torque zone test, constant power zone test and high speed overspeed test are carried out in sequence. S3: Dynamic Cyclic Operating Condition and Fault Simulation Test: Conduct high dynamic power cycle test, thermal cycle shock test and electrical fault simulation test; S4: Data Fusion Analysis and Health Status Assessment: Based on the test data from steps S2 and S3, generate a comprehensive performance boundary map of the motor, analyze the degradation of key parameters, and calculate the comprehensive health status score.

2. The test method for a high-power motor of a new energy vehicle according to claim 1, characterized in that: In step S2, the low-speed, high-torque zone test specifically involves: stabilizing the speed of the motor under test at a preset low-speed point, increasing its output torque from the rated torque to the peak torque and maintaining it until the winding temperature stabilizes or reaches a preset time, and recording the temperature rise curve and torque response time; the constant power zone test specifically involves: controlling the motor under test to accelerate from the peak power point to the highest speed, maintaining the peak power output, and recording the changes in efficiency and iron loss; the high-speed overspeed test specifically involves: driving the motor under test to 1.1-1.3 times the maximum design speed and running it stably, and testing the mechanical structure and vibration.

3. The test method for a high-power motor of a new energy vehicle according to claim 1, characterized in that: In step S3, the high dynamic power cycle test specifically involves the main control computer importing a power-time sequence simulating aggressive driving to drive the motor under test; the thermal cycle shock test specifically involves actively and rapidly changing the temperature and flow rate of the coolant during the loading test to create a thermal shock; and the electrical fault simulation test specifically involves simulating non-destructive controller fault signals to test the motor's fault operation and diagnostic capabilities.

4. The test method for a high-power motor of a new energy vehicle according to claim 1, characterized in that: In step S4, the comprehensive performance boundary map includes at least a three-dimensional cloud map of torque-speed-efficiency, a safe operating boundary line based on temperature rise limitation, and a peak power envelope.

5. The test method for a high-power motor of a new energy vehicle according to claim 1, characterized in that: The test system in step S1 also includes a thermal management simulation subsystem (7), which is used to precisely control the temperature and flow rate of the cooling medium in step S3 to simulate the thermal management environment of the whole vehicle and perform thermal cycling shock tests.

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